530SW136C
        ASSESSMENT OF  INDUSTRIAL HAZARDOUS
WASTE PRACTICES - ELECTROPLATING AND  METAL FINISHING
            INDUSTRIES - JOB SHOPS
   This final report (SW-136C) describes work performed
      for the Federal solid waste management programs
        under contract no.  68-01-2664 and is
      reproduced as received from the contractor.
       U.S.  ENVIRONMENTAL PROTECTION AGENCY
                     1977

            LIBT>A BY
            vi  -           1/1 PROTECTION *F"

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     This report has been reviewed by the U.S. Environmental Protection
Agency and approved for publication.  Its publication does not signify
that the contents necessarily reflect the views and policies of the U.S.
Environmental Protection Agency, nor does mention of commercial products
constitute endorsement or recommendation for use by the U.S. Government.


An environmental protection publication (SW-136c) in the solid waste
management series.

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                              EXECUTIVE SUMMARY
                                Introduction
          This report is the result of a study commissioned by the U.S.
Environmental Protection Agency to assess the "Industrial Hazardous Waste
Practices -- Electroplating and Metal Finishing Industries" (SIC 3471).
This is one of a series of industry studies by the Office of Solid Waste,
Hazardous Waste Management Division.  The studies were conducted for
information purposes only and not in response toa Congressional regulatory
mandate.  As such, the studies serve to provide EPA with:  (1)  an initial
data base concerning current and projected types and quantities of total
industry and potentially hazardous wastes and applicable disposal methods
and costs; (2)  a data base for technical assistance activities; and  (3) a
background for guidelines development work.

          Although metal finishing embraces many industrial operations,
this study was limited to:

          (1)  Electroplating
          (2)  Anodizing and dyeing
          (3)  Electroless and immersion plating
          (4)  Chemical conversion coating (phosphate, chromate, etc.)
          (5)  Chemical polishing and electropolishing.

          Specifically excluded from the study were:

          (1)  Coloring
          (2)  Chemical milling and etching
          (3)  Electrochemical machining
          (4)  Pickling, descaling, bright dipping, stripping
          (5)  Electropainting.

          There is no accurate information on the number and location  of all
of the electroplating and metal finishing operations in the U.S. (recent
estimates of the number of installations range from 3,000 to 22,000)*.
Included in this segment of industry are small, independent companies which
employ only a few persons and do specialty plating and large, complex  instal-
lations owned and operated by major manufacturers as a service facility.

          The definition of "potentially hazardous waste" in this study was
developed on the basis of contractor investigations and professional judg-
ment.  This definition does not necessarily reflect EPA thinking since such
a definition, especially in a regulatory context, must be broadly applicable
to widely differing types of waste streams.  Obviously, the presence of a
toxic substance should not be the major determinant of hazardousness if there
were mechanisms to represent or illustrate actual effects of wastes in

*Federal Register, VoT7 40, No. 80, Thursday, April 24, 1975, p. 18133.

                                    iii

-------
specified environments.  Thus, the reader is cautioned that the data pre-
sented in this report constitute only the contractor's assessment of the
hazardous waste management problem in this industry.

          The basic objectives of this study are discussed in the report in
four major sections:

          (1)  Industry Characterization.  To develop an industry
               profile in terms of number of plants, geograph-
               ical distribution, plant size, age of plants,
               products produced, and production distribution.

          (2)  Waste Characterization.  To identify the types of
               wastes, their source, their chemical form, and the
               quantity of total industry and potentially hazardous
               wastes generated during 1975, with projections for
               1977, and 1983.

          (3)  Treatment and Disposal Technology.  To identify
               treatment/disposal technologies now and to be
               explored in the future by the industry for those
               potentially hazardous wastes.

          (4)  Cost Analysis.  To determine and analyze the costs
               associated with the above treatment and disposal
               practices.

          The results of this study are presented in the sections of this
report which follow.  The organization of the report generally follows the
four phases described above, i.e., Industry Characterization, Waste Char-
acterization, Treatment and Disposal Technology, and Cost Analysis.
                            Program Methodology
          The data collected for this study were obtained from four different
sources.  The first source was the published and unpublished literature,
such as trade journals, technical literature, and government reports.

          The second source of data was the various industry trade asso-
ciations.  The National Association of Metal Finishers, the American Electro-
platers Society, Inc., the Metal Finishing Suppliers Association, and the
Institute of Printed Circuits participated in the study.

          The third method of data acquisition was the distribution by mail
of a questionnaire to more than 7,000 electroplating and metal finishing
facilities through the National Association of Metal Finishers.  The response
to the questionnaire was very poor.  Only 130 facilities returned the ques-
tionnaire.

          The fourth method of data acquisition was through personal contacts
                                    IV

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and telephone conversations with personnel associated with the electro-
plating and metal finishing facilities, and with waste treatment and disposal
contractors.  The number of visits made to and telephone conversations with
each of these two groups was as follows:

                             Electroplating and Metal  Treatment/Disposal
                               Finishing Facilities       Contractors

Plant Visits                            29                     17

Telephone Conversations                 90                     37

A waste sampling and analysis program was not a part of this study since it
was felt initially that enough data were available regarding the constituents
which might appear in electroplating and metal finishing industry wastes.


                         Industry Characterization


Geographic Distribution and Size
          The geographic distribution and size of the electroplating and
metal finishing industry (job shops) were determined using the state
directories of manufacturers.  A total of 2,254 job shops were identified.
Additionally, use of the data from other state directories enabled the con-
tractor to develop a breakdown as to the size of the towns in which electro-
plating and metal finishing establishments are located (Table 1).

          As shown in Table 1, the heaviest concentrations of electroplating
and metal finishing facilities are in the North Central Region of the U.S.
EPA Region V has nearly 40 percent of the total number of industry job
shops, with Michigan accounting for 12 percent, followed by Ohio and Illinois,
with 11 percent and 8 percent, respectively, of the job shops.  The Atlantic
Coast states, EPA Regions I, II, and III, are second with nearly 35 percent
of the electroplating and metal finishing plants.  The third heaviest concen-
tration is in EPA Region IX, particularly in the State of California, with
6 percent of the job shops.  The remaining sectors of the country share 20
percent of the electroplating and metal finishing plants.

          Evaluation of the data presented in Table 1 also shows that more
than 52 percent of all electroplating and metal finishing establishments
are located in cities having a population greater than 100,000, and more
than three-quarters of the plants are located in cities with a population
greater than 20,000.  It is reasoned that the urban location of the job
shop portion of the industry would result in limits (either physical or
economic) of plant space available for the treatment and disposal of
wastes and also would be associated with wastewater disposal to sewers
according to applicable local regulations.  Thus, the distribution cited
above would favor such waste disposal practices as sewering of liquid
wastes (with or without treatment or solids separation) and off-site
disposal of nonsewerable wastes, and therefore the use of contractor
services.
                                     v

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TABLE  1.   DISTRIBUTION OF PLANTS GEOGRAPHICALLY AND  BY CITY  POPULATION
                                                                               (1-51)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Kaine
Vermont
Region II
New .'crsey
New York
Region III
T*l 1
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region V
Illinois
Indiana
MJ. .-.igan
!!i:./.csoti
Ohio
Wisconsin
Region VI
Arkansas
Louisiana
X*A. . JL'rt V-t fr.
*vew ficxxco
Oklahoma
Texas
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VIII
Colorado
Xf .
noti t 30 ti
Ix O T C 1 1 U cl K O V 3
South Dakr ;a
Utah
Vyoninfi
Region IX
Arl zona
California
i (nwci i. 1
Nevada
Region X
A 1 *i c L- o
J\ I <\ 5 K. n
Idn!: .
Oi cgon
Washington
Tot.-.] United St.iles

A
16
7
7
0
1
1
0
44
16
28
33

1
28
1
3
29
5
7
3
2
2
5
4
1
89
8
8
49
f\
./
16
5
2
0
0

0
2
14
7
1
6
0
2
1
1
J.
n
\j
0
0
0
3
1
1
Q
1
0
o
0
0
0
232
Number
B
55
16
29
5
2
0
3
37
22
15
34

2
30
0
2
20
2
4
1
3
2
3
2
3
104
14
13
35
4,
34
4
7
1
0

1
5
15
2
7
5
1
2
1

Q
0
1
0
14
1
13
n
\j
0
1
o
0
0
1
2C9
of PJnnf;(J)
C
135
59
51
23
0
2
0
64
36
28
37

3
25
0
9
41
8
13
3
1
2
5
4
5
174
44
22
55
£
33
14
13
2
1

0
10
15
9
0
6
0
4
2

'
n
V
1
1
0
52
1
48
3
13
Q
3
4
6
548 J
0
120
34
37
49
0
0
0
132
39
93
72

14
55
2
0
67
6
17
9
6
2
10
2
15
494
123
26
137
-LO
179
11
77
2
1

17
51
71
4
13
50
4
23
18

A
V
0
5
0
94
15
74
•»
j
2
35

0
18
17
,185
Total
326
116
124
77
3
3
3
277
113
164
176

20
138
3
14
157
21
41
16
12
8
23
12
24
861
189
69
276
31
262
34
99
5
2
f.
o
18
68
115
22
21
67
5
31
22


1
7
0
163
18
136
~\
J
6
49

3
22
24
2,25/-
Percent Dl
A
0.71
0.31
0.31
	
0.04
0.04
	
1.95
0.71
1.24
1.47

0.04
1.24
0.04
0.13
1.29
0.22
0.31
0.13
0.09
0.09
0.22
0.18
0.04
3.95
0.26
0.36
2.18
0. 13
0.71
0.22
0.09
	
	

	
0.29
0.62
0.31
0.04
0.27
	
0.09
0.04
OA /
• U4


	


0.13
0.04
0.0-'.
0.04
	

	


	
10 "a

B
2.44
0.71
1.29
0.22
0.09
	
0.13
1.64
0.98
0.67
1.51

0.09
1.33


0.09
O.S9
0.09
0.13
0.04
0.13
0.09
0.13
0.09
0.13
4.62
0.62
0.5S
1.55
0 . io
1.51
0.18
0.31
0.04
	

0.04
0.22
0.67
0.09
0.31
0.22
0.04
0.09
0.04




0.04


0.62
0.0-'.
0.5?
	
0 . 04

	 	


0.04
1 -) ^ •>

-.trlbuclon of PI ,mt »(«•»)
C
6.00
2.62
2.27
1.02


0.09
	
2.34
1.60
1.24
1.64

0.13
1.11


0.40
1.S2
0.36
0.53
0.13
0.04
0.09
0.22
0.18
0.22
7.73
1.S5
0.93
o / '
U . i /
1.47
0.62
0.5S
0.09
0.04

	
0.44
0.67
0.--0
	
0.27
	
0.1S
O.C9


0.04
o.c;


2.31
0.0-
2 . ] 3
0.13
0.53

0.13
O.JS
0.27
7 4 -,

D
5.33
1.51
1.64
2.18


	
	
5.91
1.73
4.13
3.15
Of)/.
. UH
0.62
2.44
0.09
	
2.98
0.27
0.76
0.40
0.27
0.09
0.44
0.09
0.67
21.95
5.46
1.16
6.09
u . cO
7.95
0.49
3.42
0.09
0.04
n 77
U . £- 1
0.76
2.27
3.15
0.1S
0.53
2.22
0.1S
1.02
O.SO


	 .
0.22


4.0-'.
0.67
3.29
01 ^
• 1 J
0.09
1.55

Total
14.
5.
5.
3.
0.
0.
0.
12.
5.
7.
7.

.
0.
6.
0.
0.
6.
0.
1
0.
0.
0.
1.
0.
1
33 !
8.
3.
12.
j..
11.
T_ _
£
0.
0.
0.
0.
3 .
5.
0.
0.
1
4. .
0.
^ _
0.

•
0.
0.


7.
0.
6.
0.
0.
-7

48
15
51
42
13
13
13
34
02
23
77
r\f.
v4
88
12
13
62
98
94
83
70
53
36
01
54
06
25
39
OS
26
3s
64
i>l
40
22
09
27
80
02
11
93
93
93
22
33
93
Of
*•(
04
31


11
SO
04
13
27
,18

	 0.13
O.SO
0.76
52 r>7

0.9P
1.
100
,07
.00
 (n)  Cl.-u.r, ific-c'  t.\ CHy ropul.it inn:  A = <50fiO; !>
      C " 20,000  to 1UO.OOO; 1) - >10U.OOO.
                                           v±
5000  to 20,000;

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Distribution by Number
of Employees
          The distribution of job shops by number of employees is given in
Table 2.  Examination of this table reveals that the greatest percentage
(30 percent) of the total number of shops have 11-25 employees; 27 percent
have 5-10 employees; 20 percent, 26-50 employees; and 12 percent, 1-4
employees.  Thus, 89 percent of the total number of job shops have between
1 and 50 employees.
Distribution by Age
of Facilities
          A sampling of the industry established no definite pattern regard-
ing the age range among facilities.  Companies report having equipment as
new as 2 years or as old as 30 years.  Waste treatment equipment for chem-
ical in-line or end-of-line wastewater control is generally less than 5
years old, although some equipment in a few cases has been used for about
25 years.
Distribution by Types
of Operations
          Most electroplating or metal finishing operations involve a
sequence of unit operations which may be classified as prefinishing,
finishing, and postfinishing operations.  Prefinishing operations are those
which clean and otherwise prepare a surface for finishing, such as deburring,
degreasing, acid pickling, and alkaline cleaning.  Finishing operations
include the application of one or more electroplates, such as copper, nickel,
chromium, zinc, or anodizing, and electroless plating.  Postfinishing
operations include bright-dipping, passivating, chromating, phosphating,
buffing, and polishing.

          Information supplied by the industry job shops during this study
indicates that there are a total of 12 electroplating and metal finishing
processes, with most of the operations being electroplating.  Of the 130
plants providing information, 65 have electroplating lines depositing 14
different metals or alloys in 265 rack- or barrel-type operations.  It is
concluded that four different metaJs or alloys are deposited on the average
per job shop.
Value Added and Cost Information
          Job shops are included in Standard Industrial Classification (SIC)
3471 as part of the metal services industries doing work on materials owned
by others.  For 1972, the value added by manufacture was $749,100,000.  The

                                   vii

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TABLE 2.  DISTRIBUTION OF ELECTROPLATING AND METAL FINISHING
          JOB SHOPS BY NUMBER OF EMPLOYEES

Cl'A i^-fjKtn  U
W.isliiiu.ioM
lot,.! i !•:;•'.. ,is 1 X

1-4
53
23
30
—
-
-
—
1
1
—
42
—
7
35
-
-
22
—
9
5
1
-
2
1
4
88
19
—
19
—
50
—
8
_
—
_
8
_
22
_
_
22
_
-
—
—
-
-
—
-
13
2
7
2
2
8
I
a
_
257

5-10
CO
25
30
-
1
2
2
73
41
32
38
_
4
30
-
4
42
9
13
3
3
1
4
4
5
215
53
21
54
G
73
8
30
2
1
5
4
18
28
15
_
13
—
16
12
1
-
1
2
-
41
5
31
1
4
18
1
5
17
5G7

11-25
55
31
22
-
2
—
—
110
44
Gf.
51
1
7
39
-
4
42
5
13
3
1
6
7
4
3
247
57
26
G9
12
71
12
31
_
—
—
3
28
34
—
14
17
3
6
2
-
-
-
4
-
55
6
49
-
_.
15
2
5
8
GIG

?C> 50
116
29
15
71
-
-
1
53
18
35
25
_.
2
17
2
4
34
5
3
2
5
-
8
1
10
120
32
10
3?
4
?3
4
18
2
1
1
1
13
11
3
—
G
2
4
3
-
-
-
1
-
33
4
2J

-
11
_.
.-
4
4 i Si
N'ui-.l.
51-75
7
-
G
—
—
1
_
13
3
10
5
	 	
—
4
1
_
6
-~
1
2
1
—
—
2
—
42
10
—
1C
3
11
2
2
_
_
_
2
—
3
_
—
3
—
3
3
-
-
--
--
-
G
-
C
-
-
2
_
2
-
89
,-r of Fir;
7(- 1CU
10
G
3
1
—
—
_
8
1
7
7
_
_
5
-
2
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—
-
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1
1
_
1
24
5
6
8
-
3
2
0
1
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_
8
10
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4
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—
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• •
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1
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CO
,;u,j,.l ^
101-150 I 51 -2:50
1 G
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1 1
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— —
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5 1
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„ _
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1 -
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ID 12
6 2
— 3
4 3
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1 —
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— —
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— —
6
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3 -
1 -
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— —
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- -
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2 3
-
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33 23

JG1-WHJ N.,-. Ciu,,,
12
2
10
_ _
^ -
_
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13
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6
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1 3
1
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— —
1
4 93
1 4
3
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- 5
8
1 4
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1
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1 5
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7 KM

To;,,l
3?C
16
i24
77
3
3
3
277
113
164
176
1
20
133
3
14
15.'
21
41
10
12
8
23
12
2<1
801
189
G'i
2V G
?1
262
34
99
5
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18
68
115
22
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5
31
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--
163
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3
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49
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77
2-1
225-1
                          Vlll

-------
cost of materials and fuels was $297,400,000, or about 40 percent of the
value added.  The capital expenditures in 1972 were $41,000,000, up 32
percent from 1971.  Wages in 1972 were $393,300,000, an increase of 8 percent
over the previous year, and represented 52 percent of the value added.
During the period 1971 to 1972, industry employment rose 0.75 percent.
                          Waste Characterization
Types and Sources of Wastes
          The job shop segment of the electroplating and metal finishing
industry is characterized by many individual variations in both practice
and facilities.  The service offered by this industry may vary from a single
operation to multiple-step processing.  Although these operations may be
classified in many ways, for the purpose of characterizing the wastes, they
have been classified into three different categories:  mechanical, chemical,
and electrochemical.

          Mechanical operations include:  grinding, grit blasting, shot
blasting, buffing, deburring, and polishing.

          Chemical processes include:  degreasing, acid pickling, £ilkaline
cleaning, acid cleaning, surface neutralizing, chromating, phosphating,
bright dipping, chemical polishing, passivating, and stripping.  A special
case in this category is electroless nickel and electroless copper plating,
in which the surface of the workpiece acts as a catalyst for the decom-
position of the solution, with the deposition of a metal on the workpiere.

          Electrochemical processes in the industry include:  anodic cleaning,
cathodic cleaning, anodizing, and electroplating.  Special cases under this
category would include those processes which use no external electrical
connections but depend on the electrochemical reactions between the basis
material and the solution to produce a metallic coating, such as stannating
and zincating.  These latter processes are referred to as immeroion plating,

          The operations summarized above may be performed singly or in
combination to produce the surface properties desired by a customer.  They
are the sources of the various potentially hazardous waste streams which
are generated by this industry.  The relationship of these sources to the
potentially hazardous wastes which may be generated is showa in Figure 1.

          In performing the study of the electroplating and melal finishing
industry, four types of wastes were identified as being destined for land
disposal.  These are:

          Water pollution control sludges
          Process wastes
          Degreaser sludges
          Salt precipitates from electroless nickel batli regeneration.
                                    IX

-------
Waste Source
                 Waste  Type
Process
Solutions

Spent Process Solutions
	 	 — — — — • — — 	 • 	 ' — J
Spills and Leaks N
Water Pollution
Control
Equipment
water foiiution
Control Sludges
	 •->
1
  Grinding,
  Polishing,
  & Buffing
  Operations
  Metal Anode
  Scrap Rack
  Materials
   Rejects
                   Process Wastes,
  Degreasing
  Operations
  on Soiled
  V?ork pieces
                Degreaser Sludges,
  Electroless
  Nickel
  Plating
  Operations
   Bath
Regeneration
Calcium Salt . Precioitate «
                         FIGURE 1.   GENERALIZED DIAGRAM OF TYPES
                                    AND  SOURCES OF WASTES 	
                                    ELECTROPLATING AND METAL FINISHING
                                    INDUSTRY  (JOB SHOPS)

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          Water pollution control sludges have been identified as a class
because they constitute the largest single waste category destined for
land disposal.  (Although the majority of facilities do not treat their
wastewater and thus do not generate sludge at present, pending regulations
will require such treatment with the concommitant generation of these
sludges.)  Water pollution control, when practiced at an electroplating
and metal finishing plant, will precipitate the dissolved, potentially
hazardous materials, thus generating a waste for land disposal.

          Process waste materials include grinding, polishing, and buffing
wastes; filter aids; anode sludges and anode bags; and plating racks and
rack materials.  Most of these materials bear occluded or absorbed
process chemicals and generally are disposed in landfills.

          Degreaser sludges arise from chlorinated hydrocarbons, which are
used to remove grease and oil from mechanically finished parts by polishing
and buffing.  These sludges then contain dissolved greases and oils,
buffing compounds, abrasives, cloths, and metals.  They may be discarded
through the routes of direct disposal to the land or may be routed to a
reclamation operation (e.g., distillation).

          Salt precipitates from electroless nickel plating operations are
produced during the regeneration of the bath composed of calcium ortho-
phosphite and calcium sulfate.  This particular type of waste may not
always be present because electroless nickel plating operations are not as
common as electroplating or because small volume solutions arc not regen-
erated.
Criteria for Establishing Hazardous Wastes
          In this study, the first criterion for designating a waste as
potentially hazardous has been the destiny of the waste material—to be
included the waste must be destined for land disposal.  The four classes of
wastes described above meet this criterion.  Materials which normally are
reclaimed, e.g., used degreasing solvents, have not been included because
the reclaimed solvents are recycled or sold.  Other materials which have
not been included as a separate class are spent pickling and plating baths.
In some instances these materials may be sent to a reclaimer and thus do
-ot meet the land disposal criterion; in other instances, they are met°r2d
into the water pollution control system and become a part of the waste
category termed "water pollution control sludges".

          The second—and more important—criterion for inclusion of a
material as a potentially hazardous waste is its possible detrimental
effects upon human health and ecology and the possible degradation of
ground and surface waters.  The specific data on the toxic effects of the
wastes from this industry which are destined for land disposal are very
sparse.  In addition, little is known about possible synergistic effects.
The most widely accepted basis for defining many of these materials as
potentially hazardous are the relatively low acceptable levels of the
various metals in drinking water.  Values derived  from water quality criteria

                                    xi

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for the State of California are shown in Table 3,*  In most cases, the accep-
table levels of the metals commonly found in electroplating and metal finishing
wastes are less than 0.1 ppm.  Wastes containing any of these metals in a
concentration equal to or more than that listed are considered potentially
hazardous.  On this basis, all known wastes from electroplating and metal
finishing operations are defined as potentially hazardous.  Proper treatment
or disposal can eliminate the potential hazard.

          The organic solvents used for degreasing operations usually are
polychlorinated hydrocarbons—a class of organic chemicals which has
received wide publicity for its carcinogenicity.  Since these solvents are
present in the degreaser sludges,  another class of components is added to
the list of potentially hazardous  constituents generated by the electro-
plating and metal finishing industry which are destined for land disposal.

          Because all of the four  classes of wastes previously listed either
contain heavy metals and/or polychlorinated hydrocarbons, all of these
wastes are considered potentially  hazardous.
Determination of Quantity of Wastes Generated


          Estimates of the quantity of wastes currently generated and
expected in the future from the electroplating and metal finishing industry
were developed based on the data obtained for three model plants, statis-
tical data, and responses from industry.  The use of models and statistical
data was necessitated by the poor response to several requests for actual
plant data.

          The following items were evaluated in the development of the
three model plants:

          •  Plant size
             - number of employees
             - industry production rates
          •  Product mix
             - plating process, consisting of a major
               portion of copper, nickel, chromium, and
               zinc plating; with anodizing, electroless
               aickt], cadmium, and other finishes repre-
               bfc.ni.ed in a minor portion of the product mix.
             - a mix of automated and manual operations
               compatible with the number of employees
             - base metal to be finished
          »  Plant operating criteria based on electroplating
             engineering technology, including
             - preparing, plating, and postplating steps
             - solution compositions
             - haf.h dump rates, spills, and leaks
             - arsa plated
   McKee, J.  E. , and H. W. Wolfe.  Water Quality Criteria.  2nd Ed., Publi-
   cation No. 3-A, Resources Agency of California, State Water Quality
   Control Board, 1963.

                                     xii

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 TABLE 3.  WASTE CONSTITUENTS AND POTENTIALLY HAZARDOUS
           CONCENTRATION LEVELS
   Waste                    Potentially Hazardous
Constituents	Concentration,

Arsenic                             0.05
Beryllium                           0.2
Cadmium                             0.05
Chromium                            0.05
Copper                              0.02
Cyanide                             0.01
Gold                                0.4
Iron                                0.1
Lead                                0.1
Manganese                         300
Mercury                             0.004
Nickel                              0.8
Oil and Grease                      7
Palladium                           7
Phosphates                        545
Selenium                            0.05
Silver                              0.003
Sulfates                          200
Tin                                 1.2
Zinc*                                0.01
(a)   Concentration which produces damage to human
     health,  livestock, and/or aquatic organisms.
                     xiii

-------
             - tank sizes or solution volumes
             - solution drag out rates
             - rinse water usage
             - material consumption
             - plant operating times
          •  Industry-reported data from questionnaires
          •  Design water pollution control systems based
             on chemical treatment technology, the
             prevailing present practice in the industry,
             and derive the sludge production rates
          •  Derive rates of waste generation during production.

          One of the points worthy of discussion is the waste load produced
with each regeneration of the electroless nickel bath.  Electroless nickel
plating was included as representative of the industry and it was further
assumed that the bath would be regenerated in-house.  Because of the large
quantity of salts precipitated from the large volume of bath necessary for
a high rate of production, these process wastes are identified separately.

          The data developed regarding waste generation by model plants,
and the state and EPA regional distribution of job shops, were used to
calculate the quantity of waste destined for land disposal.

          The number of job shops in a given state was aggregated into
three size ranges corresponding to the model plants.  The waste generation
rates of each of the model plants were then multiplied by the number of
plants in each size range for each of the states.

          The waste generation rates of the model plants are based on the
proposed U.S. EPA effluent limitations and guidelines which are to apply
in 1977 and 1983 and on the estimated production for those years.  To
establish estimates for 1975, various factors have been taken into con-
sideration.  The adjustment of the basic 1977 model plant waste quantities
to 1975 required an allowance for those plants not currently producing
water pollution control sludges.  To simulate this situation, pertinent
information was gathered from state and local agencies in order to determine
the degree and incidence of pollution control currently existing.  Such
estimates were developed to the best degree possible for areas (states)
containing the large numbers of electroplating job shops.  A review of the
industry responses showed that about 35 percent of the reporting plants
produced water pollution control sludge in 1975.

          Economic data indicate that the industry will not undergo any
major expansion or reduction.  Consequently, the wastes generated from
electroplating and metal finishing processes other than water pollution
control sludges are projected as unchanged between 1975 and 1977.  Thus,  it
is concluded that the significant differences in waste quantities between
1977 and 1975 will be in water pollution control sludge quantities.

          The estimated quantities of waste destined for land disposal by
the electroplating and metal finishing industry (job shops) for each state,
EPA Region, and nationally during 1975 are shown in Table 4,  The major
portion of the wastes, 54 percent, are process wastes.  The water pollution

                                    xiv

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                  TABLE 4.  QUANTITY OF TOTAL INDUSTRY AND POTENTIALLY HAZARDOUS
                            WASTES DESTINED FOR LAND DISPOSAL FROM THE ELECTRO-
                            PLATING AND METAL FINISHING INDUSTRY (JOB SHOPS);
                            METRIC TONS; DRY WEIGHT*; 1975
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Water Pollution
Control Sludges

847.77
926.66
1,039.85
15.96
38.99
22.89
2,892.12

879.55
1,667.96
2,547.51

5.32
83.02
960.68
52.85
148.26
1,250.13

176.33
203.42
141.47
139.23
65.59
213.22
111.51
193.41
1,244.18

1,706.60
664.44
2,827.16
319.41
1,953.28
374.50
7,845.39
Process
Wastes

1,814.25
1,979.51
2,148.49
36.33
82.80
49.53
6,110.91

1,912.34
3,555.91
5,468.25

12.11
183.83
2,062.10
109.20
315.28
2,682.52

379.98
449.37
299.02
292.15
143.35
452.85
239.35
408.56
2,664.63

3,649.18
1,425.42
5,978.98
680.09
4,196.86
796.16
16,726.69
Degreaser
Sludges

251.35
254.96
280.15
6.15
8.31
7.69
808.61

274.90
450.86
725.76

2.05
29.73
270.33
11.39
39.18
352.68

54.45
68.28
32.11
34.57
18.56
59.69
28.41
56.51
352.58

455.78
180.91
753.67
86.05
552.96
94.98
2,124.35
Electroless
Ni Wastes

541.13
526.50
1,126.13
0.00
14.63
14.63
2,223.02

394.88
965.25
1,360.13

0.00
29.25
497.25
43.88
87.75
658.13

102.38
58.50
73.13
102.38
14.63
146.25
43.88
160.88
702.03

877.50
321.75
1,959.75
190.13
994.50
204.75
4,548.38
Total**

3,454.50
3,687.63
4,594.62
58.44
144.73
94.74
12,034.66

3,461.67
6,639.98
10,101.65

19.48
325.83
3,790.36
217.32
590.47
4,943.46

713.14
779.57
545.73
568.33
242.13
872.01
423.15
819.36
4,963.42

6,689.06
2,592.52
11,519.56
1,275.68
7,697.60
1,470.39
31,244.81
Total Hazar-
dous Consti-
tuents in
Water Pollu-
tion Control
Sludges***

338.07
376.51
416.04
6.09
16.69
8.84
1,162.24

349.04
679.84
1,028.88

2.04
31.93
389.26
22.21
60.66
506.10

69.81
79.81
59.64
57.36
26.85
85.94
46.30
76.80
502.51

698.96
271.38
1,150.53
130.19
790.69
154.72
3,196.47
     These dry weights can be converted to wet weights by multiolying bv the following"
     factors:  WPCS - 20;  PW - 1;  DS - 1;  ENW - 2.
**   Note:  Total Industry Wastes = Potentially Hazardous Wastes.
***  Estimated compositional information is not available for the other classes of potentially
     hazardous wastes.
                                                XV

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                                       TABLE  4.   (Continued)


EPA Region and State


Water Pollution
Control Sludges


Process
Wastes


Degreaser
Sludges


Electroless
Ni Wastes
Total Hazar-
dous Consti-
tuents in
Water Pollu-
tion Control
Total** Sludges***
Region VI
  Arkansas                 63.49          133.42      15.49
  Louisiana                17.57           37.42       5.64
  New Mexico               38.85           85.86      13.84
  Oklahoma                106.19          227.24      26.36
  Texas                   643.02        1,380.04     178.24
  Region VI Total         869.12        1,863.98     239.57

Region VII
  Iowa                    229.95          491.90      58.36
  Kansas                  272.93          579.60      58.17
  Missouri                488.25        1,042.38     120.93
  Nebraska                 40.46           86.95      13.33
  Region VII Total      1,031.59        2,200.83     250.79

Region VIII
  Colorado                252.98          538.37      60.52
  Montana                   5.32           12.11
  North Dakota              0.00            0.00
  South Dakota              5.32           12.11
  Utah                     44.17           97.97
  Wyoming                   0.00            0.00
  Region VIII Total       307.79          660.56

Region IX
  Arizona                 135.87          293.03      41.12
  California            1,267.35        2,708.04     349.21
  Hawaii                    5.32           12.11       2.05
  Nevada                   21.28           48.44       8.20
  Region IX Total       1,429.82        3,061.62     400.58
  .05
  .00
  .05
  .89
 0.00
80.51
 2.
 0.
 2.
15.
            43.88
            14.63
            14.63
            43.88
           321.75
           438.77
           102.38
           102.38
           219.38
            29.25
           453.39
117.00
  0.00
  0.00
  0.00
 14.63
  0.00
131.63
            73.13
           716.63
             0.00
             0.00
           789.76
                       256.28
                        75.26
                       153.18
                       403.67
                     2,523.05
                     3,411.44
                       882.58
                     1,013.08
                     1,870.94
                       169.99
                     3,936.59
  968.87
   19.48
    0.00
   19.48
  172.66
    0.00
1,180.49
                       543.15
                     5,041.23
                        19.48
                        77.92
                     5,601.78
                         26.28
                          6.82
                         14.94
                         44.26
                        261.53
                        353.83
                         95.34
                        116.83
                        203.31
                         15.68
                        431.16
105.95
  2.04
  0.00
  2.04
 16.99
  0.00
127.02
                         54.15
                        514.83
                          2.04
                          8.12
                        579.14
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.

0.00
15.96
150.50
155.40
321.86
19,739.51

0.00
36.33
322.15
343.44
701.92
42,141.91

0.00
6.15
36.72
55.36
98.23
5,433.66

0.00
0.00
58.50
58.50
117.00
11,422.24

0.00
58.44
567.87
612.70
1,239.01
78,737.32

0.00
6.09
62.98
59.78
128.85
8,016.20
**   Note:  Total Industry Wastes = Potentially Hazardous Wastes.
***  Estimated compositional information is not available for the other classes of potentially
     hazardous wastes.
                                               XVI

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control sludges are 25 percent of the total, followed by electroless
nickel plating wastes at 15 percent, and 6 percent for degreaser sludges.
The fact that only an estimated 35 percent of the total job shops are
producing water pollution control sludges in 1975 is the reason that the
general wastes associated with all metal finishing operations account for
more than half of the total wastes.

          The estimated quantities of potentially hazardous waste to be
destined for land disposal by the electroplating and metal finishing
industry (job shops) in 1977 are given in Table 5.  The 115,396 metric
tons (dry weight) represents an almost 50 percent increase in waste quantity
over 1975, all of it coming from the additional load of water pollution
control sludge.  Forty-nine percent of the 1977 total waste is water
pollution control sludge, while process wastes amount to only approximately
37 percent.  Electroless nickel wastes and degreaser sludge constitute 10
and 4 percent of the waste, respectively.

          Waste projections for 1983 are based on a study by the U.S. EPA's
Effluent Guidelines Division.*  The responses obtained from the job shops
for this study did not provide projections to 1983, naming the proposed
1983 zero-discharge limitation of plant effluents as the reason for the
inability to determine or predict water pollution control sludge loads.
Necessary changes in treatment practices are another reason given.  The
above cited report projects an industry growth of 31 percent from 1977 to
1983.  Consequently, 1983 estimated land-destined waste quantity projections
were calculated by multiplying the 1977 waste quantity estimate by the
factor 1.31.

          The data for each state and EPA Region and nationally are
summarized in Table 6 in terms of the four designated waste categories.
The total estimated quantity of waste destined for land disposal in 1983
is 151,166 metric tons.  Almost 40 percent of this waste will be from
plants located in Region V and more than 67 percent will be from plants
located in Regions I, II, and V.

          A summary of all the wastes destined for land disposal by the
electroplating and metal finishing job shop industry for 1975, 1977, and
1983 is given in Table 7 in order to compare waste loads and ratios of
waste categories from the job shops represented by one of these model
plants:

          Small with an average of 16 employees in plating.
          Medium with an average of 38 employees in plating.
          Large with an average of 87 employees in plating.

The 38-employee model plant (or medium-sized job shop) represents the group
of plants with the greatest waste load.  Water pollution control sludges
are the most important contributors to that waste load, which contains
large amounts of hazardous metal hydroxides and soluble salts.
   Economic Analysis of Effluent Guidelines - Metal Finishing Industry.
   Report No. EPA 230/1-74-032, Sept. 1974, p. VI-8.

                                   xvii

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                  TABLE  5.  QUANTITY OF TOTAL INDUSTRY AND POTENTIALLY HAZARDOUS
                           WASTES DESTINED FOR LAND DISPOSAL FROM THE ELECTRO-
                           PLATING AND METAL FINISHING INDUSTRY (JOB SHOPS);
                           METRIC TONS; DRY WEIGHT*; 1977
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Water Pollution Process
Control Sludges Wastes

2,422.20
2,647.60
2,971.00
45.60
111.40
65.40
8,263.20

2,513.00
4,765.60
7,278.60

15.20
237.20
2,744.80
151.00
423.60
3,571.80

503.80
581.20
404.20
397.80
187.40
609.20
318.60
552.60
3,554.80

4,876.00
1,898.40
8,077.60
912.60
5,580.80
1,070.00
22,415.40

1,814.25
1,979.51
2,148.49
36.33
82.80
49.53
6,110.91

1,912.34
3,555.91
5,468.25

12.11
183.83
2,062.10
109.20
315.28
2,682.52

379.98
449.37
299.02
292.15
143.35
452.85
239.35
408.56
2,664.63

3,649.18
1,425.42
5,978.98
680.09
4,196.86
796.16
16,726.69
Degreaser
Sludges

251.35
254.96
280.15
6.15
8.31
7.69
808.61

274.90
450.86
725.76

2.05
29.73
270.33
11.39
39.18
352.68

54.45
68.28
32.11
34.57
18.56
59.69
28.41
56.51
352.53

455.78
180.91
753.67
86.05
552.96
94.98
2,124.35
Total Hazar-
dous Consti-
tuents in
Water Pollu-
Electroless tion Control
Ni Wastes Total** Sludges***

541.13
526.50
1,126.13
0.00
14.63
14.63
2,223.02

394.88
965.25
1,360.13

0.00
29.25
497.25
43.88
87.75
658.13

102 . 38
58.50
73.13
102.38
14.63
146.25
43.88
160.88
/02.03

877.50
321.75
1,959.75
190.13
994.50
204.75
4,548.38

5,028.93
5,408.57
6,525.77
88.08
217.14
137.25
17,405.74

5,095.12
9,737.62
14,832.74
1
29.36
480.01
5,574.48
315.47
865.81
7,265.13

1,040.61
1,157.35
808.46
826.90
363.94
1,267.99
630.24
1,178.55
7,274.04

9,858.46
3,826.48
16,770.00
1,868.87
11,325.12
2,165.89
45,814.82

975.89
1,075.70
1,188.67
17.41
47.68
25.28
3,330.63

997.25
1,942.43
2,939.68

5.80
91.21
1,112.14
63.44
173.33
1,445.92

199.46
228.02
170.44
163.83
76.69
245.54
132.26
219.43
1,435.67

1,997.03
775.41
3,287.21
372.00
2,259.14
442.04
9,132.83
     These dry weights can be converted to wet weights by multiplying  by the following factors:
     WPCS - 20;  PW - 1;  DS - 1;   ENW - 2.
**   Note:  Total Industry Wastes  = Potentially Hazardous Wastes.
***  Estimated compositional information is not available for the  other classes  of  potentially
     hazardous wastes.
                                            xviii

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                                       TABLE 5.   (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Water Pollution Process
Control Sludges Wastes

181.40
50.20
111.00
303.40
1,837.20
2,483.20

657.00
779.80
1,395.00
115.60
2,947.40

722.80
15.20
0.00
15.20
126.20
0.00
879.40

388.20
3,621.00
15.20
60.80
4,085.20

0.00
45.60
430.00
444.00
919.60
56,398.60

133.42
37.42
85.86
227.24
1,380.04
1,863.98

491.90
579.60
1,042.38
86.95
2,200.83

538.37
12.11
0.00
12.11
97.97
0.00
660.56

293.03
2,708.04
12.11
48.44
3,061.62

0.00
36.33
322.15
343.44
701.92
42,141.91
Degreaser
Sludges

15.49
5.64
13.84
26.36
178.24
239.57

58.36
58.17
120.93
13.33
250.79

60.52
2.05
0.00
2.05
15.89
0.00
80.51

41.12
349.21
2.05
8.20
400.58

0.00
6.15
36.72
55.36
98.23
5,433.66
Electroless
Ni Wastes Total**

43.88
14.63
14.63
43.88
321.75
430.77

102.38
102.38
219.38
29.25
453.39

117.00
0.00
0.00
0.00
14.63
0.00
131.63

73.13
716.63
0.00
0.00
789.76

0.00
0.00
58.50
58.50
117.00
11,422.24

374.19
107.89
225.33
600.88
3,717.23
5,025.52

1,309.64
1,519.95
2,777.69
245.13
5,852.41

1,438.69
29.36
0.00
29.36
254.69
0.00
1,752.10

795.48
7,394.88
29.36
117.44
8,337.16

0.00
88.08
847.37
901.30
1,836.75
115,396.41
Total Hazar-
dous Consti-
tuents in
Water Pollu-
tion Control
Sludges***

75.06
19.50
42.70
126.45
747.21
1,010.92

272.42
333.76
580.90
44.78
1,231.86

302.69
5.80
0.00
5.80
48.50
0.00
362.79

154.68
1,470.91
5.80
23.21
1,654.60

0.00
17.41
179.94
170.83
368.18
22,913.08
**   Note:  Total Industry Wastes = Potentially Hazardous Wastes.
***  Estimated compositional information is not available for the  other classes of potentially
     hazardous wastes.
                                                XIX

-------
                   TABLE 6.   QUANTITY OF TOTAL INDUSTRY AND  POTENTIALLY HAZARDOUS
                             WASTES DESTINED FOR LAND  DISPOSAL FROM THE ELECTRO-
                             PLATING AND METAL FINISHING INDUSTRY  (JOB SHOPS);
                             METRIC TONS;  DRY WEIGHT*;   1983
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Water Pollution Process
Control Sludges Wastes

3,173.08
3,468.36
3,892.01
59.74
145.93
85.67
10,824.79

3,292.03
6,242.94
9,534.97

19.91
310.73
3,595.69
197.81
554.92
4,679.06

659.98
761.37
529.50
521.12
245.49
798.05
417.37
723.91
4,656.79

6,387.56
2,486,90
10,581.66
1,195.51
7,310.85
1,401.70
29,364.18

2,376.67
2,593.16
2,814.52
47.59
108.47
64.88
8,005.29

2,505.17
4,658.21
7,163.38

15.86
240.82
2,701.35
143.05
413.02
3,514.10

497.77
588.67
391.72
382.72
187.79
593.23
313.55
535.21
3,490.66

4,780.43
1,867.30
7,832.46
890.92
5,497.89
1,042.97
21,911.97
Degreaser
Sludges

329.27
334.00
367.00
8.06
10.89
10.07
1,059.29

360.12
590.63
950.75

2.69
38.95
354.13
14.92
51.33
462.02

71.33
89.45
42.06
45.29
24.31
78.19
37.22
74.03
461.88

597.07
236.99
987.31
112.73
724.38
124.42
2,782.90
Electroless
Ni Wastes Total**

708.87
689.72
1,475.22
0.00
19.16
19.16
2,912.13

517.29
1,364.48
1,881.77

0.00
38.32
651.40
57.48
114.95
862.15

134.11
76.64
95.79
134.11
19.16
191.59
57.48
210.75
919.63

1,149.53
421.49
2,567.27
249.06
1,302.80
268.22
5,958.37

6,587.89
7,085.24
8,548.75
115.39
284.45
179.78
22,801.50

6,674.61
12,856.26
19,530.87

38.46
628.82
7,302.57
413.26
1,134.22
9,517.33

1,363.19
1,516.13
1,059.07
1,083.24
476.75
1,661.06
825.62
1,543.90
9,528.96

12,914.59
5,012.68
21,968.70
2,448.22
14,835.92
2,837.31
60,017.42
Total Hazar-
dous Consti-
tuents in
Water Pollu-
tion Control
Sludges***

1,265.32
1,409.19
1,557.15
22.79
62.46
33.13
4,350.04

1,306.38
2,544.58
3,850.96

7.60
119.50
1,456.91
83.14
227.08
1,894.23

261.31
298.71
223.26
214.60
100.56
321.64
173.26
287.45
1,880.79

2,616.13
1,015.78
4,306.24
487.30
3,959.43
579.05
11,963.93
*    These dry weights can be converted to wet weights by multiplying by the following factors:
     WPCS - 20;  PW - 1;  DS - 1;  ENW - 2.
**   Note:  Total Industry Wastes = Potentially Hazardous Wastes.
***  Estimated compositional information is not available for the other classes of potentially
     hazardous wastes.
                                              XX

-------
                                       TABLE 6.   (Continued)
EPA Region and State
Water Pollution
Control Sludges
                                         Process
                                         Wastes
           Degreaser
            Sludges
          Electroless
           Ni Wastes
             Total**
           Total Hazar-
           dous Consti-
           tuents in
           Water Pollu-
           tion Control
           Sludges***
Region VI
  Arkansas
  Louisiana
  New Mexico
  Oklahoma
  Texas
  Region VI Total

Region VII
  Iowa
  Kansas
  Missouri
  Nebraska
  Region VIITotal

Region VIII
  Colorado
  Montana
  North Dakota
  South Dakota
  Utah
  Wyoming
  Region VIII Total

Region IX
  Arizona
  California
  Hawaii
  Nevada
  Region IX Total

Region X
  Alaska
  Idaho
  Oregon
  Washington
  Region X Total

Total U. S.
    237.63
     65.76
    145.41
    397.45
  2,406.73
  3,252.98
    860.67
  1,021.54
  1,827.45
    151.44
  3,861.10
    946.87
     19.91
      0.00
     19.91
    165.32
      0.00
  1,152.01
    508.54
  4,743.51
     19.91
     79.65
  5,351.61
      0.00
     59.74
    563.30
    581.64
  1,204.68

 73,882.17
   174.78
    49.02
   112.48
   297.68
 1,807.85
 2,441.81
   644.39
   759.28
 1,365.52
   113.90
 2,883.09
   705.26
    15.86
     0.00
    15.86
   128.34
     0.00
   865.32
   383.87
 3,547.53
    15.86
    63.46
 4,010.72
     0.00
    47.59
   422.02
   449.91
   919.52
 20.29
  7.39
 18.13
 34.53
233.49
313.83
 76.45
 76.20
158.42
 17.46
328.53
 79.28
  2.69
  0.00
  2.69
 20.82
  0.00
105.48
 53.87
457.47
  2.69
 10.74
524.77
  0.00
  8.06
 48.10
 72.52
128.68
   57.48
   19.16
   19.16
   57.48
  421.49
  574.77
  134.11
  134.11
  287.38
   38.32
  593.92
  153.27
    0.00
    0.00
    0.00
   19.16
    0.00
  172.43
   95.79
  938.78
    0.00
    0.00
1,034.57
    0.00
    0.00
   76.64
   76.64
  153.28
   490.18
   141.33
   295.18
   787.14
 4,869.56
 6,583.39
 1,715.62
 1,991.13
 3,638.77
   321.12
 7,666.64
 1,884.68
    38.46
     0.00
    38.46
   333.64
     0.00
 2,295.24
 1,042.07
 9,687.29
    38.46
   153.85
10,921.67
     0.00
   115.39
 1,110.06
 1,180.71
 2,406.16
   98.36
   25.53
   55.94
  151.64
  960.85
1,324.32
  356.87
  437.23
  760.99
   58.69
1,613.78
  396.51
    7.60
    0.00
    7.60
   63.56
    0.00
  475.27
  202.64
1,826.88
    7.60
   30.42
2,067.54
    0.00
   22.79
  235.74
  223.80
  482.33
55,205.86  7,118.13   15,063.02  151,269.18   29,903.19
**   Note:  Total Industry Wastes = Potentially Hazardous Wastes.
***  Estimated compositional information is not available for the other classes of potentially
     hazardous wastes.
                                             XX i

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                      Treatment and Disposal Technology


          The current prevalent practice for the disposal of the four
classes of potentially hazardous wastes from the electroplating and meta!
finishing industry is the use of a landfill.  The landfill operation may
range from an open dump to a covered landfill, and includes the use of
abandoned mines and quarries.  Approximately 60 to 70 percent of the plai
reporting use off-site disposal for their wastes.  Although a few plants
may employ safeguards such as chemical fixation, solidification, etc,, tt
prevalent practice generally utilizes the simplest possible disposal tech-
niques acceptable to local authorities.  This generalization holds true
whether the disposal is carried out by the operators of the electroplatin
facility or by a private contractor.

          The three levels of treatment and disposal technology defined i
the disposal of wastes from job shops are as follows:

          Level I   - Prevalent practice
          Level II  - Best technology currently used
          Level III - Practice considered environmentally adequate.

          The broad average treatment and disposal practice for wastes
destined for land disposal, defined as Level I, is discussed below for th<
following four major waste streams:  (1) water pollution control sludge,
(2) process wastes, (3) solvent sludges, and (4) electroless nickel wastes

          The prevalent treatment/disposal practice for water pollution
control sludge is concentration to 1-5 percent solids content, followed "by
land disposal.  The waste is an aqueous slurry of metal hydroxides.  The
Level I technology is inadequate to provide acceptable health and environ-
mental protection, primarily because of the potential contamination of
ground water and surface water supplies possible with this method of dispo

          In some instances, concentrated inorganic solutions  (precious me
baths, and selected, rich, noncontaminated solutions of chromium, nickel,
or copper) are reclaimed and no waste is generated.  In other  cases, the
spent concentrated solutions are treated in the water pollution control
open facility, and the metals become a part of the water pollution control
sludges.

          The prevalent treatment/disposal practice for process wastes is
municipal landfill disposal.  Process wastes are composed of solids and
semi-solids contaminated with toxic metals from the metal-finishing operati
These wastes are not normally regarded as hazardous by the industry and are
therefore disposed of with nonhazardous plant trash in municipal landfills.
This disposal method is not considered adequate for health and environments
protection because of the potential for ground water and surface water
contamination.

          The solvents used in degreasing operations become contaminated
with toxic metals.  These metals are removed in the reclamation operations
and transferred to a solvent sludge.  The prevalent disposal practice for

                                    xxiii

-------
solvent sludges is simple land disposal with the process wastes or water
pollution control sludges.  This practice is considered inadequate because
of potential ground and surface water contamination.

          Wastes also are generated during the regeneration of electroless
nickel baths.  Although not specifically included as a component of the
wastes produced by plants responding to inquiries made during this study,
they are produced by facilities which include electroless plating operations.
Most of the successful regeneration operations are based on the chemical
precipitation of the phosphite ion.  These precipitated materials usually
are taken to a landfill for disposal.  This is considered prevalent practice
for this class of wastes.

          The best current (Level II) treatment/disposal practice for water
pollution control sludge involves (1) solids concentration, (2) dewatering
to greater than or equal to 20 percent solids cake, and (3) disposal in a
sanitary landfill approved by a state or local authority for receiving
wastes of this nature.  The additional safeguards above the Level I techno-
logy include the dewatering operation, which produces a high-solids (increase
from 1-6 to 20 percent solids), lower volume, sludge cake.  In addition to
easier, more economical disposal, the higher-solids cake has increased
resistance to metal hydroxide resolubilization and mobilization to toxic
metal ions.  The most important additional safeguard, however, is the change
from simple land disposal  (surface burial, open dumps, municipal landfills,
etc.) in Level I to an approved sanitary landfill for Level II.  An approved
sanitary landfill is a disposal site where extraordinary precautions have
been taken in the areas of site selection and leachate control monitoring.
Disposal of water pollution control sludges in such a disposal site is
considered adequate for short-term disposal.  Long-term protection, however,
cannot be assured since surface runoff and rain water can still percolate
through the disposal area, leading to leachate formation.  If the impervious
barriers placed in the bottom of the landfill should become ruptured, break,
or otherwise fail, no means are available to collect the leachate for
treatment or excavate the problem hazardous wastes.

          The best current treatment/disposal practice for the contaminated
solid and semi-solid process wastes is disposal in an approved sanitary
landfill.  As noted above, an approved sanitary landfill is considered
adequate for short-term disposal.  However, because such facilities do
not provide  the means for  leachate collection and treatment, waste segre-
gation and mapping, long-term protection of the environment cannot be
assured.

          The best treatment/disposal practice for solvent sludges and for
electroless nickel wastes  is disposal in an approved sanitary landfill.
This disposal method is considered adequate for short-term disposal. Long-
term protection, however,  cannot be assured because of the lack of facil-
ities for leachate collection and treatment, waste segregation and mapping.

          The technology identified as environmentally adequate  (Level III)
in this study consists principally of the present best technology described
with some modifications in the preparation and operation of the approved
sanitary landfills.

                                   xx iv

-------
          The selected site should undergo extensive geological evaluation
for hydraulic connections to ground and surface waters.  Subsoil character-
izations should also be made to determine where there is the need for
impervious liners to prevent horizontal and vertical migration of hazardous
constituents.  A characterization of surrounding ground water and surface
waters before the site is activated is required.  In addition, the site
should be operated in such a fashion as to permit disposal of similar
materials in separated and isolated cells.  The location of each cell should
be identified and mapped and its Contents recorded.  Facilities for leachate
collection are essential for liquid, low-solids slurries and/or soluble
metal waste disposal.  The&e'safeguards would permit easy isolation of
problem areas and the removal of wastes to remedy the problem.  It would also
permit the excavation for recovery of such wastes for resource reclamation.
Since long-term physical protection of the environment is the goal, surveil-
lance and monitoring of the disposal sites, including regular analysis of
ground and surface waters for changes in background levels, are necessary.
There are several designs in operation or under consideration to facilitate
leachate collection  (for surveillance and treatment, if necessary) from
potentially hazardous waste disposal sites.  Leachate may be  collected by
sumps at the bottom  of each disposal cell, infiltration piping  along  trenches
in the disposal site, a perimeter trench to catch horizontal migration of
liquid wastes, diversion ditches to collect and transport runoff and
leachate, and ground water wells.  Once the leachate is collected, it is
neutralized with lime to precipitate metal hydroxides.  The dewatered solids
can be returned to the disposal site and the effluent can be discharged to
the sewer.
Cost Analysis
          For purpose of the cost analysis of Level I technology for the
model plants, a water pollution control  (WPC) sludge containing 5 percent
solids was assumed to have been produced by the use of clarifiers and/or
settling tanks.  The production of the 5 percent solids sludge was consi-
dered to have been part of the waste water treatment operation and its
costs.  The principal item of equipment required for this sludge at the
electroplating plant is the storage vessel.

          For Level II and III technologies for the model plants, the WPC
stream underflow from a clarifier containing 2 percent solids was assumed
to be dewatered to a 20 percent sludge with a centrifuge.  The production
of the 2. percent solids underflow was considered to be part of the waste
water treatment operation and its costs.  The principal item of cost to
the electroplater is a centrifuge and associated pipes, pumps, and vessels.

          Contractor hauling, treatment, and off-site landfill disposal of
electroplating and metal finishing wastes was assumed to be employed at the
three model plants for the three technology levels.  Such contractor hauling
and disposal of wastes had been identified as the prevalent practice in
the industry.  The wastes from all four streams (i.e., water pollution
control (WPC) sludge, process wastes, degreaser solvent sludge, and electro-
less Ni-bath treatment sludge) were considered potentially hazardous and
were assumed to be handled and disposed of in the same manner.
                                    xxv

-------
           The contractor charges for combined hauling,  treatment,  and
 disposal of the wastes were developed as shown below:
 Technology
    Level

      I
     II
    III
    Disposal
Land Burial
Approved Landfill
Secured Landfill
Contractor Waste Hauling,
Treatment, and Disposal
	Charge*	
                        ? **
$34.30/MT ($13.90/1000 iru)
$41.95/MT ($ 5.00/1000 nu)**
$68.45/MT ($ 8.15/1000 m )**
 *  Costs are in dollars per metric ton  of gross weight of all combined
    categories of wastes.
**  Cost based on area of workpieces processed, i.e., production.

           The total costs for treatment and disposal, at the three techno-
 logy levels, of WPC sludges, process wastes, solvent sludges, and electro-
 less Ni sludges for all U.S. job shops for 1975 are shown on an individual-
 stream and combined-stream basis in Table 8.

           The costs of treatment and disposal for Level I technology ranged
 from about $56/MT (dry weight) for process wastes to about $820/MT (dry
 weight) for water pollution control sludges.  For Level II technology the
 costs ranged from about $66/MT (dry weight) for process wastes to about
 $477/MT (dry weight) for water pollution control sludges.  For Level III
 technology the cost range was about $82/MT  (dry weight) to $588/MT (dry
 weight), respectively.

           It is readily apparent from Table 8 that the costs for treatment
 and disposal of wastes at Technology Level  I are significantly higher than
 those for Levels II and III for all the model plants.  The reason for this
 apparent discrepancy is the fact that Level I technology involves the
 treatment and disposal of WPC sludge containing 5 percent solids as opposed
 to WPC sludge containing 20 percent solids  for Technology Levels II and III.
 Dewatering the sludge from 5 to 20 percent  solids results in a 4.4-fold
 reduction in the volume of sludge, and accounts for the significantly lower
 overall treatment and disposal costs for Levels II and III.  As expected,
 the waste treatment and disposal costs for Level II technology were lower
 than those for Level III technology, with the cost difference being accounted
 for by the higher contractor charge for Level III landfill disposal.

           Larger volumes of sludge are generated in the water pollution con-
 trol (WPC) stream in comparison with the other waste streams because of the
 large amounts of water associated with the WPC sludges.  For this reason
 the costs for the treatment and disposal of the WPC sludges ranged from
 about 80 to 93 percent of the costs for the combined waste streams irres-
 pective of the plant size and treatment technology levels.  Accordingly,
 the use of in-process controls, such as save rinses, or the use of techniques
 such as evaporation, reverse osmosis, or ion-exchange for the recovery of
 drag out chemicals, offers the most promise for reducing the quantity of
 sludge and thereby cutting the costs related to the treatment and disposal
 of WPC sludges at all treatment levels.
                                    xxvi

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xxvii

-------
          The value added by manufacturing in the electroplating and metal
finishing job shops was $749,100,000 in 1972.  Assuming an inflation rate
of 6 percent to convert the 1972 value to December 1973, dollars, the
value-added figure becomes $794,000,000.  The ratios of waste management
costs at different treatment and disposal technology levels to the value-
added statistic for the industry range from 1.83 to 2.60 percent for 1975
(Table 9).  Thus, the waste treatment and disposal cost constitutes a rela-
tively small part of the overall production costs in the electroplating and
metal finishing  industry.


                                Captive Shops
          The captive shop is an electroplating or metal finishing operation
included in a manufacturing operation, and which works on parts connected
only with that manufacturing operation.  The fact that this category of
shops is a part of some manufacturing operation results in a situation
where the captive shops are not discernible in U.S. Bureau of Census statistics.
In the Census statistics, the various manufacturing operations in the U.S.
are reported in terms of the Standard Industrial Classification (SIC) of
the final product.  In many cases, the contributing captive electroplating
operation remains unidentified.  Thus, there are no reliable data on the
number or size of captive shops.

          A preliminary assessment of the potentially hazardous waste
practices of the captive shop segment of the metal finishing industries
has been completed.  This assessment consisted of:

          (1)  The characterization of this industrial segment
          (2)  The characterization of its potentially hazardous
               wastes
          (3)  The identification of the treatment and disposal
               technology which it practices
          (4)  The estimation of costs associated with treatment
               and disposal of these wastes.

          Information related to the factors listed above was sought
through:

          (1)  Questionnaires mailed to more than 7,000 companies
               through the National Association of Metal Finishers
          (2)  Telephone conversations with personnel associated
               with metal finishing facilities and with treatment
               and disposal contractors
          (3)  Visits to captive shops and to treatment and
               disposal facilities
          (4)  In-depth studies at four complex plants.

          No accurate data could be obtained during this study on the
number  of plants,  the size of  these plants, or their  specific geographical
location.  Only a  small number  (53) of captive shops  provided information
pertinent to the  study.  Since  estimates of the total number range  from

                                   xxviii

-------
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                     xxix

-------
2,000 to 22,000, this is an extremely small sample of the industry.  The
average size of the shops providing data was 53 employees.  This number is
the number of employees associated with plating and metal finishing.  Some
captive shops were in manufacturing plants with considerably (up to 2000)
more total employees.

          Although the specific geographical locations of all of the captive
shops are not known, these facilities usually are associated with manufac-
turing complexes of various types.  It is believed that the geographical
distribution of captive shops follows both that of heavy manufacturing
industries and that of the job shops.  Thus, there are heavy concentrations
of captive shops in the north and middle Atlantic states, in the north
central states, and in California, or in EPA Regions I, II, III, V, and
IX.

          Potentially hazardous waste streams generated by captive shops
have been categorized as follows:

          (1)  Water pollution control sludges
          (2)  Process wastes
          (3)  Degreaser sludges
          (4)  Electroless nickel wastes.

          The principal potentially hazardous constituents found in these
wastes are heavy metals and residual organic materials.  The rationale for
the classification of these materials as potentially hazardous is presented
in the previous discussion on the job shop segment of the industry.

          Because of the extremely limited data acquired through direct
means, information on the quantities of wastes generated has been obtained
by using model plant calculations prepared for the job shop segment of this
industry.  On the basis of those calculations and the assumptions that the
average captive shop employes 53 persons, that there are 12,000 of these
average shops in the U.S., and that they all will meet effluent limitation
guidelines requirements  in 1977  and  1983, preliminary  projections  of
potentially  hazardous wastes  destined  for land disposal  on a national  basis
were made as follows:

                                    Total Wastes Destined for Land Disposal
             Year                    Dry, metric tons       Wet, metric tons

             1975                          830,000            4,810,000
             1977                        1,200,000            3,700,000
             1983                        1,600,000            4,800,000

          The three levels of treatment and disposal technology defined for
the disposal of wastes from captive shops are as follows:

          Level I   -  Prevalent practice:  simple landfill

          Level II  -  Best technology currently used:  dewatering
                       of sludges, with disposal in an approved landfill
                                   xxx

-------
          Level III - Practice considered environmentally adequate:
                      dewatering of sludges, with disposal in a
                      secured landfill.

          It is estimated that the total annual operating costs for waste
treatment and disposal on a national basis for these levels are as follows:

          Level I        $516,000,000
          Level II       $324,000,000
          Level III      $432,000,000

The lesser costs for Levels II and III occur because the total weight of
water pollution control sludges is reduced by a factor of four through
dewatering.

          In conclusion, it must be reemphasized that the projections of
waste quantities and treatment and disposal costs presented herein are
based on extremely sparse data.  They may be in error by an order of magni-
tude because of the lack of information from a representative sample of the
industry.  Therefore they should be used discretely and only as a
preliminary indication of the levels which ultimately may be determined if
a more comprehensive future study is undertaken.

          Further details on electroplating captive shops may be obtained
from an unpublished report maintained in OSF   files.
                                    xxxi

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                              TABLE OF CONTENTS
EXECUTIVE SUMMARY 	    ill

     Introduction 	    iii
     Program Methodology  	     iv
     Industry Characterization  	      v
          Geographic Distribution and Size  	      v
          Distribution by Number of Employees 	    vii
          Distribution by Age of Facilities	    vii
          Distribution by Types of Operations 	    vii
          Value Added and Cost Information	    vii
     Waste Characterization 	     ix
          Types and Sources of Wastes	     ix
          Criteria for Establishing Hazardous Wastes  	     xi
          Determination of Quantity of Wastes Generated 	    xii
     Treatment and Disposal Technology  	  xxiii
          Cost Analysis	    xxv
     Captive Shops  	 xxviii

  I. INDUSTRY CHARACTERIZATION  	      1

     Introduction 	      1
     Products of the Industry 	      1
     Current Economic Status  	      4
     Future Trends and Developments 	      4
     Geographic Distribution of Plants  	      6
     Distribution of Plants by Size	      7
     Distribution of Plants by Age	     10
     Distribution of Plants by Process  	     10
     References	     12

 II. WASTE CHARACTERIZATION 	     16

     Introduction 	     16
     Generalized Process Description  	     16
          Electroplating and Metal Finishing Engineering   ....     17
          Process Sequencing  	     19
     Criteria for Defining a Waste as Potentially Hazardous  ...     19
     Detailed Process Descriptions  	  . 	     25
          Mechanical Operations 	     25
          Chemical Processes  	     30
          Electroplating Processes  	     39
          Materials Reclamation 	     55
     Waste Stream Generation  	     62
          Water Pollution Control Sludges  	     63
          Process Wastes  	     70
          Degreaser Sludges .	     81
          Salt Precipitates from Electroless Nickel
            Bath Regeneration	     83

                                   xxxii

-------
                        TABLE OF CONTENTS (Continued)
          Waste Projections	     84
     References	    115

III. TREATMENT AND DISPOSAL TECHNOLOGY  	    116

     Description of Wastes Destined for Land Disposal 	    116
          Water Pollution Control Sludge  	    116
          Process Wastes  	    117
          Degreaser Sludges 	    117
          Electroless Nickel Wastes 	  .    118
     Acquisition and Analysis of Data	    118
          NAMF Questionnaires	    118
          Safeguards Used in Disposal	    120
          Private Contractors and Service Organizations 	    128
     Description of Waste Treatment and Disposal Methods  ....    132
          Treatment Methods 	    132
          Disposal Methods  	    136
     Development of Technology Levels 	    138
          Prevalent Treatment and Disposal Technology-Level I  .  .    139
          Evaluation of Prevalent Treatment/Disposal
            Technology-Level I	    142
          Evaluation of Best Technology Currently
            Employed-Level II	    150
          Evaluation of Treatment/Disposal Technology
            Considered Adequate for Health and Environ-
            mental Protection-Level III	    151

 IV. COST ANALYSIS	    153

     Introduction and Methodology 	    153
          Contractor Treatment and Disposal Costs 	    154
          Sludge Handling-Disposal Costs from
            Industry Responses  	    159
          Costs of Landfill Disposal	    163
          Sanitary Landfill Fees  	    167
          Summary of Contractor Charges for Hauling,
            Treatment, and Landfill Disposal of
            Wastes at Different Sites 	    172
          Capital and Operating Costs for Waste Treatment
            and Disposal at Three Technology Levels for
            Three Model Plants	    174
          National Costs for Treatment and Disposal of
            Electroplating and Metal Finishing Wastes
            for 1975	    185
                                  xxxiii

-------
                        TABLE OF CONTENTS (Continued)
                                 APPENDICES

A.  Methodology for Acquiring Information 	    A-l

B.  Model Plant A (38 Employees)	    B-l

C.  Model Plant B (16 Employees)	    C-l

D.  Model Plant C (87 Employees)	    D-l

E.  Tables of Waste Quantities of Various Types Generated
    by the Electroplating and Metal Finishing Industry   	    E-l

F.  Detailed Cost Data on Selected Level II  (Sludge
    Dewatering) - Level I (Landfill Burial)  Case Studies   ....    F-l

G.  Tabulation of Original Data and Plots of Parameters  	    G-l

H.  Waste Characteristics Reported by Electroplating
    and Metal Finishing Job Shops	    H-l

I.  Glossary	    1-1
                                   xxxiv

-------
                              LIST OF TABLES
Table 1.   Distribution of Plants by Process and
           Product Mix in 70 SIC 3471 Plants (Job Shops)	2-3
Table 2.

Table 3.

Table 4.
Table 5.
Table 6.
Table 7.

Table 8.
Table 9.
Table 10.

Table 11.
Table 12.

Table 13.

Table 14.

Distribution of Plants by the Number of
Establishments 	
Distribution of Electroplating and Metal
Finishing Job Shops by Size (Number of Employees) ....
Processing Sequences for Chromium Plating 	
Processing Sequences for Nickel Plating 	 ....
Processing Sequences for Zinc Plating 	
Processing Sequences — Decorative
Copper-Nickel-Chromium Plating 	
Criteria for Public Water Supplies 	
Media Used for Mass-Finishing Operation 	
Production Techniques for the Polishing and
Buffing of Metal 	
Typical Applications for Vapor-Degreasing Solvents . . .
Alkaline Cleaning Solutions and Operating
Conditions 	
Some Acid Treatments Used for Pickling,
Cleaning, and Brightening 	
Ranges of Compositions of Electroless Nickel
Plating Solutions 	

8

9
20
21
22

23
24
27

29
31

32

34

38
Table 15.


Table 16.


Table 17.


Table 18.

Table 19.
Typical Bath Compositions and Operating
Conditions for Nickel Plating Operations

Typical Bath Compositions and Operating
Conditions for Chromium Plating 	
Representative Compositions and Operating
Conditions for Cadmium Plating Baths  .  .
Typical Zinc Cyanide Plating Baths
Typical Compositions and Operating Conditions
for Cyanide Copper Plating Baths  	
41


43


45

46


48
                                  XXXV

-------
                        LIST OF TABLES (Continued)

                                                                     Page

Table 20.  Typical Compositions and Operating
           Conditions for Acid Copper Plating Baths 	  49

Table 21.  Representative Compositions and Operating
           Conditions for Stannate Tin Plating Baths  	  51

Table 22.  Compositions and Operating Conditions for
           Acid Tin Plating Baths	51

Table 23.  Ranges of Compositions and Operating
           Conditions for Cyanide Gold-Plating
           Solutions	53

Table 24.  Production Techniques for Mechanical
           Polishing and Buffing of Metal 	  73

Table 25.  Media Used for Mass-Finishing Operations	74

Table 26.  Data on Rack Insulating Materials	79

Table 27.  Typical Applications for Vapor-Degreasing Solvents  ....  82

Table 28.  Plating Operations for Model Plant A (Intermediate)  ...  89

Table 29.  Plating Operations for Model Plant B (Small)	90

Table 30.  Plating Operations for Model Plant C (Large) 	  92

Table 31.  Assumed Metal Concentrations in Wastewater 	  96

Table 32.  Characteristics and Sludge Production
           Rates of the Model Plants	97

Table 33.  Solid Wastes from Plating Operations of
           Model Plant A	98

Table 34.  Miscellaneous Wastes from Operation of Model Plant A ...  99

Table 35.  Summary of Waste Quantities Derived from Model Plants   .  . 101

Table 36.  Distribution and Number of Electroplating and
           Metal Finishing Job Shops Used in Estimation
           of Solid Waste Generation  	 102

Table 37.  Quantity of Total Industry and Potentially
           Hazardous Wastes Destined for Land Disposal
           from the Electroplating and Metal Finishing
           Industry (Job Shops); Metric Tons; Dry
           Weight; 1975    	105
                                 XXXVI

-------
                        LIST OF TABLES (Continued)
                                                                     Page
Table 38.  Quantity of Total Industry and Potentially
           Hazardous Wastes Destined for Land Disposal
           from the Electroplating and Metal Finishing
           Industry (Job Shops); Metric Tons; Dry
           Weight; 1977	108

Table 39.  Quantity of Total Industry and Potentially
           Hazardous Wastes Destined for Land Disposal
           from the Electroplating and Metal Finishing
           Industry (Job Shops); Metric Tons; Dry
           Weight; 1983	110

Table 40.  Total Estimated Hazardous Wastes from
           Electroplating and Metal Finishing Job
           Shops, Metric Tons, Dry Weight (50 Week Year)	113

Table 41.  Total Estimated Hazardous Wastes from 1977
           Electroplating and Metal Finishing Job
           Shops, Metric Tons, Dry Weight (50 Week Year)	114

Table 42.  Breakdown of Reporting Job Shops Based on
           the Method of Data Assembly and Analysis
           of Heavy Metal Pollutant Handling  	 121

Table 43,  A Comparison of On-Site Versus Off-Site
           Treatment and Disposal Practices Employed
           By the Electroplating and Metal Finishing Industry .... 122

Table 44.  Safeguards Used and the Percentage of Waste
           Disposed of From the Metal Finishing Industry  	 124

Table 45.  Summary of Telephone Survey Data Characterizing
           Waste Contractor Operations  	 129

Table 46.  Treatment and Disposal Contractors Handling
           Electroplating or Metal Finishing Wastes Visited 	 131

Table 47.  Treatment Methods Used by the Sampled Job Shops
           to Separate Solids from Treated Wastewater 	 140

Table 48.  Disposal Methods Used by the Sampled Job Shops
           for Sludges and Process Wastes 	 141

Table 49A. Summary of Treatment and Disposal Technologies
           (Water Pollution Control Sludge and
           Electroless Nickel Sludge) 	 , 	 143

Table 49B. Summary of Treatment and Disposal Technologies 	 145
                                 xxxvii

-------
                       LIST OF TABLES (Continued)

                                                                     Page

Table 49C. Summary of Treatment and Disposal
           Technologies (Process Wastes) 	  147

Table 49D. Summary of Treatment and Disposal
           Technologies (Degreaser Sludges)  	  148

Table 50.  Contractor Charges for Waste Handling
           and Disposal	156
                        *
Table 51.  Summary of Average Waste Handling Fees	158

Table 52.  Summary of Contractor Waste Handling Charges  	  160

Table 53.  Summary Cost Data for Sludge Dewatering
           and Disposal Systems  	  162

Table 54.  Initial Costs for Three Sanitary Landfills
           of Different Capacities, 1973	164

Table 55.  Fees Charged by Los Angeles Class I Disposal
           Sites - Fee Schedule 1970-72 to July 1974	170

Table 56.  Summary of Estimated Contractor Hauling, Treatment,
           and Disposal Charges for Electroplating and
           Metal Finishing Waste Destined for Land Disposal   ....  173
Table 57.
Table 58.
Table 59.
Table 60.
Determination of Estimated Capital and Operating
Costs for Waste Handling and Disposal At Three
Technology Levels for Three Different Sized
Electroplating and Metal Finishing Model Plants .  .

Summarized Estimated Costs for Treatment and
Disposal of Different Waste Streams at Three
Technology Levels for Three Different Sized
Electroplating and Metal Finishing Model Plants .  .

1975 National Costs for the Treatment and Disposal
of Electroplating and Metal Finishing Wastes
At Different Technology Levels  	
                                                                      175
                                                                      181
                                                                      186
Comparison of Waste Treatment and Disposal
Costs to Value Added Statistic for the
Electroplating and Metal Finishing Industry
for Different Treatment Technology Levels .
                                                                      189
                                 xxxviii

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                             LIST OF FIGURES

                                                                     Page

Figure 1.   Manufacturing Plants and Employment in SIC 3471 	   5

Figure 2.   Total and Partial Reclamation of Plating
            Chemicals Lost Through Drag Out	56

Figure 3.   Chromic Acid Recovery by Ion Exchange	58

Figure 4.   Corning Climbing Film Evaporation Recovery
            Unit for Plating Chemicals	60

Figure 5.   Features of Sludge Generation in Model Plant A  	  94

Figure 6.   Options for Waste Disposal from Electroplating,
            Metal Finishing and Printed Circuit Industry  	 119

Figure 7.   Composite Schematic of Electroplating and Metal
            Finishing Hazardous Waste Treatment and Disposal
            Contractor Operations 	 133

Figure 8.   Cost-Capacity Relationship for Sludge Dewatering
            and Disposal Systems	161

Figure 9.   Capital and 0/M Costs for Sanitary Landfills  	 166

Figure 10.  Range of Sanitary Landfill Operating Costs  	 168

Figure 11.  Estimated Sanitary Landfill Operation and
            Maintenance Costs 	 169

Figure 12.  Centrifuge Capacities and Costs 	 179

Figure 13.  Waste Treatment and Disposal Costs for Model
            Plants at Three Treatment Technology Levels 	 182
                                   xxxix

-------
                        I.  INDUSTRY CHARACTERIZATION
                                INTRODUCTION
          Practically all types of manufacturing involve electroplating and
metal finishing operations.  Two distinct types of facilities that do elec-
troplating and metal finishing operations are recognized.  One is job shops,
which are independent companies doing work on materials own;   b  others.
The second is captive shops which are part of a larger corporate organization
and do work on materials owned by that organization.  Job shops are the
subject of the following discussion.

          This section of this report contains information on the following
characteristics of the electroplating and metal finishing job shop industry:

          Products of the industry
          Current economic status
          Future trends and developments
          Geographic distribution of plants
          Distribution of plants by size
          Distribution of plants by age
          Distribution of plants by process
                          PRODUCTS OF THE INDUSTRY
          As defined by the Department of Commerce:  "The Plating and
Polishing Industry includes establishments primarily engaged in all types
of electroplating, plating, anodizing, coloring, and finishing metal, and
formed products for the trade.  Most of the work done in this industry is
done on materials owned by others."      The electroplating industry
utilizes chemical and electrochemical operations to effect an improvement
in the surface properties of metals and other materials.

          Thus the products of the industry are metallic coatings applied
to metallic or nonmetallic products manufactured by others.  Each product
requires specific process sequences to obtain the desired physical, chem-
ical, or aesthetic values.  Table 1 summarizes the metal finishing operations
and the metals most frequently deposited as coatings.  The processes used
to achieve these coatings on ferrous, nonferrous, and nonmetallic materials
are described in the following section entitled "Generalized Process
Description".  The coating may consist of a single or of multiple electro-
deposits.  For example, automotive trim may be finished with successive
coatings of copper-nickel-nickel-chromium which provides corrosion protection
and is also decorative, or chromium only may be applied to steel as a wear
resistant coating.

          The manufacturing industries which are normally services by the
electroplating and metal finishing establishments are SIC groups 34 (Fabri-

-------
TABLE 1.  DISTRIBUTION OF PLANTS BY PROCESS AND
Metal Finishing Processes
Number of
EPA Region
and State
U.S. TOTAL
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region II
New Jersey
New York
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region IX
Arizona
California
Nevada
Region X
Idaho
Oregon
Washington
Alaska
Hawaii
Virgin Islands
Puerto Rico
(1 ) WD = wire drawing
(2) S = spinning
(3) PS = paint stripping
Plants
Reporting
70
14
5
6
1
0
2
0
10
2
8
5
0
2
3
0
0
3
0
0
0
0
1
0
1
1
22
5
0
5
2
7
3
2
0
0
0
0
2
1
0
0
0
1
0
0
0
0
0
0
0
13
0
13
0

0
0
0
0
0
0
0



Electro-
plating
65
14
5
6
1
-
2
_
10
2
8
4
—
2
2
-
—
3
—
_
-
—
1
_
1
1
20
4
—
5
2
7
2
2
—
_
_
_
2
1
—
—
_
1
-
—
—
_
—
_
-
11
—
11
-

—
-
—
—
_
-
—



(4) B = wet or dry grit blasting
(5) HT = heat treating
(6) P = painting




Electroless
Plating
21
6
1
5
0
_
0
-
5
2
3
0
—
0
0
-
—
0
—
_
-
—
0
_
0
0
3
1
—
1
1
0
0
1
—
—
_
_
1
1
—
—
_
1
-
—
_
—
—
_
-
5
—
5
-

—
-
—
—
—
-
—
(7)
(3)
(9)
(10)
(11)
(12)
Anodizing Chromating
19
7
2
3
0
-
2
_
3
1
2
2
—
1
1
-
—
1
—
_
-
—
0
_
0
1
2
0
—
1
0
1
0
1
—
—
_
_
1
1
—
—
_
1
-
—
_
_
—
_
-
2
—
2
-

—
-
—
—
_
-
—
H = honing
D= descaling
ST = stamping
50
12
3
6
1
_
2
_
3
0
3
4
—
1
3
-
—
2
—
_
-
—
1
_
0
1
12
2
_
3
1
5
1
1
—
_
_
_
1
1
—
—
_
1
-
—
—
—
—
_
-
7
—
7
-

—
-
—
—
—
-
—



Phosphating
22
8
2
4
0
-
2
-
2
0
2
1
—
1
0
-
—
1
—
_
-
—
0
—
0
1
6
2
—
2
0
1
1
1
—
—
—
—
1
0
—
—
—
0
-
—
—
—
—
—
-
3
—
3
-

—
-
—
—
—
-
—



Bright
Dipping
31
10
3
4
1
—
2
_
5
1
4
1
—
0
1
-
—
2
—
_
-
—
1
-
0
1
6
0
-
0
2
4
0
1
-
_
-
—
1
1
—
-
—
1
-
—
—
—
—
—
-
5
—
5
-

—
—
—
—
—
-
—



Chemical
Polishing
5
1
0
0
0
—
1
_
1
0
1
0
—
0
0
-
—
1
—
_
-
—
0
—
0
1
0
0
—
0
0
0
0
0
—
—
—
—
0
0
—
—
—
0
-
—
—
—
—
_
-
2
—
2
-

—
—
—
—
_
-
—




Dying
17
6
2
1
1
-
2
_
3
0
3
0
—
0
0
-
—
1
—
_
-
—
0
—
0
1
3
0
—
1
0
2
0
1
—
—
—
—
1
1
—
—
—
1
-
—
—
—
—
—
-
2
—
2
-

—
-
—
—
—
-
—



F = cold forming
E = enameling
M = machining.











-------
PRODUCT MIX IN 70 SIC 3471 PLANTS (JOB SHOPS)'521

Debarring
12
4
1
1
0
2
2
0
2
0
0
0
2
1
0
1
2
0
0
0
1
1
0
0
0
0
2
2

Passivating
26
9
3
3
1
2
4
0
4
1
0
1
2
1
0
1
3
0
1
0
2
0
0
0
1
1
6
6

Stripping
1
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
1

Grinding
Polishing
or Buff ing
13
2
1
0
0
1
3
0
3
1
0
1
0
1
0
1
0
3
1
1
0
1
0
0
0
1
1
2
2 E

Other
Plant
Operations
12
1
None
WD(1)
None
None
None
None
1
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
B H"P5)
'None
plO)
HT(5)
H(7) B(4)
b<8>
1
None
None
None
None
None
None
None
None
None
None
None
None
None
None
None
4
'None
None
None
None
None
None
None
None
Metals Deposited
Cu
40
10
1
6
1
2
^
1
6
3
1
2
2
1
0
1
11
2
1
2
4
2
0
0
1
1
6
•1 6
Brass
10
2
0
2
0
0
4
2
2
0
0
0
1

-
1
0
0
1
0
0
0
0
1
0
0
0
0
2
2
Ni
47
11
2
6
1
2
6
0
6
2
1
1
2

-
1
0
1
16
4
3
2
5
1
1



1
1
1

-


8
8







Cr
42
9
3
4
0
2
5
1
4
3
1
2
2

-
0
1
1
13
2
3
1
5
2
2



2
1
1

-


8
8







Zn
32
7
2
2
1
2
2
0
2
2
1
1
2

-
1
0
1
13
3
3
1
4
2
1



1
1
1

-


4
4







Sn
20
8
1
5
1
1
3
1
2
1
0
1
2

-
1
0
1
3
0
1
1
0
1
0



0
1
1

-


2
2







Pb
4
2
0
2
0
0
0
0
0
0
0
0
0

-
0
0
0
1
1
0
0
0
0
0



0
0
0

-


1
1







Sn-Pb
4
3
0
2
0
1
0
0
0
0
0
0
0

—
0
0
0
0
0
0
0
0
0
0



0
0
0

—


1
1







Au
10
5
1
3
1
0
2
0
2
0
0
0
0

-
0
0
0
1
0
0
1
0
0
0



0
1
1

-


1
1







Ag
16
8
1
5
1
1
3
0
3
0
0
0
0

-
0
0
0
1
0
0
1
0
0
0



0
1
1

-


3
3







Pt-metals
2
1
0
1
0
0
0
0
0
0
0
0
0

-
0
0
0
0
0
0
0
0
0
0



0
0
0

—


1
1







Cd
37
10
2
5
1
2
2
0
2
3
1
2
2

-
1
0
1
12
2
3
1
4
2
1



1
1
1

-


6
6







Co
2
1
1
0
0
0
0
0
0
0
0
0
0

-
0
0
0
1
0
1
0
0
0
0



0
0
0

-


0
0







Fe
1
0
0
0
0
0
0
0
0
0
0
0
0

-
0
0
0
0
0
0
0
0
0
0



0
0
0

—


1
1








-------
cated Metal Products), 35 and 36 (Machinery), 37 (Transportation Equipment),
38 (Instruments and Related Products), 39 (Miscellaneous Manufacturing),
and 19 (Ordnance and Accessories).  The annual production of the metal
finishing industry is measured as value added to the products of others.
The distribution of these values can be related to the distribution of
plants (Tables 2 and 3).  A precise measure of the distribution of the
materials and products processed is not feasible from the statistical data
available.  Similarly, no data are known to exist which would allow one to
project the types of materials added to the products for any geographic
region.  The data of Table 1, discussed above, shows some trends of material
usages.
                           CURRENT ECONOMIC STATUS


          The number of manufacturing plants and employment in SIC 3471
for the years 1958 through 1972 are shown in Figure 1.  The total number of
plants is higher than the numbers given in Tables 2 and 3 for reasons given
in the "Geographic Distribution of Plants" section of this report.  The
economic trends of the industry are not affected by the absolute number of
facilities.  Industry plants in general are small.  More than 75 percent
of the plants show fewer than 20 employees.  The employment peaked in 1969
with 69,000 and decreased to near 52,000 employees by 1971.  The latest
census of manufacturing facilities, in 1972, shows a modest increase to
about 53,000 employees.

          The total number of plants also peaked in 1969 to about 3300 at
a rate of approximately 65 plants, or 2.5 percent annually, for the period
from 1958 to 1969.  The following years to 1972 showed a stabilization of
the number of industrial plants with an annual decrease of less than 10
plants or about 0.2 percent.  The slightly fewer number of plants showed
an increase in employment for the year 1972.

          For 1972, the value added by manufacture was $749,100,000.  The
cost of materials and fuels was $297,400,000, or about 40 percent of the
value added and 28 percent of the value of industry shipments of
$1,062,100,000.  The capital expenditures in 1972 were $41,000,000, up
$9,920,000 or 32 percent from 1971, and amounted to about 4 percent of the
value of industry shipments.  Wages in 1972 were $393,300,000, an increase
of 8 percent from $864,000,000 for the wages of the previous year, and
represented 52 percent of the value added or nearly 38 percent of the
value of industry shipments.
                       FUTURE TRENDS AND DEVELOPMENTS
          Based on the statistical data from the Census of Manufactures
for the years 1958 to 1972  (Figure 1) for the electroplating and metal
finishing industry little or no growth is projected for the near future.
Similarly, the number of employees is expected to hold near its present
level.  The value added by manufacture will increase as the costs for
materials and labor increase.  Price rises in fuel will contribute to

-------
o
S3
H
o
g

o

w

i
2;
        4400
        4000  -
        3600  _
        3200  -
       2800
       2400  _
       2000 __/ -
       1600
       1200
        800 l_
        400
                                          Total Number

                                          of Employees
                        Plants having

                          20 Employees
                                                                          64,000
                                                                          56,000
                                                                           48,000
                                                                           40,000
                                                                          32,000
                                                                          24,000
                                                                                      co
                                                                                      w
                                                                                      w
                                                                                      >1
                                                                                      o

                                                                                      p-l
           1958
                            1962
                                             1966
                                                               1970
                                      CALENDAR YEAR
            FIGURE 1.  MANUFACTURING PLANTS AND EMPLOYMENT IN SIC  3471
                                                                      (53)

-------
increased costs of shipments.  The rate of these increases should follow
the overall economic conditions prevalent for all manufacturing.  Capital
expenditures are expected to increase as replacement costs, purchase of new
equipment, and plant space costs increase.  Pollution control equipment will
be needed to comply with Effluent Guideline regulations for the industry.
The amount of these expenditures is undetermined since they are dependent.
on the severity of effluent restrictions.  Consequently, expenditures for
equipment purchases may range from $22,000 for a plant with less than 5
employees practicing only acid-base neutralization, to $400,000 for a plant
with about 50 employees carrying out a complete wastewater treatment with
clarification and filtering.  The annual operating costs for such wastewater
systems may range from $12,000 to $160,000, respectively.  Some savings may
be made possible by regeneration of plating chemicals.

          Technical developments for the industry are expected in the area
of metals reclamation from spent plating solutions and from rinses.  Major
breakthroughs can reduce the quantities of plating metals needed in produc-
tion.  Research efforts in the area of metal substitution by less costly
materials may produce a reduction in process costs.  An example would be the
replacement of nickel with iron-nickel alloys for some products.  Additionally,
improved processes can be expected to provide material savings.  New processes
and new coating materials developed constantly find applications for products
not oreviously finished by the electroplating industry, thus enhancing the
economic growth ootential.
                      GEOGRAPHIC DISTRIBUTION OF PLANTS
          The geographic distribution of electroplating and metal finish
job shops was determined using the state directories of manufacturers
State directories were used in preference to federal statistics since the
companies are identified by name and address, the distribution with regard
to city size may be determined, and the data are more recent  (that is,
since 1972).

          State directories contain listings of establishments (i.e.,
engraving, sand blasting of monuments, heat treating, and others of lesser
importance) which are not truly metal finishing operations as defined for
this study which was limited to

           (1)  Electroplating
           (2)  Anodizing and dyeing
           (3)  Electroless and immersion plating
           (4)  Chemical conversion coating  (phosphate, chromate, etc.)
           (5)  Chemical polishing and electropolishing.

          Specifically excluded from the study were

           (1)  Coloring
           (2)  Chemical milling and etching
           (3)  Electrochemical machining
           (4)  Pickling, descaling, bright dipping, stripping
           (5)  Electropainting.

-------
In dealing directly with the state directories, it was possible to exclude
plants other than those in the first category.  This is reflected in a
lesser number of facilities.  Additionally, the use of the data from state
directories enabled a breakdown as to the size of towns in which electro-
plating and metal finishing establishments are located.

          The number of job shops is listed in Table 2 by State, EPA Region,
and nationally, under the headings of size of towns or cities.

          As shown in Table 2, the heaviest concentration of electroplating
and metal finishing facilities are in the North Central Region of the U.S.
EPA Region V has nearly 40 percent of the total number of industry job shops,
with Michigan accounting for 12 percent followed by Ohio (over 11 percent)
and Illinois (~8 percent).  The Atlantic Coast states are second with 35
percent of the electroplating and metal finishing plants.  The third
heaviest concentration is in EPA Region IX, particularly in the State of
California (6 percent).  The remaining sectors of the country share 20
percent of the electroplating and metal finishing plants.  This distribution
appears to be coincident with that for manufacturing facilities.  For example,
the heavy concentration of electroplating and metal finishing plants in
Michigan, Ohio, and Illinois coincides with the automotive industry in that
area.

          Evaluation of the data presented in Table 2 also shows that more
than 52 percent of all electroplating and metal finishing establishments
are located in cities having a population greater than 100,000, and that
more than three quarters of the plants are located in towns with a popula-
tion greater than 20,000.  Only 10 percent of the establishments are in
towns with a population of less than 5,000 inhabitants.  The fact that 52
percent or more than 75 percent of the job shops are located in cities of
more than 100,000 or 20,000 population, respectively, is reasoned to affect
the type of treatment and disposal practices employed by the plants so
located.  It is reasoned that the urban location of the electroplating and
metal finishing industry would result in limits (either physical or economic)
on plant space available for the treatment and disposal of wastes, and would
also be associated with wastewater disposal to sewers according to applicable
local regulations.  Thus, the distribution in large cities cited above would
be reasoned to favor such waste disposal practices as sewering of liquid
wastes  (with or without treatment or solids separation) and off-site disposal
of nonsewerable wastes, thus the use of contractor services.  The prevalence
of such practices is discussed in a later section of this report.
                       DISTRIBUTION OF PLANTS BY SIZE
          The distribution of establishments by number of employees is
shown in Table 3.  Examination of this table reveals that 89 percent of the
total number of plants have 1 to 50 employees.  The greatest percentage (30
percent) have 11 to 25 employees, with 27 percent having 5 to 10, 20 percent
having 26 to 50, and 12 percent 1 to 4 employees.  About half of the plants
employing more than 100 persons and over 40 percent employing more than 50
persons are located in Region V.

-------
            TABLE  2.  DISTRIBUTION OF PLANTS  BY THE NUMBER OF ESTABLISHMENTS
                                                                            (1-51)
Number
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region II
New Jersey
New York
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region VI
Arkansas
Louisiana
._ . . .
new nexico
Oklahoma
Texas
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VIII
Colorado
.. .
Montana
Nnvf*h T\si\mt" a
nortn L/atcui-u
South Dakota
Utah
Wyoming
Region IX
Arizona
California
Hawaii
Nevada
Region X
A 1 4 olr a
A lutSKa
Idaho
Oregon
Washington
Total United States
A
16
7
7
0
1
1
0
44
16
28
33
0
1
28
1
3
29
5
7
3
2
2
5
4
1
89
8
8
49
3
16
5
2
0
0

0
2
14
7
1
6
0
2
1

n
\j
0
0
0
3
1
1
0
1
0
o
0
0
0
232
B
55
16
29
5
2
0
3
37
22
15
34
0
2
30
0
2
20
2
4
1
3
2
3
2
3
104
14
13
35
4
34
4
7
1
0

1
5
15
2
7
5
1
2
1


0
1
0
14
1
13
0
0
1
o
0
0
1
289
of Plants (a)
C
135
59
51
23
0
2
0
64
36
28
37
0
3
25
0
9
41
8
13
3
1
2
5
4
5
174
44
22
55
6
33
14
13
2
1

0
10
15
9
0
6
0
4
2

n
u
1
1
0
52
1
48
0
3
13
o
3
4
6
548
D
120
34
37
49
0
0
0
132
39
93
72
1
14
55
2
0
67
6
17
9
6
2
10
2
15
494
123
26
137
18
179
11
77
2
1

17
51
71
4
13
50
4
23
18


0
5
0
94
15
74
3
2
35

0
18
17
1.1E5
Total
326
116
124
77
3
3
3
277
113
164
176
1
20
138
3
14
157
21
41
16
12
8
23
12
24
861
189
69
276
31
262
34
99
5
2

18
68
115
22
21
67
5
31
22


1
7
0
163
18
136
3
6
49

3
22
24
2,254
Percent Distribution of Plants (a)
A
0.71
0.31
0.31
	
0.04
0.04
	
1.95
0.71
1.24
1.46
	
0.04
1.25
0.04
0.13
1.29
0.22
0.31
0.13
0.09
0.09
0.22
0.18
0.04
3.95
0.36
0.36
2.18
0.13
0.70
0.22
0.09
	
	

	
0.29
0.62
0.31
0.04
0.27
	
0.09
0.04
On/.
. vy4*
	 	
	


0.13
0.04
0.04


0.04
	

........
	
	
10.29
B
2.44
0.71
1.29
0.22
0.09
	
0.13
1.64
0.97
0.67
1.51


0.09
1.33
	
0.09
0.89
0.09
0.18
0.04
0.13
0.09
0.13
0.09
0.13
4.61
0.62
0.58
1.54
0.18
1.51
0.18
0.31
0.04
	

0.04
0.22
0.67
0.09
0.31
0.22
0.04
0.09
0.04


	
0.04


0.62
0.04
0.58


	
0.04

_ ..——
	
0.04
12.82
C
5.99
2.63
2.27
1.02
	
0.09
	
2.84
1.60
1.24
1.64


0.13
1.11
	
0.40
1.82
0.36
0.58
0.13
0.04
0.09
0.22
0.18
0.22
7.72
1.95
0.98
2.41
0.27
1.47
0.62
0.58
0.09
0.04

	
0.44
0.67
0.40
	
0.27
	
0.18
0.09


0.04
0.04


2.31
0.04
2.13


0.13
0.58

0.13
0.18
0.27
24.33
D
5.32
1.51
1.64
2.18
	
	
	
5.86
1.73
4.13
3.20
0.04
0.62
2.45
0.09
	
2.97
0.27
0.76
0.40
0.27
0.09
0.44
0.09
0.67
21.92
5.46
1.14
6.09
0.80
7.94
0.49
3.41
0.09
0.04
n 97
\j . *- 1
0.76
2.26
3.14
0.18
0.58
2.21
0.18
1.02
0.80


	
0.22


4.17
0.67
3.29
0.13
0.09
1.55

____
0.80
0.75
52.56
Total
14.46
5.16
5.51
3.42
0.13
0.13
0.13
12.29
5.01
7.28
7.81
0.04
0.88
6.14
0.13
0.62
6.97
0.94
1.83
0.70
0.53
0.36
1.01
0.54
1.06
38.20
8.39
3.06
12.24
1.38
11.62
1.51
4.39
0.22
0.09
0. 27
0.80
3.01
5.10
0.98
0.93
2.97
0.22
1.38
0.98
n DA
U . VJ4
0.04
0.31


7.23
0.80
6.03
0.13
0.27
2.17

0.13
0.98
1.06
100.00
(a)   Classified  by  City  Population:  A =  <5000; B = 5000  to 20,000;
     C »  20,000  to  100,000;  D  = >100,000.

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TABLE 3. DISTRIBUTION OF ELECTROPLATING AND METAL FINISHING JOB-SHOPS BY SIZE
        (NUMBER OF EMPLOYEES)
Number of Employees
EPA Region and State
Region 1
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region II
New Jersey
New York
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region IX
Arizona
California
Hawaii
Nevada
Region X
Alaska
Idaho
Oregon
Washington
Total Regions I-X
1-4
53
23
30
_
-
_
_
1
1
_
42
	
7
35
-
-
22
_
9
5
1
-
2
1
4
88
19
-
19
—
50
_
8
_
-
-
8
_
22
—
—
22
_
-
-
-
_
_
_
-
13
2
7
2
2
8
_
-
8
-
257
5-10
66
25
36
_
1
2
2
73
41
32
38
_
4
30
-
4
42
9
13
3
3
1
4
4
5
215
53
21
54
6
73
8
30
2
1
5
4
18
28
15
_
13
_
16
12
1
-
1
2
-
41
5
31
1
4
18
—
1
5
12
567
11-25
55
31
22
-
2
_
_
110
44
66
51
1
7
39
-
4
42
5
13
3
1
6
7
4
3
247
57
26
69
12
71
12
31
—
-
-
3
28
34
—
14
17
3
6
2
-
-
—
4
-
55
6
49
-
-
15
_
2
5
8
646
26-50
116
29
15
71
-
—
1
53
18
35
25
_
2
17
2
4
34
5
3
2
5
-
8
1
10
120
32
10
32
4
38
4
18
2
1
1
1
13
11
3
—
6
2
4
3
-
-
_
1
-
33
4
29
-
-
4
—
-
-
4
418
51-75
7
_
6
-
-
1
_
13
3
10
5
	
-
4
1
-
6
_
1
2
1
-
_
2
-
42
10
-
16
3
11
2
2
_
_
_
2
_
3
—
_
3
_
3
3
-
-
_
-
-
6
-
6
_
-
2
_
-
2
-
89
76-100
10
C
3
1
_
_
_
8
1
7
;
	
-
5
-
2
5
1
_
-
1
1
1
-
1
24
5
6
8
—
3
2
9
1
-
_
_
8
10
2
4
4
_
2
2
-
-
_
-
-
4
1
3
-
-
1
_
-
1
-
80
101-150
1
_
1
_
-
_
_
5
2
3
2
_
-
2
-
-
1
_
_
1
-
-
_
_
-
16
6
-
4
—
5
1
-
—
-
-
—
_
6
2
3
1
—
-
-
-
-
.-
_
-
2
-
2
-
-
-
_
-
-
-
33
151-250
6
—
1
5
-
—
—
1
_
1
_
_
-
-
-
-
1
_
_
—
-
-
1
—
-
12
2
3
3
1
3
—
-
-
-
_
_
_
-
—
_
_
_
_
-
—
-
„
—
-
3
_
3
_
-
_
_
-
_
-
23
2b1-GOC
_.
—
-
-
-
—
-
-
-
_
-
_
-
-
-
-
1
_
_
-
-
-
_
_
1
4
1
-
2
—
-
1
-
_
-
_
_
_
1
—
_
1
_
-
_
-
_
_
_
-
1
_
1
_
_
_
_
_
_
_
7
1 Not Given
12
2
10
-
-
—
-
13
3
10
6
—
-
6
-
-
3
1
2
-
-
-
—
-
-
93
4
3
69
5
8
4
1
—
-
—
_
1
-
—
_
_
_
-
-
_
_
_
_
-
5
_
5
_
_
1
_
_
1
_
134
Total
326
116
124
77
3
3
3
277
113
164
176
1
20
13R
3
14
157
21
41
16
12
8
23
12
24
861
189
69
276
31
262
34
99
5
2
6
18
68
115
22
21
67
5
31
22
1
_
1
7
-
163
18
136
3
6
49
__
3
22
24
2254

-------
          Other measures of size that could be used in this industry
include surface area processed, power consumption, or consumption of chem-
icals.  The variety of work done in job shops, the variation in the number
of steps used by different shops to produce the same nominal finish, the
degree of automation of the process, and the variations in practice make
the description of size of operation by such measures so complex as to
preclude the presentation of any overall data for the industry.
                        DISTRIBUTION OF PLANTS BY AGE
          The types of electroplating and metal finishing operations con-
ducted are the same in all facilities regardless of the age for a given
process.  The quantity of waste produced is also independent of the age of
the facility.  Older installations employ mainly hand-operated equipment,
while in newer facilities equipment tends to be automated.  However, for a
given product being finished, the loss of chemical solutions per unit area
processed is the same for both manual and automated operations and conse-
quently the same quantity of water pollution control sludges is generated.
In terms of polishing or buffing, automatic operations are somewhat more
efficient than manual operations because of equalized wheel pressure and
the uniform applications of the compound.  Automated equipment installed
within the past 20 years is expected to produce 10 to 20 percent less waste
than older manual equipment.

          A sampling of the industry established no definite age range
among the facilities.  Companies report having equipment as new as 2 years
and as old as 30 years.  Equipment is continuously purchased as the changes
in product mix and/or the volume of business dictate.  The work being done
by the industry on materials owned by others requires flexibility in processes
as well as in size of equipment. Waste treatment equipment for chemical
in-line or end-of-line waste control is generally less than 5 years old,
although some equipment has been used for about 25 years.
                     DISTRIBUTION OF PLANTS BY PROCESS
          Statistical data on the distribution of the processes used in the
industry is nonexistent.  The analysis that follows is based on the infor-
mation supplied by 70 facilities during this study.  The results are given
in Table 1.  Electroplating operations are reported in 65 of the plants
which together deposit 14 different metals or alloys in 265 rack- or barrel-
type operations.  Copper, nickel, chromium, zinc, and cadmium comprise
nearly 80 percent of the operations.  Less than one third of the plants have
tin-plating operations, about 20 percent plate silver, and about 15 percent
have installations for plating brass and gold.  Lead and lead alloys, iron,
cobalt, and the platinum metals are deposited in the lowest number of facil-
ities.

          A chromating operation is in existence in 50 of the 70 facilities.
Most applications of the process are on zinc deposits.  Electroless plating
of nickel and copper is carried out in 30 percent of the plants, and

                                    10

-------
processes for phosphating of steel and anodizing of aluminum are practiced
in just under 30 percent of the reporting facilities.   Of the 19 plants
that reported anodizing, 17 are applying dyes to finish coatings.  About
one third of the plants have equipment for passivating metals to protect
against tarnish and corrosion.  These applications would be most common
on copper and copper alloys and silver.

          Some form of basis metal preparation is carried out in almost
half of the facilities.  Bright dipping and chemical polishing produce acid
metal wastes and are carried out in at least 45 percent of the plants.
Deburring, grinding, polishing, or buffing is reported by 12 or 13 plants,
about 17 percent of the facilities.  Twelve of the plants reported the
performance of other operations, normally not associated with metal finishing,
such as machining, enameling, stamping, painting, or heat treating.

          The national distribution of the reporting facilities follows
approximately the distribution of plants as given in Table 2 (state direc-
tories distribution).  Thirty percent of the plants are located in EPA
Region V, heavily engaged in copper, nickel, chromium, zinc, and cadmium
plating with very little activity in precious metals plating (< 7%).   About
one half of all precious metals operations were reported from Region I which
has 20 percent of the total facilities.  Region IX, specifically California,
with about 18 percent of the facilities reporting, appears to have the most
uniform metal finishing process distribution.  All tabulated processing
with the exception of cobalt plating is performed in Region IX.  Consequently,
job shop electroplating process characteristics can be expected to coincide
with the industrial activities in a given area.  The automotive manufacturing
industry in the Midwest, requiring copper, nickel, chromium, and zinc coatings
for corrosion protection causes a concentration of such facilities in that
area.  Similarly, the production of electronic gear, printed circuits, and
precious metal products carried out in the Northeast and California required
that specific electroplating processes needed for products by those indus-
tries are concentrated in these regions.  Such a distribution will have a
bearing on characteristic wastes and their quantities for each region or
state.
                                      11

-------
                                  REFERENCES
                           INDUSTRY  CHARACTERIZATION
 (1)   Director of Alaska  Commercial Establishments,  July,  1974,  State  of
      Alaska,  Department  of  Economic  Development, Division of Economic
      Enterprise, Pouch E, Juneau.

 (2)   Arizona  Directory of Manufactures,  1974, Arizona  Department  of Econ-
      omic Security,  Phoenix, Arizona.

 (3)   Director of Manufacturers  in Arkansas,  1974 Edition,  Arkansas Indus-
      trial Development Foundation, Little  Rock, Arkansas.

 (4)   1974 California Manufacturers Register,  California Manufacturers
      Association,  Los  Angeles,  California,  1974.

 (5)   1974 Connecticut  State Industrial Directory, Connecticut State Indus-
      trial Director, New York,  New York, 1974.

 (6)   Directory of  Commerce  and  Industry, State of Delaware, 1970, Delaware-
      State Chamber of  Commarce,  Inc., Delaware, 1970.

 (7)   Director of Florida Industries,  1973  Florida State Chamber of Commerce,
      Jacksonville, Florida, 1973.

 (8)   Directory of  Manufacturers, State of  Hawaii, Chamber of Commerce of
      Hawaii,  Honolulu, Hawaii,  1973.

 (9)   Manufacturing Directory of Idaho, 1973  Idaho Department of Commerce
      and  Development,  Boise, Idaho,  1973.

(10)   Chicago  Buyer's Guide, Chicago  Association of  Commerce and Industry,
      Chicago, Illinois,  1975.

(11)   The  Indiana Industrial Directory (1972-73 Edition),  The Indiana  State
      Chamber  of Commerce, Indianapolis,  Indiana, 1972.

(12)   Directory of  Iowa Manufacturers  1973-1974, The State of Iowa - Iowa
      Development Commission, Des Moines, Iowa.

(13)   1974 Kentucky Directory of Manufacturers, Seventeenth Edition,
      Kentucky Department of Commerce, Frankfort, Kentucky.

(14)   Louisiana Directory of Manufacturers,  1972 Edition,  State  of Louisiana,
      Department of Commerce and Industry,  Baton Rouge, Louisiana.

(15)   Directory 1973-1974 Maryland Manufacturers, Maryland Division of
      Economic Development,  Anapolis,  Maryland, 1973.

(16)   Massachusetts Industrial Directory  1971, Massachusetts Department of
      Commerce and  Development,  Boston, Massachusetts.


                                      12

-------
(17)   The Directory of Michigan Manufactures,  1971,  Manufacturer Publishing
      Company,  Detroit, Michigan,  1970.

(18)   Maine Buyer's Guide and Directory  of Maine Manufacturers,  1970,  1971,
      Maine Department of Economic Development,  Augusta,  Maine,  1970.

(19)   Minnesota Directory of Manufacturers 1975-76,  Minnesota Department of
      Economic Development,  St. Paul,  Minnesota.

(20)   1971-1972 Mississippi  Manufacturers Directory, Mississippi Research
      and Development Center, Jackson, Mississippi,  1972.

(21)   Missouri Directory of  Manufacturing and  Mining, 1973 Edition,  Missouri
      Division of Commerce and Industrial Development,  Jefferson City,
      Missouri.

(22)   Montana Directory of Manufacturers, 1973-1974, Department  of Inter-
      governmental Relations, Helena,  Montana.

(23)   Nebraska Manufacturers and Their Products, 1974-1975, Nebraska Depart-
      ment of Economic Development, Lincoln, Nebraska.

(24)   1974 Directory of Nevada Businesses, Department of  Economic Development,
      Carson City, Nevada.

(25)   Made in New Hampshire, 1975, State of New  Hampshire, Office of Indus-
      trial Development, Division  of Economic  Development, Department  of
      Resources and Economic Development, Concord, New Hampshire.

(26)   1975 New Jersey State  Industrial Directory, New Jersey State Industrial
      Directory, New York, New York,  1975.

(27)   1974-1975 Directory of New Mexico  Manufacturing and Mining, Economic
      Development Division of the  New  Mexico Department of Development and
      Bureau of Business and Economic  Research,  Institute for Social
      Research and Development, The University of New Mexico, Santa  Fe,
      New Mexico, May, 1974.

(28)   1974 New York State Industrial Directory,  New  York  State Industrial
      Directory, New York, New York,  1974.

(29)   Directory of North Carolina  Manufacturing  Firms,  1974-75 Edition,
      Division of Commerce and Industry, Office  of  Industrial Tourist  and
      Community Resources, Department  of Natural and Economic Resources,
      Raleigh,  North Carolina.

(30)   1972-1973 Directory of North Dakota Manufacturers,  Business and  Indus-
      trial Development Department, Bismarck,  North  Dakota.

(31)   1975 Directory of Ohio Manufacturers, Ohio Department of Economic  and
      Community Development, Columbus, Ohio.
                                     13

-------
(32)   Supplement  to  the  Geographical  Section,  Oklahoma Directory  of Manu-
      facturers and  Products,  1974 Edition, March,  1975.

(33)   1975 Georgia Manufacturing  Directory, Georgia Bureau  of  Industry  and
      Trade,  Atlanta,  Georgia.

(34)   Directory of Oregon Manufacturers,  1974,  Oregon Economic Development
      Commission, State  of  Oregon, Department  of Economic Development,
      Portland, Oregon.

(35)   1973 Industrial  Directory of the  Commonwealth of Pennsylvania,  Twenty
      First Edition, Department of Commerce, Harrisburg,  Pennsylvania,  1973.

(36)   Rhode Island Directory of Manufacturers  and List of Commercial
      Establishments,  The Rhode Island  Development  Council, Providence,
      Rhode Island,  January,  1973.

(37)   Oklahoma Directory of Manufacturers and  Products,  1974 Edition,
      State of Oklahoma, Oklahoma Industrial Development Department,  Okla-
      home City,  Oklahoma.

(38)   Industrial  Directory  of South  Carolina,  Planning and  Research Division,
      South Carolina State  Development  Board,  Columbia,  South  Carolina,
      1973-1974.

(39)   1972 Directory of  South Dakota Manufacturers  and Processors, South
      Dakota  Industrial  Development  Expansion  Agency,  Pierre,  South Dakota.

(40)   Directory of Texas Manufacturers, 1974,  Bureau of  Business  Research,
      The University of  Texas at  Austin,  Austin, Texas,  1974.

(41)   Directory of Utah  Manufacturers,  1975-76, Utah Department of Employ-
      ment Security, Salt Lake City,  Utah.

(42)   Directory of Washington Manufacturers, 1974,  Trade  Development  Comm-
      ission, Washington State Department of Commerce, Olympia, Washington.

(43)   Wast Virginia  Manufacturing Directory, 1974,  West  Virginia  Department
      of Commerce,  Industrial Development Division, Charleston, West  Virginia,

(44)   Classified  Directory  of Wisconsin Manufacturers  1974, Wisconsin Manu-
      facturers Association, Milwaukee, Wisconsin,  1973.

(45)   Wyoming Directory  of  Manufacturing and Mining, 1973,  Wyoming Depart-
      ment of Economic Planning and  Development, Cheyenne,  Wyoming.

(46)   Directory  of  Colorado Manufacturers, 1974-75, Business Research
      Division,  University  of Colorado, Boulder, Colorado,  1974.

(47)   1974-1975  Vermont  Directory of Manufacturers, Agency  of Development
      and Community  Affairs, Montpelier, Vermont.
                                     14

-------
(48)   Dun & Bradstreet  Metalworking Directory 1974,  Dun & Bradstreet,  New
      York,  New York,  1974.

(49)   Directory of  Kansas  Manufacturers  and Products,  Kansas  Industrial
      Development  Commission,  Topeka,  Kansas.

(50)   Directory of Tennessee Industries, Tennessee  State Planning Commission,
      Nashville, Tennessee.

(51)   Industrial Alabama,  A  Directory  of Manufacturers 1972-1973,  Alabama
      State Chamber of  Commerce,  Mongomery, Alabama.

(52)   Written information  supplied  by  personnel at  job shops  to  the  contrac-
      tor through  the National Association of Metal  Finishers.

(53)   U.  S.  Bureau of  the  Census, Census of Manufactures,  1972,  Industry
      Series:   Screw Machine Products, Fasteners and Washers; Metal  Forgings
      and Stampings; and Metal Services, MC72(2)-34D,  U. S. Government
      Printing Office,  Washington,  D.C., 1975.
                                     15

-------
                          II.  WASTE CHARACTERIZATION
                                 INTRODUCTION
          This section provides generalized process description, criteria
for defining a waste as potentially hazardous are presented, and various
plating operations are discussed in detail.  Also presented are survey
data and descriptions of the model plants together with a discussion on
the types and quantities of wastes generated.
                        GENERALIZED PROCESS DESCRIPTION
          The electroplating and metal finishing industry is characterized
by many individual variations of both practice and terminology.  The dis-
cussion presented in this subsection is general in nature.  A more detailed
discussion is presented in a later subsection (see p. 24) and in Appendixes
B, C, and D.  A glossary is presented in Appendix I.

          The service offered by this industry may vary from a single oper-
ation to multiple-step processing.  The operations may be classified in
many ways in various degrees of discrimination.   For the first part of
this discussion, the operations are classified into three different cate-
gories:  mechanical, chemical, and electrochemical.

          Mechanical operations include grinding, grit blasting, shot
blasting, buffing, deburring, and polishing.

          Chemical processes in the industry include degreasing, acid pick-
ling, alkaline cleaning, acid cleaning, surface neutralizing, chromating,
phosphating, bright dipping, chemical polishing, passivating, and stripping.
Special cases in this category are electroless nickel and electroless cop-
per plating, in which the surface of the workpiece acts as a catalyst for
the decomposition of the solution, with the deposition of a metal on the
workpiece.

          Electrochemical processes in the industry include anodic clean-
ing, cathodic cleaning, anodizing, and electroplating.  Special cases under
this category would include those processes which use no external electri-
cal connections but depend on the electrochemical reactions between the
basis material and the solution to produce a metallic coating, such as
stannating and zincating.  These latter processes are referred to as immer-
sion plating.

          The above operations may be performed singly or in combination
to produce the surface properties desired by a customer.
                                    16

-------
                Electroplating and Metal Finishing Engineering


          The purpose of this section is to summarize the principles and
methods that are applied in the finishing of metallic or nonmetallic sub-
strates or basis materials.  The condition of these substrates, especially
the metals, has a direct bearing on the properties and the performance of
the electrodeposits.  Consequently, basis metals are generally prepared
for plating by mechanical, chemical or electrochemical finishing.  Metal
imperfections, scales, oils, and grease must be removed from the surface
if electroplating is to be successful.

          Oils, grease, buffing, polishing compounds, etc., may be removed
by alkaline spray cleaners or by vapor degreasing and this is commonly carried
out before scale removal.  Scales and oxides can be removed by chemical
pickling in strong acids, sometimes in combination with the mechanical fin-
ishing processes described in the next paragraph.  In electropolishing
operations the metal is made from the anode and its surface is improved by
selective dissolution.  This process has found wide application for steels,
aluminum and other nonferrous single-phase metals and alloys.

          In the mechanical finishing processes of polishing,  buffing, and
grinding, the surface of the work is cut or worked by abrasives which are
moved over the surface of the work by rotating wheels or moving belts.
Deburring may be performed manually or by placing many small workpieces in
a rotating container, with abrasive materials, so that a smoothing action
results.  Shot blasting or grit blasting involves the entrainment of the
shot or grit in a stream of air so as to impact the workpiece.  The equip-
ment required is that providing a forced air stream, an enclosure, grit
collection, and air pollution control.  Workpieces may be processed by hand
or on racks, conveyors, or holders.

          The plating cycle following the pretreatment steps can be very
simple, such as a sequence of cleaning-rinsing-plating-rinsing-drying, or
very complex, requiring a number of cleaning steps with additional steps
of acid dipping, striking, activation, multiple rinses and the deposition
of more than one metal.  All processing steps within a given cycle must be
arranged so that the solutions will not be contaminated.  Cleaners, acid
dips and strikes vary in composition and concentration and are formulated
for a particular basis material.  Cleaners are generally alkaline and are
used to remove the last traces of oil and grease.  Acid dips are not in-
tended to remove scales or oxides but are used to neutralize traces of
alkaline cleaners left on the basis material after rinsing and to activate
the surface to receive the electrodeposit.  Some materials require more
intense activation steps than others.  Dilute acids, mainly t^SO, or HC1,
are sufficient for the preparation of copper base alloys or carbon steels
for plating, whereas stainless steels require a cathodic activation step
in a N1C12-HC1 solution.  Each basis material must be treated  differently
and each metal deposited requires a specific cycle.

          Metal deposition can occur from acid or alkaline solutions.   The
most important acid plating baths contain the metal salt in a  form of  a
sulfate or chloride or a mixture of the two with some free acid present and
some inorganic buffer to maintain a specific solution pH.  Examples are

                                    17

-------
plating solutions for nickel, copper, iron, zinc and the platinum metals.
Lead, tin, or copper solutions may be prepared with fluoborates, and sul-
famate is often used for nickel plating.  Chromium deposition takes place
in solutions made up with chromic acid which dissociates into an anion
radical in water.  Copper, zinc, cadmium, silver or gold are deposited
from alkaline solutions, often containing cyanides.  Besides the single
metals, a large combination of alloys can be electrodeposited from all
types of solutions cited above.

          Each process cycle is composed of such process steps, and the
time required for each cycle varies with the number of stations in each
cycle, the transfer time from station to station, the type of basis mat-
erial processed, and the coating or coatings which are deposited.  Coat-
ing specifications determine what thicknesses of metals are to be deposited,
varying from less than 1 to several tens of micrometers.

          Thus, each electroplating operation is comprised of a number of
steps of different duration, where the products are moved in a sequence
from one chemical solution to another.  Solution volume, and therefore
rank size, depends on product size, shape, and the number of parts to be
processed per unit time.  Tank materials and equipment must be chemically
inert to the solutions at their operating temperature.  Heating or cooling
must be provided for the solutions, and equipment must be installed for
solution agitation, filtration, and piping for transfer as well as fume
control.  Direct current power is carried from motor generators or rectifiers
to the electrochemically onerated solutions by means of copper busbars.
Parts may be processed in barrels or on racks.

          Barrel operations are used for small parts that tumble freely in
rotating barrels.  Perforated plastic barrels range in diameter from 15 to
75 cm (6 to 30 in.), depending on part size and shape.  Direct current is
distributed to the parts being plated in horizontal barrels through dang-
lers suspended from a current-carrying bar located at the longitudinal axis.
In obliquely oriented barrels, a conductive button at the bottom transmits
the current.

          Rack plating is required for a large percentage of the surface
area processed commercially.  Racks are used for reasons including mainten-
ance of shape or surface conditions, achievement of the desired distribution
of coating, or size or shape of workpiece.  The parts are attached to
plastic-coated copper frames designed to carry the current equitably to a
few hundred small parts, several medium-sized shapes, or just a few large
products through spring-like rack tips affixed to the rack splines.  Racks
fabricated for manual transfer from cleaning, plating, and rinsing  tanks
usually contain 2 to 7 kg (5 to 15 pounds) of parts having a surface area
of 0.5 to 1 sq meter (5 to 10 sq ft).  Larger racks for holding heavier
parts are constructed for use with mechanical hoist and transfer systems.
                                    18

-------
                              Process Sequencing
          The sequence of unit operations is exemplified in Tables 4, 5, 6,
and 7 for the plating of different substrate metals with chromium, nickel,
or zinc, exclusive of substrate preparation.  Oil and grease are removed
by vapor degreasing.  Scales and oxides are dissolved in acid pickles, by
anodic action or mechanically.  Aluminum and its alloys are finished by
bright dipping.  In the pretreatment steps parts may be soak cleaned, or
anodically or cathodically treated in alkaline or acid solutions.  Pre-
plate operations are composed of so-called strikes, which describes
short-time plating from low pH solutions (highly acidic) with low metal
content at relatively high current densities.  The plate may vary, as the
required properties of each coating varies.  Further discussions of the
indicated processes are given in the section on "Detailed Process Descrip-
tions".
             CRITERIA FOR DEFINING A WASTE AS POTENTIALLY HAZARDOUS
          The wastes generated by the electroplating and metal finishing
industry contain heavy metals and organic solvents.  Because the prevalent
disposal practice for these wastes is to the land, the possibility exists
that these metals and solvents may become a part of the leachate from land-
fill operations and drain into surface and underground water supplies.
While many of these materials are potentially hazardous to terrestrial and
aquatic life, the greatest concern is their potential hazard to human
health.

          Although there are many criteria for judging the potential haz-
ardous nature of various materials, one set of criteria which has been
accepted for many years is the acceptable level of various components in
public water supplies.  Because this set of criteria deals directly with
the human health issue, it has been selected as the basis for the conclu-
sion that all of the metal-bearing wastes from electroplating and metal
finishing operations are potentially hazardous.

          A table of surface water criteria for public water supplies is
reproduced as Table 8.  As shown there, the permissible levels for the
heavy metals are all low, generally less than 1 mg/1.  These data also
indicate that it is highly desirable for these components to be completely
absent from public water supplies.

          There also have been a growing concern regarding the potential
hazard to human health from various organic solvents, particularly the
possible carcinogenicity of chlorinated hydrocarbons.  This factor to-
gether with the flammable nature of some solvents, is the basis for
designating those wastes which contain solvents as potentially hazardous.

          The criteria set forth above effectively mean that all four cate-
gories of wastes generated in the subject industry are potentially hazardous
because of the presence of heavy metals and/or organic solvents.


                                    19

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TABLE 8.  CRITERIA FOR PUBLIC WATER SUPPLIES
   Waste                      Permissible
Constituents              Concentrations, ppm


Arsenic                          0.05
Beryllium                        0.2
Cadmium                          0.01
Chromium (hexavalent)            0.05
Copper                           1.0
Cyanide                          0.01
Gold                             0.4
Iron (filterable)                0.3
Lead                             0.05
Manganese (filterable)           0.05
Mercury                          0.004
Nickel                           0.8
Oil and Grease                   7
Palladium                        7
Phosphates                     545
Selenium                        10.01
Silver                           0.05
Sulfates                       250
Tin                              1.2
Zinc                             5.0

-------
                          DETAILED PROCESS DESCRIPTIONS
          The following section of this report presents additional details
of the unit operations and combinations of operations found in the electro-
plating and metal finishing industry.   The unit operations are described
in the categories of mechanical, chemical, and electrochemical operations.
                             Mechanical Operations
          Mechanical operations performed in electroplating and metal
finishing facilities include abrasive blast cleaning, barrel finishing,
grinding, polishing, and buffing.
Abrasive Blast Cleaning
          Abrasive blast cleaning entails the forceful direction of abra-
sive particles—either dry or suspended in a liquid—against the surfaces
of metal parts or products, to remove contaminants or to condition the
surfaces for subsequent finishing.  Abrasive blast cleaning is done to
remove dirt, foreign substances, oxide scales, or burrs, or to roughen the
surface in preparation for subsequent coating.  The particles may be pro-
pelled against the workpiece by entrainment in a stream of air or liquid
or by means of a rotating impeller wheel.  The abrasive materials consist
of cast iron or steel grit, cast iron or steel shot, sand, quartz, aluminum
oxide, silicon carbide, slag, nut shells, corncobs, sawdust, glass, or
plastic beads.  Blast cleaning is performed in enclosures which contain the
abrasive-propelling device, tables, conveyors or other means of holding or
manipulating the workpieces, and means for the collection and recycle of
the abrasive, as well as for control of dusts.  Blast cleaning may be done
on a piece, batch, or continuous basis with manual, semi automatic, or
automatic processing and control.

          Wet abrasive blast cleaning involves the use of finer (relative
to dry blasting) abrasive particles in chemically treated water and is
used to produce finer surface finishes than dry blasting.  In many cases,
wet blasting is preceded by precleaning such as degreasing or dry blasting
to prevent the contamination of the wet blasting medium.
Barrel Finishing
          The improvement of surface finishes, the removal of burrs, edges
or scale, and the formation of radii is specially obtained by tumbling or
vibratory finishing of several parts at one time.  Just a few large parts
may be finished to specification or thousands of small parts may be handled
by machines with revolving (tumbling) or vibratory motion.  A medium is
added to separate the workpieces and perform a finishing operation similar
                                    25

-------
to that in polishing and buffing.  Some of the different media which are
used are listed in Table 9.  Some of the media are used in conjunction
with compounds, or compounds are used by themselves.  Compounds include
sodium cyanide, sodium phosphate, abrasives, burnishing compounds, soaps,
wetting agents, silica, or proprietary compounds.  Most operations are
carried out wet.  Equipment may be made of wood or steel and may be lined
with neoprene, vinyl, or polyurethane.  Metal is removed in the process
either as a solid or as dissolved ions depending on the specific compound
used.  Compounds are lost with each cleaning of the barrel (i.e., at the
end of each operation) and are washed into a drain leading to a treatment
system, to a neutralization sump where available, or into the sanitary
sewer.  The media, which have been reduced in size by the abrasive action
employed, are washed out with the compounds.
Grinding
          Grinding is the application of abrasives to a workpiece to effect
the removal of surface material.  In metal finishing shops, grinding may be
performed to achieve a desired surface finish to remove undesirable mater-
ial from the surface, to remove burrs or sharp edges, or to achieve close
dimensional tolerance.

          Grinding equipment includes belts, disks, or wheels consisting
of or covered with various abrasives, e.g., silica, alumina, silicon car-
bide, garnet, alundum, or emery.  Grinding equipment may be portable or
stationary.  Grinding may be with or without the use of lubricants or
coolants such as water or water-based mixtures, solutions, or emulsions
containing cutting oils, soaps, detergents, wetting agents, or proprietary
compounds.  Auxiliary equipment associated with grinding operations includes
hoods, vents, ducts, and dust collectors, and in the case of wet grinding,
tanks, pumps, and pipes for the supply, collection, and recycle of lubri-
cants or coolants.

          A special-purpose grinding operation is associated with the depo-
sition of hard-chromium plate.  Hard chromium plating is used for finishing
parts requiring high wear resistance, such as crankshaft bearings, cam
surfaces, dies, gauges, etc.  The finishing of such workpieces is done by
applying slightly thicker plate than is required, and then grinding to
final dimensions.  In refinishing worn parts such as those mentioned above,
the old chromium plate is removed by grinding, the piece is then plated, and
ground to final dimensions.
Polishing and Buffing
          Polishing operations are performed for the purpose of achieving
an intermediate surface which can be refined further, normally by buffing,
prior to plating.  The operation may be carried out on metals or nonmetals,
and removes some material from the surface.  The purpose of buffing is to
smooth and brighten the surface without much metal removal.


                                    26

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          Polishing ±s carried out on hard-faced wheels varying in diameter,
thickness, and material depending upon the part that is being processed,
the finish, and the material^removal rate desired.  Wheels are constructed of
woven cotton fabrics, canvas, felt, or leather disks glued or sewn together,
or a combination of glued and sewn discs.  Felt wheels are used where true
surfaces are required or where a contoured shape is being finished.  Leather
wheels produce a finer finish, and wood wheels covered with leather are
normally used for flat surfaces.  Abrasives are generally applied to these
wheels with synthetic adhesivss or cements which have generally replaced
the hide glue formerly used.  The ratio of abrasive to glue used in the
facing of the wheels changes with grit size.  Used wheels may be recoated
after removal of lubricants from the facing or the facing itself may be
replaced.  The abrasives are fused aluminum oxide, silicon carbide, and
turkish emery.  Tallow, grease, special bar lubricants, and spray lubricants
are also used.  Woven cloth belts are also used for polishing operations after
having been treated in the same way as the wheels,,  Greaseless polishing
can be accomplished with flexible polishing wheels using softer cloths.
Burrs on castings or stampings may also be removed with the use of polishing
wheels.

          Buffing normally follows the polishing operation as the last step
before plating.  Depending on the desired finish of the product, the oper-
ations may vary.  Satin finishes are obtained using fast cutting abrasives,
mostly aluminum oxide and silicon carbide, combined with glue or adhesive
binders to form a greaseless compound buffing bar.  Grease-base buffing
bars are made of animal, vegetable, and mineral fats and waxes together
with an adhesive.  "Cut-down" buffing bars are composed of various materials,
depending on the metal to be finished.  Once-ground Tripoli and aluminum
oxide are most widely used.  An operation known as "cut-and-color" buffing
is used in place of the cut-down operation to achieve a small amount of
metal removal while at the same time giving some luster to the metal.
Basically, the same constituents are used in different compositions to
produce cut-and-color bars.  Red iron oxide powder is frequently used
for nonferrous metals.  For producing a final finish having the best color
and luster, very small amounts of very fine abrasives are used consisting
of the materials listed above plus bars containing chromium oxide for
finishing stainless steel and chromium plate.

          Where semiautomatic or automatic polishing machines are used,
the buffing compound is not in a bar form but is applied in a liquid form
from air pressure feed tanks or circulating drum pumping equipment.  The
newest development is a system of airless spray buffing.  Liquid compounds
are also available for manual buffing operations.  The same abrasives are
used as in buffing bars, but the vehicle materials are oil solutions or
water emulsions instead of grease, fat, waxes,' and oils.  Liquid buffing
compounds, besides achieving a better finish at a  lower  cost:  than manual
operations with bar compounds, are required in smaller amounts, cause less
wear on the buffing wheel, and cause less dirt to be packed onto the parts
for easier subsequent liquid cleaning.  The different production techniques
are summarized in Table 10.
                                    28

-------
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                              Chemical Processes


          Processes used in the electroplating and metal finishing industry
which involve chemical action (as compared to electrochemical action) in-
clude degreasing, alkaline cleaning, acid treatments, chromating, phos-
phating, passivating, bright dipping, chemical polishing, and electroless
nickel plating.
Degreasing
          Degreasing, also referred to as solvent cleaning, involves the
application of a solvent or solvent mixture to remove oil and grease from
the workpiece.  Two methods of degreasing are practiced:  vapor degreasing
in which the workpieces are suspended in the vapor phase of a boiling sol-
vent and dip, or cold cleaning, in which the workpieces are immersed in
the solvent.

          Equipment for vapor degreasing includes a tank with heating coils
at the bottom.  The tank is divided into a liquid solvent region, and a
solvent vapor region.  A cooling zone is at the top of the tank to condense
the rising vapor.  For cold cleaning a simpler tank is required.  Auxiliary
equipment for both degreasing methods includes hoists, racks, barrels, or
conveyors for manipulating the work into and out of the degreaser tank, and
an appropriate heat supply, ventilation and fume collection system.  Auxi-
liary equipment may also include means for recovery of the solvent.  The
vapor degreaser tank itself may be used as a still to distill off the pure
solvent, the residue being removed from the tank, and the tank refilled
with the pure solvent.  A separate still may be used to separate the pure
solvent from the residue, and may be operated on a batch or continuous
basis.

          The solvents used for vapor degreasing operations are character-
ized in Table 11.
Alkaline Cleaning
          The purpose of alkaline cleaning is to remove dirt, greases,
oils, and other foreign material from the surface of the workpiece.  Alka-
line cleaning involves the application of aqueous solutions of sodium com-
pounds such as carbonate, phosphate, silicate, or hydroxide with or
without additions of surfactants, or chelating agents.  Most alkaline
cleaning solutions are based on proprietary compounds.  Ranges of cleaning
solution compositions and operating conditions are given in Table 12
Alkaline cleaning may also be performed as an electrochemical process in
which the uorkpieces are made either the anode or cathode of an electro-
chemical circuit.  When the workpiece is made the cathode, hydrogen is
evolved at the surface of the workpiece; when the workpiece is made the
anode, oxygen is evolved at its surface.  The gas evolution aids in the
     inc' -'•- i. Ion,.
                                    30

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              TABLE 12.  ALKALINE CLEANING SOLUTIONS AND
                         OPERATING CONDITIONS(2)
Constituent or
Condition
For Ferrous
Metals
For Copper
and Brass
For
Aluminum
Sodium Carbonate,
Trisodium Phosphate,
Sodium Hydroxide,
  NaOH

Surfactant
                       Composition, grams/liter
                             30-45
                             15-30
                             7.5-15
12-22


 8-18


 3-12

0.3-0.5
                                                               23
                                                               23
                         Operating Conditions
Current Density,
Time as Cathode, min.

Time as Anode, sec.

Soak Time, min.

Temperature, C
30-60
1-2
35-30

least 9.0
10-30
1-3
5-10

60-70



1-3
60-80

-------
          The equipment required for alkaline cleaning includes tanks,
either electrical or steam heat, temperature control devices, hoists, racks,
barrels, or conveyors for moving the workpieces.  In the cases of anodic
and cathodic alkaline cleaning, an electrical power source, leads, and
contacts are also required.
Acid Treatments
          Treatment of the surface of the workpieces with a. id rolutions is
performed for oxide removal or for the neutralization of t.,  .   idual ai^^i
films.  The removal of oxide films is usually referred to as either pickling
or bright dipping.  The term pickling denotes the removal of relatively
thick oxide films and usually includes the removal of some metal.  The term
bright dipping denotes the removal of relatively thin oxide or tarnish
films with no significant removal of metal.  Pickling is usually performed
as a preparatory step before finishing, while bright dipping is usually an
intermediate or final step in a finishing process sequence.  Some acid
treatments, basis materials, and acid concentrations are illustrated in
Table 13.

          Equipment for acid treatments includes tanks with acid resistant
linings such as lead, rubber, glass, or acid-resistant brick, provisions
for heating and temperature control, and equipment for moving the work into
and out of the acid solution such as hoists, conveyors, hangers, racks,
barrels, etc.
Chromating
          The purpose of chromating is to develop a protective film on the
surface of the metal being treated.  The process involves the immersion of
the metal in an aqueous solution of chromic acid or chromium salts so that
some of the metal is dissolved and a film containing complex chromium com-
pounds is formed on the surface of the metal.  Because of the sequence of
dissolution followed by film formation, chromating is referred to as a
conversion coating.  Chromate coatings are usually applied in a final pro-
cessing step to enhance the corrosion resistance or appearance of metals
and electroplated metals including zinc, cadmium, magnesium, and aluminum.
They are also used as coatings to enhance the adhesion of subsequently
applied paint.  Chromate coatings may be clear or may be produced in a
variety of colors, including olive green.

          Most chromating solutions are made up using proprietary components.
Published data indicate that chromating solutions contain 2 to 35 mg/1 of
hexavalent chromium supplied in the form of chromic acid or salts such as
potassium chromate or dichromate.  The solutions also contain other anions
such as sulfate, nitrate, chloride, or fluoride.

          Equipment for chromating includes tanks, tank linings, and heating
coils of ceramics, acid-resistant brick, stainless steel, asphalt compounds,
plastics, quartz, or carbon.  Chromating can be performed by dipping,
spraying,  or brushing,  using manual rack, barrel, or automatic procedures.
                                    33

-------
TABLE 13.  SOME ACID TREATMENTS USED FOR PICKLING,
           CLEANING, AND BRIGHTENING
Purpose
Pickling
Pickling
Pickling
Pickling
Pickling
Bright-
ening
Bright-
ening
Acid
Cleaning
Acid
Cleaning
Acid
Cleaning
Bright-
ening
Material
Steel
Steel
Steel
Steel
Copper
Alloys
Copper
Alloys
Copper
Alloys
Aluminum
Alloys
Aluminum
Alloys
A luminum
Alloys
Aluminum
Alloys
Acid Operating
Concentration, Temperature,
Acid wt 7o C F
Su If uric
Hydrochloric
Phosphoric
Nitric
Sulfuric
Sulfuric-
Nitric
Phosphoric-
Nitric-
Acetic
Chromic -
Sulfuric
Nitric-
Hydrofluoric
Phosphoric-
Chromic
Phosphoric-
Nitric
5-16
-
-
6-8
5-10
0-100
0-100
10-80
10-50
10-80
9-19
15-19
50-75
5-38
14
4
45-99
0.5-50
Room-82 Room-180
Room-54 Room-130
-
-
Room-79 Room-175
-
88 190
43-82 110-180
Room Room
43-66 110-150
88-110 190-230
                       34

-------
          Chromating processes are usually Dreceded by water rinses or acid
dips and are usually followed by rinses.  Bleaching, or dying of the chromate
coatings may be performed by immersion in the appropriate solutions.  Chro-
mate coatings almost always require drying at temperatures up to a maximum
of 71 C (160 F) using air blasts from forced hot air ovens or other means.
Phosphate Coating
          Phosphate coating is the treatment of a metallic surface with a
dilute solution of phosphoric acid and other chemicals to produce a coating
of insoluble, crystalline phosphate compounds.  These coatings commonly
serve as a base for subsequent coatings of paint, oil, or wax, or serve to
improve corrosion and wear resistance, or as an aid in forming processes.
Phosphate coatings are commonly applied to ferrous materials, zinc, and
cadmium, are usually applied in thicknesses from 0.00025 to 0.005 centi-
meters (0.001 to 0.002 inch); they vary in color from light gray to black.
Phosphate coating solutions are generally based on proprietary mixtures.(1~
Published information indicates that the solutions contain phosphoric acid,
phosphates of iron, zinc, or manganese, plus compounds which act as oxi-
dizers or accelerators.  Phosphate coating solutions are usually operated
at temperatures of 32-99 C (90-210 F).  Phosphate coating operations are
usually preceded by cleaning operations (e.g., alkaline cleaning) and are
often followed by a chromic acid rinse, the purpose of which is to react
with any excess phosphating solution and produce a light chromate coating
which results in improved corrosion resistance.

          Phosphate coatings are applied by brush, spray, or immersion
methods using manual or automatic machine techniques which may be applied
to single or batch lots of workpieces.  Equipment used for phosphate coat-
ing includes tanks or spray cabinets, buckets, barrels, racks, hooks,
hoists, conveyors, and heating and temperature control apparatus.  Associ-
ated operations usually include drying in air blasts or controlled-
temperature, forced-air ovens, and these may be followed by the application
of paints, oils, or waxes by spraying or dipping.

          The application of phosphate coatings involves the consumption
of phosphoric acid in the coating reaction and characteristically generates
a sludge of reaction products which accumulates in the bottom of the pro-
cess tanks or in sumps in the spray systems.  The sludge must necessarily
be periodically removed.

Passivating
          Passivating treatments are performed almost entirely on stainless
steel to develop a uniform and protective oxide film on the workpiece.
Passivating treatments involve the immersion of stainless steel workpieces
in an aqueous solution containing 5 to 25 percent by volume of nitric acid
(an additional two percent by weight of sodium dichromate [Na2Cr20y2H20]
may or may not be added to the solution).  The passivating treatment
dissolves foreign substances such as lead,  copper, cadmium,  or imbedded iron

                                    35

-------
particles remaining from prior forming, machining,  tumbling,  or wire draw-
ing operations.  The foreign material,  if not removed, could result in an
irregular protective oxide coating, associated rust spots and selective
corrosive attacks.  Passivation is usually preceded by an appropriate
cleaning process such as any of the mechanical cleaning processes, degreas-
ing, or alkaline cleaning.  Because of  the need for uniform treatment of
surfaces, passivating is performed by dipping.

          Equipment associated with passivating operations includes tanks
of suitable material (i.e., stainless steel, aluminum, or other acid-
resistant material), heating and temperature control apparatus, materials
handling equipment such as hoists, hooks, racks, buckets, or barrels, and
hooding and ventilating equipment.  Passivating solutions are depleted
during use by reaction of the nitric acid and drag out and may be replen-
ished by addition of nitric acid.
Bright Dipping and Chemical Polishing


          Bright dipping and chemical polishing solutions usually consist
of mixtures of two or more acids such as sulfuric, nitric, hydrochloric,
phosphoric and chromic acids and are used for ferrous and nonferrous alloys.
Concentrations and dip times vary widely.  The metal surfaces may become
simply bright and clean or lustrous.  Depending on the degree of brightness
and smoothening of the surface the process may be termed bright dipping or
chemical polishing.

          Most processes are applied to nonferrous metals and are most
extensive with aluminum, where mixtures of phosphoric and nitric acid are
used with additions of acetic or sulfuric acid.  The metal removal in alum-
inum dipping may vary from 0.0025 to 0.05 urn (0.0001 to 0.002 inch).  Copper
and copper alloys are bright dipped in sulfuric acid to which an oxidizing
agent is added.  Chromic acid, dichromates, ferric sulfate and nitric acid
are useful.  The rate of attack on the metal varies with acid concentration,
the amount of oxidizing agent and inhibitor used from 0.025 to 0.2 urn
(0.0001 to 0.01 inch).  Racked work can be carried out in the more concen-
trated bath, while bulk parts are dipped in diluted solutions where the rate
of attack is slower.  Phosphoric-nitric-acetic acid solutions are used for
chemical polishing.  The attack on the copper is slower than with the
bright dipping solutions and a smoothing action results which gives a higher
luster.  Bright dips for ferrous metals contain hydrogen peroxide or are
composed of mineral acids with small amounts of inhibitors.  Phosphoric-
sulfuric-nitric acid solutions are used for nickel-alloys, while cadmium
and zinc are bright dipped in chromate and dilute nitric acid solutions;
or in peroxide solutions.  A sodium cyanide-peroxide solution is often
used for dipping silver and a peroxide-acetic acid solution finds applica-
tion with lead.  In addition, a large number of proprietary solutions are
on the market for bright dipping and chemical polishing for ferrous and non-
ferrous metals and alloys.
                                    36

-------
Electroless Nickel Plating
          Electroless nickel plating is a process in which an aqueous
solution of nickel and other compounds undergoes a catalytic decomposition,
resulting in the deposition of a nickel coating on the surface of the work-
piece.  Electroless nickel coatings are deposited on the workpiece to in-
crease corrosion resistance, dimensional build-up, and wear resistance, to
facilitate subsequent soldering or brazing operations, or to produce a
metallic coating on ceramics, plastics, or special metals not readily
electroplated.  The catalytic nature of the electroless nickel plating
process has associated with it requirements for careful surface preparation
of the material to be coated, complex solution composition, the requirement
for close control of operating conditions, and, for continuous operations,
extensive auxiliary equipment for solution make up and purification.

          Characteristics of various electroless nickel plating baths are
listed in Table 14.  The reactions which occur in the electroless nickel
plating bath include the following:

             the hypophosphate ions change to orthophosphite
             anions with the formation of hydrogen;

             the hydrogen thus formed acts to reduce the nickel
             from the ionic state to the metallic state; and

             some hydrogen also reacts with the hypophosphite
             to produce elemental phosphorus.

          The overall results of these reactions are that nickel containing
3 to 15 percent phosphorus is deposited on the surface of the workpiece
while the pH of the solution decreases.  The nickel is depleted from solu-
tion and hypophosphite is oxidized.  The original solution is metastable and
its rate of decomposition is sensitive to temperature and to other variables.
If the decomposition of the solution proceeds too rapidly, nickel is re-
jected throughout the volume of the bath rather than only at the surface.

           One  of  the  advantages  characteristic of the  electroless nickel
 plating  process  is  that  it  may be  used  on very large workpieces  such as
 tanks by using the  workpiece  as  the  container  for the  solution.

           Equipment required  for electroless nickel plating  may  vary from
 a  single vessel  to  the components  discussed below in  the  discussion of a
 continuous process.   Tank linings  are usually  inert materials such  as
 tetrafluoroethylene or a phenolic-base  organic.   Heat  supply and temperature
 control  are required  as  are means  for  pH  control,  and  controlled agitation
 achieves uniform  patterns of  escape  of  hydrogen  gas.   Heating  is usually
 achieved by a  heating jacket  on the  tank  rather  than  immersed  electrical
 or steam coils.

           In  continuous  operations,  the plating  tank  is part  of  a circuit
 that includes:

             a storage tank,  in which a prepared  solution  is  stored  or
             in which final adjustments or additions may  be
             made;
                                    37

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                TABLE 14.  RANGES OF COMPOSITIONS OF ELECTROLESS
                           NICKEL PLATING SOLUTIONS (3)
Constituent
Nickel Chloride
Nickel Sulfate
Sodium Hypophosphite
Ammonium Chloride
Sodium Citrate
Ammonium Citrate
Ammonium Hydroxide
Sodium Acetate
Sodium Hydroxyacetate
Sodium Succinate
Lactic Acid
Propionic Acid
pH***
Temperature, C
Concentrations
Alkaline Baths
30-45
None
10-11
50
1-100
0-65
*
None
None
None
None
None
8-10
91-96
, g/liter
Acid Baths
30
15-21
10-27
None
None
None
None
0-13
0-50
0-16
0-34**
0-10**
4-6
88-99
  *  Added in amounts sufficient to achieve the proper pH.
 **  Given in ml/liter.
***  pH reported in pH units.
                                     38

-------
          -  a heat exchanger, through which the used plating solution is
             passed to adjust the temperature of the solution to the
             plating temperature;

             a plating tank;

             a heat exchanger, through which used plating solution is
             passed to cool the solution to 79 C or below before
             regeneration;

             a regeneration tank, where reagents are added to restore
             the solution to the desired composition; and

             a filter, or a settling tank and a filter to remove any
             solids precipitated during the regeneration step.

          The circuit may also contain a tank or crystallizer in which the
solution is cooled to remove any excess sodium sulfate before it is
returned to the storage tank.

          Auxiliary equipment associated with electroless nickel plating
operations includes appropriate means of handling the workpieces such as
hooks, racks, barrels, or buckets, as well as hoists or conveyors.  Because
of the nature of the process, special measures are usually taken to insure
uniform escape of the hydrogen gas and uniform deposition of the coating such
as controlled oscillation, vibration, or rotation of the workpieces.


                           Electroplating Processes
          Electroplating operations performed in electroplating and metal
finishing facilities include nickel, chromium, cadmium, zinc, copper, tin,
iron, gold and silver plating as the most important processes.  Alloys may
be deposited from solutions with compatible anions; other metals such as
indium, rhodium, platinum, and cobalt are used to a very small degree in
metal finishing.  Anodizing is used most often for aluminum.
Nickel
          Nickel is one of the more important metal coatings applied by
electroplating.  Nickel plate, with or without an underlying copper strike
plate, is primarily employed as a bright coating underneath a comparatively
thin chromium electroplate to provide a decorative and corrosion-protective
coating for parts of steel, brass, zinc, and other basis metals.  Nickel,
by itself, is electrodeposited on steels and other basis metals to provide
decorative and corrosion-resistant finish.  Heavier nickel deposits are
frequently employed to build up worn parts or provide wear-resistant surfaces.
Nickel electrodeposition is used extensively to electroform intricate-shaped
articles that would be difficult or expensive to fabricate by conventional
metal-working or machining methods.


                                    39

-------
          Nickel is generally electroplated from Watts (sulfate-chloride-
boric acid), sulfamate, fluoborate, and chloride baths.  Typical composi-
tions and operating conditions for general-purpose nickel plating baths are
given in Table 15.

          When nickel is plated directly on the basis metals, the basis
metal surfaces are generally first cleaned, rinsed, and then acid dipped
and rinsed prior to nickel plating.  The basis metals are frequently
copper plated prior to nickel plating.  Such a procedure is almost always
employed with zinc and zinc alloy parts.  After copper plating, the parts
are rinsed, acid dipped, rinsed, nickel plated, rinsed, and then dried.
Table 5 illustrates the different plating operations performed for the
different basis metals.  A representative sequence of steps used for apply-
ing a triple electroplate (Cu-Ni-Cr) on steel, brass, or zinc parts is
shown in Table B-2 in Appendix B.

          Nickel can be electrodeposited in still tanks, barrels, and in a
variety of automated equipment.  Typical tank linings for nickel baths
include PVC, natural rubber, neoprene, and Saran.  External heating or
cooling of nickel baths can be carried out in heat exchangers made of heat-
resistant glass or cast graphite.  For internal heating elements, impervious
graphite and glass coils are satisfactory.

          The major source of nickel chemical waste is from the drag out
into the rinse waters.  Solution leakage from filters, pumps, and pipes is
a seconary source of nickel wastes, with accidental spills and poor house-
keeping contributing some additional wastes.  Nickel plating baths are
rarely dumped.
Chromium Plating  "


          There are two principal types of chromium plating, i.e., decora-
tive and hard.  In decorative plating, a thin chromium coating serves as a
protective, non tarnishing, durable surface finish.  It is difficult to
obtain dense pore-free chromium deposits, and therefore, chromium is gen-
erally applied over coatings of copper plus nickel, or nickel alone.  These
metals have greater ductility and good corrosion resistance.  Typical deco-
rative chromium plate thicknesses over copper-nickel or nickel undercoats
range from 2.5(1Q~5) to 5(10-5) cm [1(10-5) to 2(10-5) inch].  In hard
(also known as "industrial" or "engineering") chromium plating, heavier
coatings are used to take advntage of the special properties of chromium
plating, heavier coatings are used to take advantage of heat and corrosion.
Unlike decorative chromium plating, hard chromium is generally applied to
the basis metal without an intermediate coating.  Hard chromium is normally
deposited to thicknesses ranging from 2.5(10~4) to 5.1(10-2) cm [1(10~4) to
2(10~2) inch] and even more in some applications.

          Typical parts coated with decorative chromium include:  exterior
and interior automotive parts; boat hardware; household appliances; home,
office, and school furniture; plumbing fixtures; bicycle hardware; and
cabinet hardware.  Representative applications for hard chromium plating

                                    40

-------
            TABLE 15.    TYPICAL BATH COMPOSITIONS AND OPERATING
                         CONDITIONS FOR NICKEL PLATING OPERATIONS
(1,3)
Constituent
or Operating
Condition
Nickel sulfate,
NiSO, • 6H00
Nickel chloride,
Nickel sulfamate,
Ni(SO.,NH9)
Nickel fluoborate,
Ni(BF4)
Total nickel as metal
Boric acid, H-BO
PH
Temperature, C
Current density,
amp/sq cm
Watts ,
Bathta)
Composition,
225 - 413
30 - 60
58 - 107
30 - 45
Operating
1.5 - 5.2
46 - 71
0.011 -
0.110
Sulfa- Fluo- All
mate/ x borate ,. Chloride
( a ) ( a ) Ta )
Bathv ' Bathv ' Bathv '
grams/liter
0-30 0-15 70
263 - 450
225 - 300
62 - 113 58 - 79 17
30 - 45 15 - 30 30
Conditions
3-5 2.5-4 —1.0
38 - 60 38-71 — 55
0.027 - 0.027 - 0.054 -
0.324 0.324 0.108
(a)   Small amounts  of surfactants, wetting  agents,  or other  addition agents
     may be added  to  the  baths  to  prevent pitting,  refine  grain structure,
     or brighten plates,  etc.   Many  of these  addition agents are specially
     developed  proprietary  compounds.
                                    41

-------
include:  restoration to original dimensions of worn, mismachined, or
undersized parts; coating of tools, dies, and gauges and other parts to
minimize wear and to reduce galling, friction, and corrosion; coating of
electrotypes, engraving plates, and other items intended for prolonged
runs.

          Conventional chromium plating solutions contain chromic acid and
a small amount of sulfuric acid or a mixture of sulfuric acid and fluo-
silicate or fluoride ions.  The ratio of the concentration of the chromic
acid to the catalyst acid radicals or anions ranges from about 50:1 to
250:1, and preferably should be about 100:1,  Typical chromium plating
bath compositions and operating conditions are given in Table 16.

          Chromium can be electroplated in still tanks, barrels, and in
automatic 'equipment-  Tanks for chromium plating are usually steel tanks
lined with materials such as fiberglass-reinforced plastics, PVC, or lead
alloy (67» Sb) sheet.  Plastic linings are generally preferred with the
proprietary fluoride-containing baths.  Insoluble lead alloy anodes are
almost always used in chromium plating from chromic acid baths.  For conven-
tional sulfate baths, lead-antimony (6-8% Sb) alloy is preferred, while
for fluoride-containing baths lead-tin (4-7% Sn) alloy is recommended.
Solutions are frequently heated or cooled by lead-alloy coils inside the
tankso  Tantalum coils and heat exchangers are now being used more exten-
sively because of their long life and efficient operation.

          Table 4 illustrates the different plating operations performed
for the different basis metals.  A typical sequence of operations for the
application of chromium over copper—nickel undercoats on steel and brass
parts is shown in Appendix B, Table B-2, Line 2.  The sequence of steps
involving cleaning and anodic activating treatments used prior to applying
hard chromium on steel parts is shown in Appendix B, Table B-2, Line 6.

          Drag out of the plating solution into the rinse waters is the
major source of chromium wastes.  Spray carried from the solution by the
hydrogen and oxygen gases generated at the electrodes is a secondary source
of waste.  Scrubbers installed in the exhaust system on the tanks can re-
cycle most of the spray or collect it for transfer to the waste treatment
system.  Dumping of chromium plating solutions is not normally practiced.


Cadmium Plating (1~4-)
          Cadmium plating is used extensively to provide an attractive
corrosion-protective coating over various basis metals, especially steel
and cast iron.  Cadmium, being anodic to iron, provides protection to the
basis metal even though the cadmium coating is nicked or scratched.  The
relatively high cost of cadmium generally restricts its application to thin
coatings [less than 25 jam (1 mil) thick] on parts used indoors or in shel-
tered positions outdoors; however, the use of cadmium for aircraft, marine,
and military outdoor applications are common.  Cadmium is frequently
employed to coat parts or assemblies made up of dissimilar metals to mini-
mize corrosion.  Cadmium's excellent solderability and low contact resis-
tance also make it attractive for electrical industry uses.

                                    42

-------
            TABLE 16.    TYPICAL BATH COMPOSITIONS AND OPERATING
                         CONDITIONS FOR CHROMIUM PLATINGt1"4)
Constituent
or Operating
Condition

Chromic acid, CrO«
Sulfuric acid, H SO,
Fluoride ion, F~

Bath
No. 1
Composition,
250
2.5
--

Bath
No. 2
grams/liter
400
4.0
--

Bath
No. 3

340
2.2
--

Bath
No. 4

175
1.4
0.7
Temperature, C

Current density,
  amp/sq cm
 Operating Conditions^

 43-49         43-49      54
43-54
0.11-0.23     0.11-0.23  0.16-0.38  0.16-0.46
                                    43

-------
          Most cadmium plating is done in cyanide solutions.   Typical bath
compositions, operating conditions, and features of the cyanide and fluo-
borate baths are shown in Table 17.  Grain refiners and brighteners in
the cyanide baths can be metallic, such as nickel, cobalt, molybdenum or
selenium, or organics such as coumarin, gelatin, sugars, sulfonic acid
derivatives, and aromatic aldehydes.  Licorice is suggested for use in
the fluoborate bath.  Most additives are proprietary compounds or mixtures.

          Pretreatment of basis metals prior to cadmium cyanide plating
generally consists of cleaning, acid dipping, rinsing, and cyanide or
caustic dipping.  The pretreatment is similar when fluoborate baths are
used except an acid rinse is employed rather than caustic.  After plating
the parts are rinsed.  Although in many instances the cadmium-plated parts
are shipped without further treatment, often a post treatment is employed.
The simplest treatment is a bright dip carried out in a dilute solution of
nitric acid or chromic acid.  Chromate conversion coatings are often applied
to cadmium plated parts for applications where it is desired to minimize
"white rust" or to enhance paint adhesion.  A processing sequence for cad-
mium plating-chromating steel parts in a manual-barrel operation is shown
in Table B-2, Line 5 in Appendix B.

          For plating cadmium from cyanide solutions unlined steel tanks
are generally employed.  Lined tanks usually are used for cadmium fluoborate
baths.  Plating can be done manually or automatically using racks or barrels.
Both soluble and insoluble anodes are used with the cyanide baths.  Ball-
shaped cadmium anodes in a spiral cage holder of bare steel are used in
cyanide baths.  Insoluble anodes generally are made of low-carbon steel
strips.  Bar- type cadmium anodes are used in the fluoborate baths.

          The major source of cadmium-solution wastes is from the drag out
into the rinse waters.  A secondary source can be solution leakage from
filters, piping, and pumps.  Accidental spills and poor housekeeping can
also contribute to the cadmium waste load.  Dumping of cadmium plating
baths is not commonly practiced.
Zinc Plating
          Zinc coatings are generally applied to the workpiece to protect
iron and steel parts against corrosion.  Zinc, being anodic to iron and
steel, offers more protection at a smaller cost when applied in thin films
than similar thicknesses of nickel or other cathodic coatings.  Because
zinc is relatively inexpensive, and readily applied in tank, barrel, or
continuous plating facilities, it is frequently the preferred coating for
most ferrous parts for protection against atmospheric and indoor corrosion.

          The majority of fabricated steel parts that are zinc plated are
plated in cyanide baths.  The use of acid zinc baths is largely restricted
to the plating of mill products, such as wire, strip, sheet, and conduit.
Typical compositions and operating conditions for zinc cyanide plating
baths are given in Table 18.  During the past five years the use of non-
cyanide alkaline solutions, prepared with zinc pyrophosphate or another
chelating agent such as tetrasodium phosphate, sodium citrate, or the

                                     44

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-------
TABLE 18.
                      TYPICAL ZINC CYANIDE PLATING BATHS
Constituent
or
Condition
Plating Method
Still Tank or
Barrel Automatic

Conduit Tubing
or Strip
Zinc cyanide

Sodium cyanide

Sodium hydroxide

Sodium polysulfide
Temperature, C

Current density,
  amp/sq cm
              Composition Ranges, grams/liter

                    60-83            60-83

                    39-66            32-66

                    75-90            75-90

                     1.5              1.5


                   Operating Conditions

                    20-35            20-35


                 0.003-0.011     0.016-0.054
   60-90

   16-49

   75-90

    1.5
   32-49
0.043-0.108
(a)  Organic or metallic brighteners are generally employed in zinc
     plating baths; most brighteners used in industry are proprietary
     formulations.
                                    46

-------
sodium salt of ethylene diamine tetraacetic acid, has increased to avoid
dealing with the cyanide waste problem.

          Typical pretreatment of the basis metals (mostly ferrous mater-
ials) prior to zinc cyanide plating generally consists of (a) electrolytic
cleaning, (b) rinsing, (c) acid pickling, (d) rinsing, and (e) cyanide or
caustic dipping.  Where no posttreatment is employed, the zinc plated
parts are first rinsed in cold water, then rinsed in hot water and air
dried.  In some instances, the zinc plated parts are given a bright dip
(dilute nitric acid solution) or chromated.  Chromating is done to improve
the corrosion-resistant properties of the zinc plate or to enhance the
adhesion of paint to the zinc plated parts.  Table 6 illustrates the diff-
erent plating operations performed for the different basis metals.  Typical
processing sequences for zinc plating-chromating steel parts in automatic-
rack and automatic-barrel operations are shown in Appendix B, Table B-2,
Lines 3 and 4, respectively.

          The major source of zinc wastes results from the drag out of
plating solution into the rinse waters.  Other sources of zinc wastes are
generated during the continuous or batch filtration of the bath, solution
leakage from filters, pumps, and pipes, and floor spills.  Zinc plating
baths are rarely dumped.

              (1-4)
Copper Platingv   '
          Copper coatings are extensively used as undercoatings in multi-
ple-plate coating systems.  For example, the plating of zinc and steel
parts with copper before nickel and chromium plates is common practice in
the industry.  Copper plating is also employed in electroforming and in
the production of heavy coatings on wire for electrical applications.  For
some applications, bright electroplated copper, protected against tarnish-
ing by an overcoat of clear laquer is used as a decorative finish.  Copper
plating is also widely employed in the production of printed circuit boards.

          Copper can be electrodeposited from numerous electrolytes; how-
ever, four main types (i.e., alkaline cyanide, alkaline pyrophosphate,
acid sulfate, and acid fluoborate) account for most of the commercial
plating.  Typical compositions and operating conditions for the copper cyan-
ide baths are shown in Table 19.  Similar data for the acid sulfate and
acid fluoborate baths are presented in Table 20.

          Copper can be electroplated in still tanks, barrels, and in auto-
matic equipment.  Steel tanks, lined with rubber or plastic, are generally
employed for copper plating from cyanide and acid copper electrolytes.
External heating of cyanide baths is suggested using a steel heat exchanger
(brass or bronze fittings should not be employed).  Special grades of carbon
or graphite pipe and tubing make efficient heat exchange or cooling coils
for acid copper baths.  Soluble copper anodes in a variety of shapes are
generally employed in plating copper from the several baths, although in-
soluble anodes of steel or lead alloys are sometimes employed for special
jobs or applications.

                                    47

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         TABLE   19.   TYPICAL COMPOSITIONS AND OPERATING CONDITIONS
                      FOR CYANIDE COPPER PLATING BATHS
Constituent
or
Condition
Plain
Cyanide
Rochelle
Cyanide
High
Efficiency
Copper cyanide
Sodium cyanide
Sodium carbonate
Sodium hydroxide
Rochelle salt
Free sodium cyanide
                          Composition, grams/liter
15
23
15
26
35
30
 4
45
 6
75
93

30

11
                            Operating Conditions
Temperature, C
Cathode current density,
  amp/sq cm
Anode current density,
  amp/sq cm
55
0.022
0.008
60
0.043
0.016
70
0.065
0.027
                                    48

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         TABLE  20.   TYPICAL COMPOSITIONS AND OPERATING CONDITIONS
                      FOR ACID COPPER PLATING BATHS^
Constituent
or
Condition
Copper
Sulfate
Copper Fluoborate
Low Copper High Copper
                          Composition grams/liter
Copper sulfate, CuSO,'5H20   195 to 250
Sulfuric acid, H2S04          30 to  75
Copper fluoborate, Cu(BF,)2       -        '60            120
Fluoboric acid, HBF,              -             To pH          To pH

                            Operating Conditions
Temperature, C                21 to 49           27-77         27-77
Current density,
  amp/sq cm                0.022 to 0.108  0.081 to 0.135  0.135 to 0.378
pH                                -            0.8 to 1.7      <0.6
                                   49

-------
          Typical pre treatment steps in applying copper coatings to steel
or brass parts generally include cleaning, rinsing, acid dipping, and
rinsing.  A cyanide copper strike or nickel strike plate is usually em-
ployed before steel or zinc alloy parts are plated in an acid copper bath.
A typical sequence of operations used to apply a triple Cu-Ni-Cr coating
on steel or brass parts is shown in Appendix B, Table B-2, Line 1.

          The primary source of copper plating chemicals in the waste
results from the solution drag out into the rinse waters.  A secondary
source of wastes is from spills or leaks from filters, pumps, and piping
fixtures, etc.  Copper plating baths are rarely dumped.
Tin Plating
          Tin coatings are generally applied for their desirable character-
istics such as its resistance to corrosion and tarnish, its nontoxic nature,
its solderability, and its softness and ductility.  The largest single use
of electrodeposited tin coatings is in the tin plate industry.  Electro-
plated tin is also extensively employed as a coating on refrigerator parts,
dairy and other food handling equipment, washing machine parts, kitchen
ware, automotive pistons and piston rings, radio and electronic components,
electrical lugs and connectors, and copper wire.

          Tin is deposited from both alkaline and acid solutions.  Repre-
sentative compositions and operating conditions for stannate tin plating
baths are given in Table 21.  Similar data for acid tin plating baths are
presented in Table 22.

          Typical pretreatment steps prior to stannate tin plating are:
cleaning, rinsing, acid dipping, rinsing, cyanide or caustic dipping, and
rinsing.  For acid tin plating, the cyanide or caustic dipping step is
omitted.

          Tin can be electroplated in still tanks, barrels, and in auto-
matic equipment.  Mild steel tanks, unlined and equipped with steel heating
coils are suitable for stannate tin plating.  Rubber-lined or synthetic-
lined tanks or equipment are required for the acid tin baths.  Soluble tin
and insoluble steel anodes can be used with the stannate baths, while
soluble tin anodes are generally employed in the acid baths.

          The major source of tin waste is the drag out from the plating
baths into the rinse waters.  Settled sludges from the stannate bath, leak-
age from filtration equipment and piping in the acid baths, and accidental
spills are secondary sources of wastes from the tin plating baths.  Tin
plating baths are rarely dumped.

            (1-4*)
Iron Platingv   '
          Iron is used for building up heavy deposits on worn parts, for
printing plates, for electroforming and, occasionally as a substitute for

                                     50

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           TABLE   21.   REPRESENTATIVE  COMPOSITIONS AND  OPERATING
                        CONDITIONS FOR  STANNATE TIN PLATING BATHS
                                               (2-4)
Constituent
     or
 Condition
     Bath 1
Bath 2
Bath 3
Bath 4
 Potassium  stannate
 Potassium  hydroxide
 Sodium stannate
 Sodium hydroxide
                          Composition, grams/liter
       100
        15
 210
  22
 420
  22
                                                  100
                                                   10
Temperature, C
Current density,
  amp/s q cm
         Operating  Conditions
    65-90           70-90

  0.03 to 0.11    0.17 max
              70-90           60-85

             0.43 max 0.005 to 0.032
             TABLE  22.   COMPOSITIONS AND OPERATING  CONDITIONS
                          FOR ACID TIN PLATING BATHS  (2~4)
         Sulfate Bath
                             Fluoborate  Bath
Stannous sulfate
Sulfuric acid
Cresol sulfonic acid
B-naphthol
Gelatin
                         Composition, grams/liter
      53
      98
      98
      1.0
      2.0
     Stannous fluoborate
     Fluoboric acid  (free)
     Boric  acid (free)
     B-napthol
     Gelatin
               200
                80
                25
                1.0
                6.0
                           Operating Conditions
Temperature , C
Current density >
  amp/sq cm
  21 to 38 C
0.011 to 0.432
     Temperature 3 C
     Current  densitys
       amp/sq cm
          21  to  43
          0.08 to 0.14
                                   51

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nickel.   Iron plating solutions are slightly acidic,  containing sulfates,
chlorites, fluoborates,  or sulfamates.   The basis metal is prepared for
iron plating by cleaning, rinsing,  acid dipping,  and rinsing.   The parts
are rinsed and dried following plating.  Soluble AKMCO iron anodes are
used for the process.
          A most useful bath is the one containing 127 g/1 (17 oz/gal)
and 111 g/1 (15 oz/gal) CaCl2-   The sulfate/chloride bath contains up to
20 g/1 (3 oz/gal) of ammonium chloride in addition to 250 g/1 (33 oz/gal)
ferrous sulfate and 30 g/1 (4 oz/gal) of ferrous chloride.  The fluoborate
bath is sold as a concentrate and upon dilution with water contains typically
225 g/1 (30 oz/gal) ferrous fluoborate, 10 g/1 (1.3 oz/gal) sodium chloride
and 22.5 g/1 (3 oz/gal) of boric acid.

          Drag-in to rinse water after plating is the major source of waste;
floor spills and leakage from filter systems are a secondary source.  Fluo-
borate ions will have to be treated where such a bath is used.  Small
amounts of ferric ion in the sulfate and chloride baths precipitate as
hydroxide or oxides and are removed by filtration.
Gold Plating
          Gold and gold-alloy coatings are applied for decorative purposes,
as on jewelry, and for other applications requiring oxidation and tarnish
resistance.  Gold plating is also used in applications of electrical con-
tacts and to achieve high solderability.

          The majority of gold plating operations are performed using
cyanide solutions.  Typical compositions and operating conditions for gold
cyanide plating baths are listed in Table 23.  Additions can be made to the
various plating baths to produce various gold-alloy plates; for example,
7 to 15 mg/1 of antimony tartrate added to the cyanide gold-plating bath
produces a gold-antimony alloy deposit, indium cyanide additions produces a
gold-indium deposit, and gold-gallium deposits have been produced by the
addition of gallium salts.  Some gold plating baths contain no free cyanide
and may contain gold and potassium phosphate or gold and ammonium citrate.

          Gold coatings are predominantly produced from baths in which the
gold is supplied in the form of salts such as KAu(CN)2 or NaAu(CN)2«
Anodes used may be made of stainless steel, carbon, platinum-clad tantalum,
and platinum-plated titanium.  (Gold anodes are used to supply gold to the
solution, but are used less often than are insoluble anodes in conjunction
with gold solutions.)

          Gold solutions and the drag out to rinse tanks are largely re-
covered with the gold extracted either in the plating plant or by a separate
reclaiming service.  The gold may be recovered by evaporation, precipitation
by zinc, electrolysis, or by ion-exchange methods.
                                     52

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TABLE 23.  RANGES OF COMPOSITIONS AND OPERATING
           CONDITIONS FOR CYANIDE GOLD-PLATING
           SOLUTIONS
Constituent
or
Parameter
Gold
Free KCN
K2HP04
K2C°3
PH
Temperature
Cathode Current Density
Units
g/liter
g/liter
g/liter
g/liter
PH
C
mA/cm
Range of Variables
1-8
0.1-30
15-30
0-30
10-11.5
55-70
1-10
                     53

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              (1-4)
Silver Plating
          Silver is used for decorative, protective, and engineering coat-
ings.  Thin deposits of 2.5 jum (0.0001 inch) are applied over jewelry and
such.  Coatings from 25 to 50 urn thickness (0.001 to 0.002 inch) are applied
to tableware and holloware.  Thicker deposits of up to 1500 jum (0.060 inch)
are applied for bearings and electroforms.  The bath concentrations nor-
mally increase as the desired coating thickness is increased.

          The silver in plating baths is present as a cyanide complex
together with free cyanide and carbonate.  Silver concentrations vary
from 25 to 75 g/1 (3.5 to 10 troy oz/gal).  Additives are used for grain
refinement and brightening.

          Strike solutions are generally employed in the basis metal pre-
paration.  After cleaning, rinsing, and dipping in cyanide or acid solution,
and rinsing, the basis metal is activated by anodic or cathodic treatments.
For example, stainless steels may be anodically treated in sulfuric acids
or cathodically activated by striking in a Wood's nickel bath which is com-
posed of 250 g/1 (3.2 oz/gal) nickel chloride and 120 ml/1 (16 oz/gal)
hydrochloric acid.   Silver strike solutions, with a low metal content (of
about 6 g/1 (0.2 troy oz/gal) of silver and high cyanide content of 75
to 90 g/1 (10 to 12 oz/gal), are used for nonferrous basis metals.
Ferrous materials are prepared first by striking in copper cyanide solutions
of similar composition prior to silver striking.  Consequently, the number
of process steps is greater for silver plating than most other plating
operations.

          Steel tanks, stoneware and lined tanks are normally employed for
silver plating, and the operations can be carried out manually or auto-
matically.  Both racks and barrels are used for silver plating.  Soluble
anodes are used for normal silver plating, whereas strike solutions would
use insoluble anodes.

          The metal is generally recovered for refining and extra precau-
tions are taken to avoid spills and leaks, because of the high cost of the
metal.  Dumping of solutions is not practiced.  However, the cyanide por-
tion of the waste must be treated by destruction.
Anodizing
          Anodizing is an electrolytic oxidation process by which the sur-
face of the metal is converted to an insoluble oxide having desirable
chemical and physical properties.  Considerable aluminum is treated, some
magnesium and limited amounts of zinc and titanium.  Aluminum is anodized
in 12 to 15 percent sulfuric acid to produce an oxide coating for corrosion
protection and as a basis for decorative color finishes with dyes, or a
hard coat for extra wear resistance.  A 5-10 percent chromic acid bath is
used where solution may become entrapped without current in recesses.  In
such a case sulfuric acid would attack the aluminum.  Aluminum may also be

                                    54

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anodized in oxalic acid or boric acid.  The characteristics of anodic coat-
ings on magnesium can be varied from thin coatings to give good paint
adhesion to heavy coatings for abrasion and corrosion resistance in solu-
tions containing fluorides, phosphates and dichromates.  Some zinc parts
are anodized to improve corrosion resistance.

          Pretreatment operations for anodizing involve one or more of the
following steps:  Alkaline cleaning, caustic etching, deoxidizing, desmut-
ting and bright dipping depending on the alloy used and the desired finish.
Posttreatment includes color eying and sealing with hot water or nickel
acetate solution.

          Steel, rubber-lined, plastic, and lead-lined tanks are used for
anodizing.  The latter may be used as the cathode in sulfuric acid ano-
dizing.   Lead cathodes must be used elsewhere except for chromic acid
anodizing where a steel tank could serve as a cathode.  Wastes are generated
by drag in of process solutions into the rinse waters.  Solutions are
occasionally dumped.  Spills are a secondary source of waste from anodizing
solutions.
                              Materials Reclamation
          In conventional electroplating operations, a sludge is produced
from the dump streams and the treatment of rinse waters by the so-called
"destruct" systems in plants from a wastewater treatment system.  Examples
of these systems are the oxidation of cyanide wastewater with sodium hypo-
chlorite, NaCIO, and the reduction of hexavalent chromium to trivalent
chromium with waste pickle liquor before neutralization and precipitation
of both with either sodium hydroxide or a lime slurry.  The resulting
sludge is separated and sometimes dewatered.  The common method for hand-
ling this sludge is disposal in landfill sites.

          Several recent developments have forced changes in this procedure.
Among these are new regulations on the discharge of toxic materials, the
small number of certified landfill sites, and the rising costs of plating
metals and chemicals.  The alternative methods are aimed at reclaiming the
dissolved plating metals in the wastewater during the plating operation in
closed or partially closed systems, thus circumventing sludge formation al-
together.  However, in the present state of the art there is still a need
for a small destruct system to neutralize spills, fumes, dumped plating
baths, unrecovered plating acid drag out, etc.  Recovery units used to
recover chemicals from plating bath rinse water are fairly wideily used;
however,  they have not been installed on cleaner or acid dip lines because
the cost of chemicals is not sufficient to make recovery worthwhile.  Also,
buildup of contaminants such as oil and grease makes the use of such closed
systems difficult.

          Treatment of the effluent to recover plating chemicals falls into
two categories:  (1) treatment of the entire volume of effluent by various
recovery methods, and (2) partial recovery.   The simple schematics shown
in Figure 2 illustrates the difference.  The total recovery unit illustrated

-------
A.   Total  Reclamation
Drag In
Evapor-
ation
Losses
           Plating
            Tank
     Reclaimed
   I  Plating
   I  Solution
Drag
                                  Drag
                                  Out
             Drag
             Out
Drag
Out
Rinse
Tank
No. 1
f
*
'

Rinse
Tank
No. 2




Rinse
Tank
No. 3
                              Rinse
                         *"   "Water ""

Recovery
Unit

Purified
Water
Makeup
Water
1

 B.   Partial  Reclamation

           Evapor-
      T     ation   Drag
 Drag In   T        n  <-
« — a —  —   Losses   Out
             ?  .
Drag
I 	 ^
Plating
Tank

Reclaimed
Uj'latijig. _ „.____ „ _
Solution
Rinse
Rank
No. 1
1
.mf
^
k
Recovery
Unit
-I
PL
Iwa
?
Rinse
Tank
No. 2
i
rif ied '
ter i
^
Drag
Out
N-«l ^x ~"^ *'
Rinse
Tank
No. 2
>



Rinse
Rank
No. 3
   Drag
   Out .
  —	*
                                                            . ^ ^Rinse^
                                                                ^"
                                                      To Waste
                                    I Makeup Water
                                                _ _  Treatment
              FIGURE 2.   TOTAL AND  PARTIAL RECLAMATION OF_PLATING
                         CHEMICALS  LOST THROUGH  DRAG
                                   56

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in Figure 2A handles three times as much water as the partial recovery unit,
Figure 2B, and has a capital cost of about 2.5 times that of Figure 2B.
With careful water conservation practices, 90 percent recovery of the chro-
mium and nickel plating chemicals can be achieved with the partial recovery
unit shown in 2B.  Where the main purpose is to recover plating chemicals
and return them to the process baths, partial recovery units such as 2B
are used.  Further improvement in the recovery of plating chemicals (up to
99 percent) is possible if rinse tank No. 2 is added to the recovery loop
shown in 2B.  It is not often economically feasible (or even physically
possible) to treat the entire volume of effluent.  Usually selective
and integrated treatment is combined with conventional treatment.


Ion-Exchange Recovery Units  '


          One method for recovering metals from the plating bath is by ion
exchange.  In using this technique, the wastewater passes through an ion-
exchange system to regenerate the captured plating solution and selectively
capture the contaminants that build up in the plating bath.  The treated
water is recovered and reused as rinse water.  Figure 3 is a schematic of
an ion-exchange system used for the recovery of chromic acid.  Note that the
principle is to return as much drag out as possible to the plating baths
through countercurrent rinse baths.  Rinse water from the last rinse stage
is then recirculated over cationic and anionic filters arranged in series.
The eluate from the anionic exchanger contains sodium chromate, Na2Cr04.
It is returned to the chromium bath through a cationic exchanger saturated
with hydrated hydrogen ions.

          Ion exchange is an economically attractive method of concentrating
plating chemicals.  It also permits the removal of metallic impurities from
rinse water and its reuse.  It has not worked well on cyanide rinse water;
however, a 3-bed system consisting of a strongly acidic, weakly basic, and
strongly basic ion exchanger has been used in Europe for removing cyanides.
Small evaporative recovery units may be needed to augment ion-exchange
recovery; in some cases small evaporators may be needed to raise the con-
centration of the output from the ion-exchange unit.


                          (5-7}
Evaporative Recovery Units
          Evaporation is a firmly established procedure for recovering
plating chemicals and rinse water from plating waste effluents.  Over 100
evaporative units (i.e., single-, double-, multiple-effect, and vapor-
recompression evaporator units) have been installed in the U.S.  These
units are used in partial recovery loops such as that illustrated in
Figure 2B, and also in combination with other recovery methods such as ion
exchange and reverse osmosis.   Vapor-recompression evaporators are used
only where steam evaporators are not available, and thus the high cost of
the expensive and complex compressor can be economically justified.

          Single-effect evaporators are less efficient than double effect
or vapor-recompression units;  however, they require less initial capital,

                                    57

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and are easier to operate with inexperienced personnel.  There are a number
of single-effect evaporator units available.  They are as follows:  (1)
evaporation based on the cooling tower principle, (2) submerged-tube
evaporation, (3) flash evaporation, and (4) "climbing film" evaporation.
The latter, a new concept introduced by the Corning Glass Company, is
illustrated in Figure 4.    The illustration shows an arrangement for
partial recovery such as that shown in Figure 2B.  Only minor changes
would be required to achieve total recovery such as that diagrammed in
Figure 2A.

          The recovery unit shown at the right in Figure 4 consists of
a glass shell and a tube heat exchanger mounted vertically.  The solution
is fed through the bottom of this evaporative unit.   Boiling of the solution
causes the liquid to surge and this produces a "climbing film" effect which
improves the heat transfer.  Vapor and liquid overflow from the top of the
tube are separated in the cyclone.  Recycled rinse water containing less
than 0.05 ppm of chromic acid can be produced from chromium plating rinse
water using this method.

          In concentrating the rinse water by evaporation to recover chem-
icals in such operations as chromium and nickel plating, relatively high
plating bath temperatures aid recovery.  Nickel baths operate at around
60 C (140 F).  Accordingly, considerable evaporation at this temperature
permits the recovery of most of the drag out by countercurrent rinsing
alone.   However, to reduce the number of rinsing stages and provide for a
good rinse efficiency, evaporators (or alternative recovery mechanisms) are
used.  Chromium baths operate at lower temperatures than nickel baths, 40-
50 C (104-122 F), thus it is more difficult to recycle chemicals by counter-
current baths alone, and, therefore, evaporators (or alternative recovery
mechanisms) are necessary.

          Closed-loop evaporative recovery systems require close control of
the bath for good operation.  For example, nickel baths are treated with
activated carbon to prevent contamination by organic substances.  Metallic
impurities such as iron, copper, and zinc are precipitated selectively by
electrolysis.

          In addition to its use in nickel and chromium plating, evapora-
tive recovery units are being used on gold plating baths.  Systems for zinc,
copper, brass, and cadmium cyanide baths, and for lead-tin-copper fluoborate
baths have also been installed.

          Zinc cyanide baths operate most efficiently at 25-30 C (67-86 F)
and require cooling to maintain this temperature.  Accordingly, cooling
towers have been used to cool the baths and concentrate them at the same
time.  Carbon dioxide is absorbed in the process which in turn leads to
the rapid formation of zinc carbonate.  This must be removed either by
freezing or precipitation with calcium in a separate treatment.  This and
problems arising from small amounts of impurities in the zinc cyanide bath
make this method of recovery marginal.
                                    59

-------
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Reverse Osmosis Recovery Units   '
          Concentration of the rinse waters from nickel plating baths is
performed in a number of installations utilizing reverse osmosis units.
Commercial reverse osmosis units for zinc and copper acid plating rinse
water have also been installed.

          In reverse osmosis, a pressure differential across a membrane
forces the water through the membrane, leaving behind most of the dissolved
salts.  Using this method, salts in the rinse water from nickel and copper
sulfate plating baths can be concentrated to solutions containing up to
15 percent salts, by weight.

          Several membrane support systems are in commercial use; these
include plate and frame, tubular, spiral wound, and hollow fine fiber
designs.  The cellulose acid membrane used in most of the development work
to date has a limit on the pH of solutions that can be handled.  The pH
range of 3 to 8 precludes treating either strongly acid or alkaline solu-
tions.  Spiral wound and hollow fiber polyamide membranes have been tried
on copper, zinc, and cadmium cyanide baths on an experimental basis.  Pilot
plant trials have also been run on copper cyanide rinse water; however,
there have been problems with this system with fouling of the membrane.
One of the disadvantages of reverse osmosis recovery units is the tendency
toward fouling of the membrane by slightly soluble components in solution
and by suspended solids in feeds (feeds must be amenable to solids separa-
tion before treatment by reverse osmosis).
Other Recovery Methods;
Current State of the Art
          There are a number of other recovery methods which are being tried
out but have not yet reached commercial scale.  These include freezing,
electrodialysis, ion-flotation techniques, electrolytic stripping, carbon
absorption, and liquid-liquid extraction.  These are scattered operations
using chemical precipitation and crystallization from solution.  Commercial
electrolytic recovery of tin and silver from plating bath rinses is also
being done.

          It is evident from the discussions on materials reclamation that
there are still many types of metal plating processes which are not yet
amenable to problem-free, closed-loop reclamation.  This is particularly
true in the case of zinc, copper, and cadmium cyanide plating baths.  Con-
tinuous closed-loop reclamation of plating chemicals from nickel and
chromium plating baths has proven to be commercially feasible; however,
there are still problems with these recovery systems.  Closed-loop svsterns
are subject to impurity builiup which requires hleedoff fi uui lii.e  o lime.
While the main process loops may be closed, secondary purification loops
are much more difficult.  Thus, nickel impurities can be removed from
chromium plating baths by ion exchange and returned to the ndckol bath in
a closed-loop system, but sodium sulfate and sodium chloride at 6 excess

-------
which cannot be completely returned to the process.  There is also the
problem of sludge from acid dip and cleaner line rinses for which recycling
usually is not economical.  Research is continuing in this area of recla-
mation; the Metal Finishers Foundation has put priority on the concentration
and recycling of cyanide compounds in plating baths.
                             WASTE STREAM GENERATION
          In performing the study of the electroplating and metal finishing
industry, four waste types were identified as being destined for land dis-
posal.  These are as follows:

          Water-pollution control sludges
          Process wastes
          Degreaser sludges
          Salt precipitates from electroless nickel bath regeneration.

          Water-pollution control sludges have been identified as a class
because they constitute the largest single waste category destined for
land disposal.  Included in this category are rinse waters from each plating
step which contain potentially hazardous chemicals dragged out from concen-
trated plating solutions.  Also included are process solutions—such as
alkaline cleaners, acid dips and pickles, and conversion coating solutions—
some of which are dumped at regular intervals.  Water pollution control,
when practiced at an electroplating and metal finishing facility, will
precipitate the dissolved potentially hazardous facility materials, thus
generating a sludge for land disposal.

          Process wastes include grinding, polishing, and buffing dusts,
filter aids, anode sludges and anode bags, plating racks, and rack mater-
ials.  Most of these materials bear occluded or absorbed process chemicals
and are generally disposed of by landfill means, either separately dis-
posed or mixed with the normal refuse.

          Degreaser sludges are in most cases chlorinated hydrocarbons which
are used to remove greases and oils from mechanically finished parts.
These sludges then contain dissolved greases and oils, buffing compounds,
abrasives, cloths, and metals.  They may be discarded through the routes
of direct disposal to the land or may be routed to a reclamation operation
(e.g., distillation).

          Salt precipitates from electroless nickel plating operations are
produced during the regeneration of the bath composed of calcium ortho-
phosphite and calcium sulfate.  The plating bath chemicals contained in the
precipitate may be returned to the bath by washing the filtrate.  This parti-
cular type of waste may not always be present since electroless nickel
plating operations are not as common as electroplating operations or small
volume solutions are not regenerated.

          A simplified representation of the relationships between the
sources a ad the types of wastes is shown in Figure 5.  Details and varia-
tions from the concept are discussed in the following paragraphs.

                                    62

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                         Water Pollution Control Sludges


          The source of these sludges is the process solutions drag out
from the workpieces as they are moved from tank to tank in any plating
operation.  The concentrated process solutions carried out as drag out are
rinsed in continuously flowing water at a rate which ranges from 1 to 10
gallons per minute.  The water flow rate depends on the number of rinses
and whether or not they are connected to each other in a countercurrent
or select mode.

          The rinse waters contain alkalies, acids with dissolved metals,
and possibly cyanides from the preplating steps.  The metal or metals
being plated onto the workpieces appear as dissolved salts in the rinse
waters following metal deposition steps.  Also present are conductivity
salts and additives which were introduced to enhance electrodeposition or
the properties of the deposits.  Some plating processes incorporate a post-
plating step intended to alter the metal surface by conversion or filming
to improve on the corrosion properties of the deposits.  Drag outs from
these solutions also contain metals and chemicals.  The rinse waters are
then collected throughout the plant in three distinct streams.  One stream
carries all cyanide-bearing wastes, another all chromium-bearing wastes,
and a third stream contains all alkalies and acids and metal salt solu-
tions other than chromium and those metals which are chemically bound to
cyanide.  The hazardous chemicals are then destroyed or reduced by passing
the streams through a water pollution control system, metals are precipi-
tated and separated, and the effluent is discharged to a stream or sewer.

          Plating solutions contain valuable metals in concentrations as
high as 200 g/1 (27 oz/gal), as well as chemical salts and additives.  For
these reasons, plating solutions are maintained by purification and filter-
ing and are rarely ever disposed of.  In contrast, pre- and postplating
solutions are dumped at regular production intervals as spent baths, and
metered into the water pollution control equipment for treatment along with
the rinse waters.   Such solutions are alkaline soak and electrolytic
cleaners, acid and cyanide dips, pickles, descaling baths, chemical and
electrochemical polishing baths, oxidizing, phosphating, coloring, and
conversion coating solutions.

          Spills and leaks from process tanks may also occasionally occur.
With proper plant equipment maintenance and good housekeeping such hazard-
ous waste generation can be kept to a minimum.  When it does occur, the
wastewater is handled by the water pollution control equipment adding
additional but relatively minute quantities of sludges for disposal.
Water Pollution Control Technology
          The chemical treatment of wastewater from electroplating and
metal finishing operations involves simple chemical reactions carried out
on a batch or continuous type basis.  This type of operation should pro-
vide sufficient holding time to complete these reactions,  continuous

                                    63

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monitoring of oxidation-reduction potentials and pH, and controls for regu-
lating reagent additions.  The amount of metals precipitated depends on the
insolubility of their hydroxides.  When solubilizing complexing agents are
present, precipitation is not as complete, so additional or different chem-
ical steps may be required.  For example, cyanide ions must be destroyed,
not only because they are toxic but also because they prevent the effective
precipitation of metals as hydroxides.  Similarly, chelating agents, such
as EDTA (ethylene-diamine-tetraacetic acid), when used in some process
solutions, make complete metal hydroxide precipitation more difficult.
But since these compounds are used only in very small quantities at concen-
trations of a few mg/1, the amount of water pollution control sludge is
reduced by only an indescribably small fraction.

          The first reaction to be considered is the destruction of cyanide
to nitrogen and carbon dioxide using chlorine or hypochlorides.  Another
process to destroy cyanide is to use ferrous sulfate which forms ferro-
cyanide and does produce a solid waste.  This process is used very infre-
quently and then only for the destruction of very concentrated cyanide
wastes if for no other than economic considerations.

          Other anions found commonly in electroplating and metal finishing
operations with the exception of fluorides, fluoborates, and phosphates
cannot be removed by precipitation and therefore escape in the effluent and
do not produce a solid waste.  Fluorides and fluoborates can be used with
practically all metals for the electrodeposition and at times for etching
of certain basis metals.  The most common use is in the electrodeposition
of lead and tin coatings and their alloys for bearing materials and solder
applications.  Fluoborates hydrolize to HF and BF3 in dilute solutions and
the fluoride can be precipitated with lime for disposal as a sludge.  Fluo-
ride removal is not as complete as desired, with more than 10 ppm escaping
with the effluent stream.  Phosphates are present in alkaline cleaning
solutions; however, there is a trend to reduce their concentration or elim-
inate their use because they are difficult to remove from plant effluents
by precipitation as calcium diphosphate  (CaHPO^-Zt^O), which has a solu-
bility of 0.2 g/1 in cold water.  The sodium diphosphate which would result
from the use of caustic is much more soluble.  Heavy concentrations of
phosphates aie found in rinses following electrdpolishing and chemical
polishing operations where concentrated phosphoric acid is employed.  In
plants which process aluminum, aluminum phosphate is precipitated (AlPC^)
when these two ions are present in the same neutral solution.  Thirty to
thirty-five percent of the concentrated phosphoric acid solutions are not
expected to produce solid waste since they can be used as a raw material
for the manufacture of fertilizer.  Zinc or iron phosphates are used in
the processing of steel as a corrosion-protective undercoating and/or as
a bonding agent in electropainting processes.  Their concentrations in
this application are about one-tenth of  those used in electroplating oper-
ations, ane.1 the phosphates as well as the metals are removed from solution by
dry lime precipitation for disposal with the water pollution control wastes.

          The next chemical reaction to be considered is the reduction of
hexavalent chromium to trivalent chromium using sulfite-containing compounds
or ferrous sulfate.
                                    64

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          In acid solutions these reactions  are as follows:
or

                  2Cr03 + 6FeS04 + 6H2S

and

                  Cr2(S04)3 + eNaOH^^F 2Cr(OH)3

In using ferrous sulfate as a reducing agent, approximately twice the vol-
ume of sludge is produced since three moles of ferric sulfate must also be
precipitated and removed as the hydroxide.

          In alkaline solutions hexavalent chromium can be reduced and pre-
cipitated with hydrazine.

                  4H0CrO, + 3N0H. fZ^4Cr (OH) , + 3N + 4H_0.
                    24     24            J          /
          Chromium wastes are generated from chromium plating solutions,
chromates and dichromates from bright dipping, electropolishing, and the
conversion coatings on zinc and cadmium.   Large installations for bright
chromium plating, where the plating time is only from 5 to 15 minutes
contribute large quantities of chromium to the waste stream, whereas fewer
installations for hard chromium plating with a plating time of several
hours contribute much less to the waste.   Conversion coating solutions,
although having a much smaller bath concentration of chromium (~15 g/1),
are periodically dumped and consequently contribute significant quantities
of chromium to the waste stream.

          Other finishing operations performed in electroplating and metal
finishing facilities will also generate a waste.  Chemical milling of
aluminum is one of these operations and is carried out in an alkaline
solution.  The resulting wastes can be used for phosphate precipitation
where the phosphates are part of the plant operations, which is generally
the case in the metal finishing of aluminum.  Milling of other metals is
carried out in acid solutions and hydroxide sludges are formed by neutrali-
zation.

          Neutralization and chemical precipitation are also used to remove
heavy metals from the rinses of etching operations.  The etching solutions
themselves are generated by electrolyzing in a closed-loop system.  Where
the etchants contain chromates, acetates, or ammonia, as is the case for
some printed-circuit manufacturing, and as a pretreatment for plating on
polystyrene, polyethylene, polyvinylchloride, polycarbonate, polysulfone,
polypropylene, and ABS, they are shipped to recovery plants.  With the
exception of the last two materials, all require solvent treatment to make
the surface hydrophilic.  The contaminated solvents are reclaimed by dis-
tillation after being shipped in drums to a reclaimer or the supplier and
are, therefore, not destined for land disposal by the electroplating industry.


                                    65

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          The plating of plastics is also performed and requires some addi-
tional process steps to those commonly employed for plating on metallic
surfaces.  Some of these steps are:  (1) sensitizing the plastic, which
involves the use of stannous chloride solution; (2) nucleation, which
deposits a film of palladium metal; and (3) electroless plating.  As an
alternative to steps (1) and (2), palladium-chloride may be applied dir-
ectly onto the plastic and then reduced to the metallic form by the use
of formaldehyde, hypophosphite, hydrazine, or borane compounds.  Of all
the process steps, only the use of stannous chloride, when precipitated
as the hydroxide in chemical waste treatment practices, adds to the sludge.
Spent palladium solutions are returned to the supplier for recovery, while
the palladium concentration is in the rinse on the order of t>pb and is lost
with the effluent.

          The electroless plating solutions, which are also used to produce
deposits on metallic surfaces, contain either nickel or copper,,  Nickel and
copper wastes from both rinse waters and spent plating solutions are
treated at pH 13 with caustic soda to destroy the complex and precipitate
the metal hydroxides.  Copper may also be precipitated as a metallic sludge
by heating to ~60 C (150-160 F) for more than 4 hours.  The resulting
metal or metal hydroxide wastes go to land disposal, although it is not
uncommon for the plater to return spent solutions to a supplier or
scavenger.

          The choice of the treatment chemical for metal hydroxide preci-
pitation is between slurried lime, Ca(OH) , or caustic soda, NaOH,
purchased dry or in liquid form«  The stoichiometric quantities of hydroxide
sludge produced per kg of metal are as follows:

          A1(OH)3      2.89                Fe(OH)2        1.91
          Cd(OH)2      1.3                 Ni(OH)2        1.52
          Cr(OH)3      Io98                Zn(OH)2        1.52
          Cu(OH)2      1.54

          Insoluble calcium carbonate is formed with the use of lime thus
adding to the sludge volume; the remaining calcium or all of the sodium
part of the reagents appears in the plant water effluent.  Precipitation
with lime is generally preferred since it produces a sludge wherein the
gelatinous hydroxide colloids are less difficult to settle and easier to
separate than with caustic.  Reaction rates and efficiency are affected
by the presence of other cations (Mg) or anions (CO-j), the pH of the
solution, the time allowed before separating the solids, the precipitation
agent (lime or caustic) used, and the degree of agitation.  Reagent chem-
icals are added in excess from 5 to 10 percent.

          Coagulant aids are usually required for sedimentation and separa-
tion.  Iron salts as well as alum may serve this purpose; however, this
will increase the quantity of sludge generated as the hydroxide.  Poly-
electrolytes are most commonly used in concentrations of 1 to 40 mg/1
(0.01 to 0.03 lb/1,000 gal).  For an average-size job shop with a water
use rate of 230,000 I/day  (60,000 gal/day), as much as 9.2 kg/day (20 lb/
day) of flocculant is added.  Solids adhering to the workpieces are removed

                                    66

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during the alkaline or acid cleaning steps prior to electroplating are
added to the total solid wastes for disposal.  Alkaline wastes, such as
soaps and detergents from burnishing or tumbling operations, are simply
neutralized.  Where ion-exchange systems are used for purifying tap or
process water, any solutions used to regenerate these systems are also
passed through the treatment plant.

          Toxic fumes are also generated in many plating operations.
Electrolytic cleaning solutions, cyanide, and chromium plating solutions
all work at elevated temperatures and at current efficiencies ranging from
12 percent to less than 100 percent.  That portion of the current which
is not used for metal deposition or anode dissolution produces H2 or C>2,
respectively.  The escaping gases carry with them various amounts of solu-
tion in the form of a mist which must be exhausted.  Similar conditions
exist for pickling, descaling, bright dipping, and chemical or electro-
chemical polishing.  Dispersion of such fumes into the atmosphere is
generally not permitted so that fume scrubbers or other cleaning devices
may be required.  Wet scrubbers or spray chambers are most often used.
Depending on the waste treatment effort exercised by a plant, the result-
ing liquid wastes may either be handled with the plating wastes in the
treatment system or periodically collected from the scrubber and returned
to a scavenger.  When processed through the treatment system, the acids
or alkali are simply neutralized; but cyanides, chromic acid, and solutions
containing metal ions add to the solid waste load of the plant.

          Quantities of Sludge.  The quantity of sludge produced in an
electroplating and metal finishing plant is not uniform for any given
process because the drag out and spillage varies from plant to plant.
The reasons are:   (1) processes plating the same finishes on the same
basis metal vary from plant to plant, depending on the state of the art
practiced in each plant; (2) process lines may be hand operated, semi-
automated, or automated; (3) variations in the size and shape of the parts
causes variations in the volume of solution drag out; (4) tank sizes
affect rack design; (5) rinsing practices differ from high water-flow
single rinse tanks to save rinses, or mists which collect and return drag
out chemicals to the plating baths; (6) deposit thickness directly affects
the production rate, i.e., the thinner the coating applied the more drag
out results for a given size installation; (7) simple housekeeping prac-
tices by maintaining all equipment and containing spills reduces the waste
load; and (8) water conservation through control technology with the use
of ion exchange, evaporative recovery, reverse osmosis, freezing, electro-
dialysis, electrolytic stripping, carbon adsprtion, ion flotation, and
liquid-liquid extraction.

          The control technology which may be utilized has specific appli-
cations.  In all instances, it is applied to the plating solutions, but
not to the cleaners or acid rinses.  Ion exchange is used for in-process
control of raw water, processing baths, and rinse waters.  If the appli-
cation is to produce deionized water or to remove impurities from the
plating bath, more heavy metals are generated and have to be disposed of
as a concentrate from the backwash operations or fed to the chemical
treatment system.  On the other hand, concentrates may be returned to the
baths, eliminating the need for dispersing of a waste to the land.  Examp-
les would be the recovery of chromic acid or phosphoric acid.

                                   67

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          Evaporative recovery systems greatly reduce the quantity of
waste by returning large portions of the drag out chemicals to the baths
and also recycling the rinse waters.  These units are commercially applied
to zinc, copper, cadmium, chromium, and nickel baths.  Because continuous
recycling increases the contaminant concentration in the baths, some of the
concentrate is discharged, and the system falls short of beinp able to achieve
zero discharge and, consequently, zero sludge disposal.

          Reverse osmosis employs a pressure differential across a mem-
brane to separate the solution into a concentrate and a solution approach-
ing the purity of the solvent.  Units having a through-flow rate of less
than 1200 1/hr (300 gal/hr) have been installed to recover plating bath
chemicals and make closed-loop operations of the plating baths possible.
The disposable waste would be worn and fouled membranes.

          Electrolytic stripping has been used for the recovery of precious
metals, copper and tin.  In order to strip a solution by electrodeposition
of its metal, it is necessary that the metallic ions in a dilute solution
reach the cathode surface at a sufficient rate so that essentially all
of the metal ions can be deposited in a reasonable time.  This can be
accomplished by pumping the solution between closely spaced electrodes,
through beds of metal or metal-coated glass spheres, through expanded
metal or porous carbon electrodes.  If cyanide is present in these solu-
tions, and is not oxidized at the anode, it must be destroyed subsequently
by chemical means.

          Freezing, electrodialysis, carbon adsorption, ion flotation,
and liquid-liquid extraction have also been considered but are still in
the development stage.  Pilot plant installations will not affect the
quantities of the pollution control sludge, either now or in the near-
term future.
Solids Separation and Sludge Disposal
          The first step in separating the precipitated metals and undis-
solved solids from the treated wastewater is settling through clarifiers
or solid contactors.  Settling is accomplished by a batch process in a
stagnant tank; after a certain period of time (normally over 2 hours) and
after the clear effluent has been drawn off the side or the top of the
tank, the sludge may be emptied through the bottom.  The continuous system
uses a baffled tank allowing the stream to flow first to the bottom and
then rise with a decreasing vertical velocity until the precipitates can
settle in a practically stagnant fluid.  Clarifier underflow or "sludge"
contains typically 1 to 2 percent solids and is pumped to a pond, lagoon,
or holding sump or further processed by dewatering.  Flowthrough ponds,
lagoons, or sumps discharge some more effluent to a stream or sewer system
causing a thickening of the sludge to 4 to 6 percent solids.  (Their
holding capacity is no less than the sludge accumulated during a 30-day
production.)   This sludge is periodically removed by tank trucks to a
disposal site.  In other instances, seepage-type ponds are used where the
effluent part of the sludge is allowed to percolate through the ground
causing the sludge to thicken to where it possibly could contain as much

                                    68

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as 12 percent solids.  The dangers associated with lagooning are seepage
of wastewater associated with the sludge into the aquifer or to adjacent
streams.  Percolating ponds are found with plants located in rural areas
where there is sufficient land available.  Plants in urban areas are
forced to use holding sumps.  Depending on the size of the plant and the
space available the sumps may have to be emptied weekly, biweekly,
monthly, or in rare cases, less frequently.

          Centrifuges will also thicken sludges to a consistency of 8 to
12 percent solids.  The effluent, however, contains suspended solids in
excess of 20 mg/1 and needs to be recirculated to the clarifier.  Centri-
fuges require small amounts of floor space and less than half the land area
that is required for lagoons or ponds.  Lagooning may be avoided entirely
by dewatering the sludge to a condition containing as much as about 50
percent solids.  Rotary vacuum filters will concentrate a sludge containing
4 to 8 percent solids to 20 to 25 percent solids.  The same solids content
can be achieved with pressure filters but the filtrate contains less than
3 mg/1 of suspended solids so that a return of the effluent to the clari-
fier is not needed.  Semicontinuous tank filters may further increase the
solids content to as high as 35 percent.  Automated tank-type pressure
filters and plate-and-frame presses produce the highest solids-content
waste of about 50 percent.  The choice of which dewatering device to use
is one of economics, available space, or the limitations imposed on the
ultimate disposal.  The availability and area of privately owned land at
or near a plant site is a factor in determining the disposal mode.

          Sludge may also be solidified by addition of chemical fixing
agents which insolubilize the metal hydroxides.  The additions, of course,
increase the volume of sludge destined for land disposal.  The sludge is
then similar in consistency to dried clay and reduces leaching to a frac-
tion of a ppb of heavy metal.

          Concentrated wastes rich in metals may be considered for recovery.
This depends on the number and ratio of the constituents and the volume of
the sludge.  Large volumes of sludge in one location are economically fav-
orable.   For similar sludges from different plants a central processing
station may accomplish such a task.   However, very little effort, if any,
is being expended at present to undertake such a task.  As raw material
prices increase and their availability decreases, the economics of recovery
of sludges may become more favorable.

          Ultimate sludge disposal,  at the present,  occurs at the follow-
ing locations:

          •  Company on-site lagoons
          •  Municipal or private dumps
          •  Covered landfill
          •  Sewers.

Other possibilities are disposal at lagoons or landfill areas,  incinera-
tion, recovery and reuse, or some disposal by deep-well injection, but
none of these are practiced to any large extent.
                                    69

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                            Process Wastes
          Process wastes can be separated into two distinct types (i.e.,
pre- and postplating preparation wastes and miscellaneous wastes.  The
first type of waste is generated in the electroplating and metal finishing
process in the preparation of the basis material prior to metal deposition
or the application of surface coatings.  The appearance of the product is
in many ways reflected by the way the underlying surface has been finished.
Similarly, the protection given to a product against corrosion and wear,
or the physical-mechanical properties of the deposit are, among other
criteria, dependent on the preparation for plating.  Depending on the size,
shape, and number of parts, and finish desired, parts may be manually,
automatically, or bulk finished.  Depending on its surface condition, one
or more operations may be necessary in preplating preparation.  A post-
plating mechanical operation may also be desirable.  All of these operations
produce solid wastes which are composed of the materials being processed
and the materials used to achieve a desired finish.  These operations
are:  grinding, abrasive blasting, polishing, buffing, brushing, mass
finishing by vibratory deburring, and barrel processes.

          The second type of waste results from daily plant operations
which are not precipitated metal hydroxide sludges or solids.  They can
be metallics from used anodes, plating racks, etc., or nonmetallics such
as woven anode bags, coatings on plating racks, filter cakes, worn tank
linings, etc.
Pre- and Postplating Preparation
Process Wastes
          Grinding.  The most frequent application of grinding is associated
with hard chromium plating„  The uses of hard chromium are many, and it may be
found in all types of industry for improving hardness, heat-, wear-, and
corrosion-resistance, and for its low coefficient of friction.  Grinding
can be carried out before or after hard chromium plating.  Worn parts, such
as crankshafts, propeller shafts, cams, dies, molds, etc., can be salvaged
by grinding back or cutting beyond the old surface coating.  New parts can
be processed in the same way, but it is common to manufacture these parts
to within close tolerances and then plate the metal to the thickness desired.
Sometimes the parts are overplated and then reground to finish dimensions.
Included in this group are gauges, taps, molds for plastic and rubber,
cutting tools, printing rolls, dies, gun barrels, and various shafts.
The wastes that are generated are, of course, metallic chromium and the
basis material to which the coating is applied, or an intermediate coating.
Waste is normally disposed of along with the weekly refuse collection, or
if in sufficient quantity, to a metal scrap dealer.  Grinding carried out
on bulk material is discussed later.

          Abrasive Blasting.  Materials are frequently finished by wet or
dry abrasive blasting, for the removal of scale, rust, or other coatings;
for roughening the surface or to improve or develop the surface for finish;
for cold working (shot peening) to increase fatigue life; or to decrease

                                    70

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susceptibility to stress corrosion or correct objectionable distortion.
The amount of material removed depends on the type and quantity of abra-
sive used and the amount of mechanical or air pressure applied.  Angular
grit, steel shot, manufactured abrasives, such as aluminum oxide and
silicon carbide, natural abrasives, slag products, and some glass beads
are the most common recyclable materials, ranging in size from 50 to 500
mesh.  Precleaning of the parts for the removal of soil is recommended
to keep these materials clean for recycling.  The natural abrasives include
such items as pumice, silica, quartz, etc., and are used where metallic
impurities introduced to the part to be finished cannot be tolerated.
Sawdust, ground corncobs, crushed nut shells, glass beads, thermoplastic
materials, etc., comprise the soft abrasives which are normally discarded
with the weekly refuse.  Dirt, soil, and scale are the only waste products
from dry blasting operations where recycling equipment is attached.  Loss
of abrasives can occur by change of abrasive materials in the cabinet or
through dust filters.

          Polishing and Buffing.  In metal finishing, after grinding comes
the polishing operation which is done to achieve an intermediate surface
that can be further refined by buffing prior to plating.  The polishing
operation may be carried out on metals or nonmetals; it removes some
material from the surfaces.  The purpose of buffing is to smooth and
brighten the surface without much metal removal.

          Polishing is carried out on hard-faced wheels varying in diam-
eter, thickness, and material depending upon the part that is being pro-
cessed and the finish and material removal rate that is desired.  Wheels
are constructed of woven cotton fabrics, canvas, felt, or leather discs
glued or sewn together.  Felt wheels are used where true surfaces are
required or where a contoured shape is being finished.  Leather wheels
produce a finer finish, and wood wheels covered with leather are normally
used for flat surfaces.  Abrasives are generally applied to these wheels
with synthetic adhesives or cements which have generally replaced the
hide-glue formerly used.  The ratio of abrasive to glue used in the facing
of the wheels changes with grit size.  Used wheels may be recoated after
removal of lubricants from the facing or the facing itself may be replaced.
The abrasives are fused-aluminum oxide, silicon carbide, and turkish emery.
Tallow, grease, special bar lubricants, and spray lubricants are also used.
Woven cloth belts are also used for polishing operations after having been
treated in the same way as the wheels.  Greaseless polishing can be accomp-
lished with flexible polishing wheels using softer cloths.  Burrs on
castings or stampings may also be removed with the use of polishing wheels.

          Buffing normally follows the polishing operation as the last step
before plating.  Depending on the desired finish of the product, the oper-
ations may vary.  Satin finishes are obtained using fast cutting abrasives,
mostly aluminum oxide and silicon carbide.  Glue or adhesive binders are
used to hold the abrasives, forming a greaseless compound buffing bar.
Grease-base buffing bars are made of animal, vegetable, mineral fats,
and waxes together with an adhesive.  "Cut-down" buffing bars are composed
of various materials, depending on the metal to be finished.  Once-ground
tripoli and aluminum oxide are the most widely used.  An operation known as
"cut-and-color" buffing is used in place of the cut-down operation to

                                    71

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achieve a small amount of metal removal while at the  same time giving  some
luster to the metal.  Basically, the same constituents are used  in different
compositions to produce cut-and-color bars.  Red iron oxide powder is
frequently used for nonferrous metals.  For producing a  final finish having
the best color and  luster, very small amounts of very fine abrasives are
used consisting of  the materials listed above plus bars  containing
chromium oxide for  finishing stainless steel and chromium,,

          Where semiautomatic or automatic machines are used,  the buffing
compound is not in a bar form but is applied in a liquid form from air
pressure feed tanks or circulating drum pumping equipment.   The newest
development is a system of airless spray buffing.   Liquid compounds are
also available for manual buffing operations.   The same abrasives that
are used in buffing bars are used in liquid buffing;  however,  materials
are oil solutions or water emulsions instead of grease,  fat,  waxes, and
oils.   Liquid buffing compounds produce better finish at a lower cost than
maual operations with bar compounds, are required in smaller amounts,
cause less wear on the buffing wheel,  and cause less dirt to be packed onto
the parts,  which makes subsequent liquid cleaning easier.  The different
production techniques are summarized in Table 24.

          The wastes produced from these operations contain three basic
materials:   (1) the metal removed by the abrasive media which will vary
in quantity depending on the type and size of the abrasive,  the contact
time,  the wheel diameter and speed, (2) the constituents of the specific
compounds used, and (3)  the materials used on the wheels and buffs.  Items
(1) through (3) are combined as one waste and collected from mechanical
exhaust systems.  This waste is disposed of in a landfill,  although other
means,  such as incineration,  are possible.  Precious-metal wastes are
more likely to be collected and incinerated, with the metals recovered from
the ashes.

          Wheels and buffs are consumed to about one-half of their diameter
and then discarded as solid waste or returned to a supplier for recycling.
In shops with small polishing and buffing operations, the former procedure
is more likely to occur.

          Where plastics are being processed (thermosetting,  thermoplastic,
molded or laminated, with or without fibrous filters), these materials are
also part of the waste.

          Mass Finishing.   The improvement of surface finishes,  the removal
of burrs, edges and scales, and the forming of radii is specially obtained
by tumbling or vibratory finishing of several parts at one time.   Just a
few large parts may be finished to specification or thousands of small
parts may be handled by machines with revolving (tumbling)  or vibratory
motion.  A medium is added to separate the workpieces and perform a finish-
ing operation similar to that in polishing and buffing.   The media which
are used are listed in Table 25.   Some of the media are used in conjunc-
tion with proprietary chemical compounds, or these compounds can be used
by themselves.  Most operations are carried out wet.  Equipment may be
made of wood or steel and may be lined with neoprene, vinyl, or polyure-
thane.   Metal is removed in the process either as solid or dissolved ions
depending on the specific compound used.  The proprietary chemical compounds

                                     72

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Footnotes for Table 25:
          (1)   Usual average dimensions.  Other sizes available for special
               applications.
          (2)   Although occasionally used alone, particularly with parts
               which can be self-tumbled, this grain is usually mixed with
               other media.
          (3)   Available in quarried state or processed to remove sharp
               corners.  Quarried form is only good for the very roughest
               of operations and becomes processed form after a few hours
               of use.
          (4)   Symbols  indicate the following:
                  Y - most used
                  y - often used or possible use
                  N - never used
                  YW or yW - used with added fine abrasive

          (5)   Also used for drying after polishing or burnishing of all
               metals and plastics and as a medium extender for all media
               to reduce harsh action.
          (6)   With or  without other media.
          (7)   See wood balls.
          (a)   Electroplating Engineering Handbook,  Ed.  by A.  Kenneth
               Graham,  3rd Edition,  1971, Van Nostrand Bernhold Company,
               New York,  p. 93.
                                    75

-------
are discarded into the drain leading to the water pollution control system
or the sewer at the end of each mass finishing operation.   Some media is
also lost by abrasive action.  The quantity of wastes (e.g., metal chips,
soaps, etc.) contributed by mass finishing operations are estimated to be
less than 0-3 percent of the total waste load on the basis that the greater
portion of the materials pass through the waste treatment system (e.g.,
ions of the chemical compounds) or are directly discharged to sanitary
sewers.
Miscellaneous Process Wastes
          Filtration.  One of the stringent requirements for producing
electrodeposits is the maintenance of the plating bath by addition of
chemical components lost by drag out with the plated parts and the purifi-
cation of the solutions to remove suspended solids and organic contaminants
as well as dissolved metals foreign to the bath.  As a general routine,
copper, nickel, zinc, tin, silver, gold, cadmium, or their alloy baths
are continuously filtered at a rate which ranges from one-fourth to six
times the bath volume per hour.  The filter type and size has to be
fitted for each type of solution, with volumes ranging from 600 to
2000 liters per square meter (15 to 50 gallons per square foot) of filter
area per hour.  The solids contained in a plating bath are such that they
would easily clog the applied filter media, which are woven cloth or syn-
thetic fibers, porous carbon, stoneware, yarnwound cartridges, and paper.
To improve filtering efficiency and to ease the removal of the contaminated
filter cake, a coating of 600 grams of filter aid per square meter (2
ounces per square foot) is applied onto the filter medium either before
filtering operations are started or continuously by means of a proportion-
ing pump.

          Heavily contaminated baths, or baths which are not set up with
individual filtering units, are normally batch treated in a separate puri-
fication tank by adding the filter aid directly to the bath together with
other purifying agents (activated carbon, oxidizing agents).  The filter
aids most commonly used are diatomaceous earth, perlite, asbestos fibers,
and alpha-cellulose fibers.  Silica-containing filter aids are normally
not used with fluoborate solutions because of the chemical attack on the
silica.  Asbestos fibers are used as a precoat under diatomaceous earth
or mixed to about 20 percent with diatomaceous earth or cellulose for
increased filtering rates and better adhesion of the filter cake to the
filter membrane.  All aids are supplied in grades varying from coarse to
fine.  Since most plating baths contain organic additives, which decompose
during the operation, carbon is also added to the filter cake.  The amount
of carbon used ranges from 60 to 480 grams per 100 liters (1/2 to 4 pounds
per each 100 gallons) of solution, depending on the degree of contamination
or the available filter area.  Generally, 900 grams of carbon are applied
per square meter of filter area  (3 oz/sq ft) from a slurry composed of the
carbon and about 450 grams of filter aid.

          Chemical purification is often used to remove inorganic impurities
from plating baths.  The methods are specific for the kind of impurity that
is to be removed, the bath composition and the basis metal processed.  For

                                     76

-------
example, zinc dust is added to a zinc plating bath to chemically precipi-
tate metals more noble than zinc (e.g., copper, iron).  Zinc and lead
present as foreign ions in cyanide plating baths can be removed by precip-
itation as the sulfides.  Iron can be precipitated from nickel plating
solutions by raising the pH and temperature of the solution and adding
hydrogen peroxide to oxidize the iron.  In each case the formed solids
are removed by filtration.

          Only the filter cake is disposed of when precoat filter membranes
are used.  When filter disks made of paper or yarn-wound cartridges are
used, they are disposed of along with the filter cakes each time a filter
is cleaned.  For example, a solution volume of 4000 1 (1000 gal) passed
through a membrane filter once every hour at a rate of 1400 1/m2 of filter
area (35 gal/ft2) would have a cake volume of about 30,000 cm^ (1 ft^)
consisting of 3/4-filter aid and 1/4-activated carbon onto which dirt
particles and precipitated metal salts are absorbed.  The filter will also
contain an equal volume of plating solution.   At a density of 2 g/cnH,
the weight of disposable filter cake would be 60 kg (130 Ib).   This waste
would then be discarded by backwashing the filter to a water pollution
control facility, where available,  or to the sewer.  If yarn-wound cart-
ridge or paper filter disks were used instead of a filter membrane, they
would be discarded with general refuse.

          Anode Wastes.  Most electroplating solutions use soluble anodes
as the source of the metal being plated.  These dissolve at a rate approxi-
mately equal to the metal deposition rate.  Insoluble anodes are used in
precious-metal plating, anodizing,  and electropolishing.  Chromium plating
is carried out with an insoluble lead-alloy (^94 percent lead, remainder
antimony or tin) anode.  A small loss of anode material is encountered by
the formation of lead chromate on the anode surface during inactive periods.
The film is brushed off and settles as a sludge on the bottom of the chro-
mium tank or can be removed chemically in a solution of Rochelle salt and
caustic soda.  The life of a lead anode, nevertheless, is very long, in
terms of years, and depends on how often and how long it is left in the
bath without current flowing.  A 10-year or more life for insoluble anodes
is not uncommon.

          Bags are used for most soluble anodes to collect insoluble anode
materials, called anode sludge, during the electrochemical dissolution.
The bags are loosely fitted around the anodes and are made of cotton,
flannel, muslin, nylon, Dynel, and Vinyon.  Blue African asbestos is used
in iron plating baths at times.  The life of an anode bag is dependent on
the material and the type of solution in which it is used, but it should
be used with several soluble anodes.  Using the nickel plating bath of    «
Line 1 of the 38-man model plant (Table B-l) as an example, 560 m2 (6030 ft ;
of parts are plated daily in a tank containing 17,000 1 (4500 gal) of nickel
solution.  The nickel anodes have an area of 16 m2 (174 ft2) and weigh
2090 kg (4610 Ib).  To produce a deposit of 15 Aim (0.0066 inch) requires
74.8 kg/day (165 Ib/day) of nickel and the annual weight sold as product
is 18,700 kg (41,280 Ib).  In addition, about 15 percent of the nickel
anodes or 2960 kg (6536 Ib) are returned to the supplier as unusable scrap.
The anode sludge accumulating in the anode bags is about 198 kg/year
(436 Ib/year) and is taken from the bags at each anode change, or every 22 days.

                                    77

-------
The anode bags have a service life of about 1 year.  When discarded, they
weigh 12.5 kg (27.5 Ib) and contain 12.5 kg (27.5 Ib) of nickel salts
from the plating bath, and would normally be carried away weekly with the
regular trash.

          The anode scrap from this operation is estimated at about 9,550
kilograms (21,000 pounds) which, of course, would be sold to a nickel
scrap dealer.

          Although this example gives an indication of the volume of
waste generated by one plating operation, it is by no means universal.
Nickel anodes are also manufactured in small "rounds", about 1 inch in
diameter and 1/4-inch thick.  These anodes are held in insoluble baskets,
requiring less nickel material because of much greater active surface
area.  These nickel anodes are designed such that they will use up almost
100 percent of the anode, resulting in no anode scrap.  The anode bag
consumption is somewhat greater than with rolled anodes, whereas the anode
sludge formed is about the same.  Other anode metals may be formed into
balls, rolled into sheets, or cast as slabs, and all contain varying
additives to enhance dissolution or activity.

          Plating Racks.  The function of a plating rack is to hold the
workpiece to be plated and to conduct current to the workpieces.  Depend-
ing on the shape and size of the part to be plated, a rack can be a simple
wire arrangement or a complicated fixture, or even be supplied with auxi-
liary anodes.  Racks are made of materials with high current-carrying
capacity, copper being the one most widely used.  Titanium is used for
anodizing and as rack tips.  Other materials used in the construction of
racks are brass, bronze, nickel, steel, stainless steel, lead, Monel, and
aluminum.  The bare metals are insulated with rack coatings by dipping the
rack into a two-coat system and baking.  Coating materials, listed in
Table 46, have a limited life because of the corrosive nature of the plating
solutions.  Any separation of the coating from the metal causes drag in
of unwanted chemicals into the plating baths, which is detrimental to the
deposit.  For that reason, many electroplating facilities are equipped
with a rack department; here, new racks are designed and constructed,
while old racks are repaired (1) by removing the old coating and applying
a new insulating coating, and (2) by cleaning the contact points of the
electrodeposited metal.  The rack coating is normally softened with an
organic solvent and then mechanically stripped.  The waste coating leaves
the plant destined for land disposal.  The metal removed from or with the
rack tips is also discarded.  Before recoating the racks, the basis metal
is cleaned, normally by grit blasting, which would add small amounts of
metallic wastes to the disposal load of such a plant.  There are rack
specialty shops which supply that part of the industry too small to have
its own rack department.

          Tank Linings.  Plating tanks are generally protected from corro-
sion by various linings.  The linings are made of rubbers and plastics,
thermosetting resins and metallics, which in most cases is lead.  The
nonmetallic linings also act to insulate the tanks against stray currents,
whereas the lead lining is often used as the cathode material in anodizing
and electropolishing.  Linings may have to be replaced occasionally due
to excessive damage from tears or extreme heat.  Small defects to the

                                    78

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linings can be repaired.  The extent of the disposal of linings cannot
be ascertained because repair of linings is generally carried out by the
supplier of tanks.

          Rejects, Used Equipment, and Supplies.   The multiple steps per-
formed in the electroplating and metal finishing industry have to be
carefully watched and controlled, since small variations may cause defects
which may result in the rejection of the finished products.   Depending on
their value, parts may be salvaged by stripping the coating, refinishing
the basis metal, and replating.  Items where this may occur are, for
example, automotive bumpers and silver- and gold-plated products.  Where
it is uneconomical or the basis metal is adversely affected by stripping,
parts are not salvaged for replating.  Zinc die castings are scrapped and
remelted without stripping the coating.  Plated steel, brass, or bronze
parts are also sold as scrap.  It is not unusual, however, for small
quantities of off-spec products to be discarded.   Stripping solutions
differ depending on the coating or coatings to be deposited and the
kind of metal to be coated.  They may be either chemical or electrochemical
in nature.  Some of the chemicals used are:  inorganic acids, chromates,
peroxides, hydroxides and salts of peracids, cyanides, and some proprie-
tary organic acid salts.  The stripped metals are present as ions at
fairly strong concentrations (>1M) in solutions which may be fed to the
wastewater treatment plant or discarded with the water discharge from the
plant.  Quantitative determinations of the chemicals used for stripping
and the metals lost by stripping are not possible since the published data
are lacking and the information contributed by the industry on the use of
chemicals and discharge of metal ions from stripping was insufficient.

          As in all manufacturing, production equipment has to be replaced
or repaired.  Solutions are circulated through filters, heat exchangers,
and purification equipment, requiring the replacement of pump parts,
valves, pipes, etc.  Because of the corrosivity of the plating baths at
elevated temperatures, replacement parts may be needed more often than
in other process operations.  Immersion heaters,  heating coils, anode
baskets made of titanium or plastic-coated steel, filters, temperature
controls, pH meters, conductivity bridges, spray and mist nozzles, anode
and cathode bus bars, (which supply electric current to the plating pro-
cess), moving and hydraulic parts of conveyors or automatic machines,
duct hoods, piping, and exhaust fans handling corrosive fumes, all have
limited life and need occasional replacement or repair.  Undisclosed
amounts of these materials may either be collected and sold as metal
scrap or be discarded as waste.

          Since electroplating and metal finishing operations always con-
sume chemicals, it is necessary for facilities conducting these operations
to store a certain amount of these materials.  Acids are contained in
carboys; while alkaline cleaning compounds, chromic acid, and cyanide-
containing salts come in drums ranging in volume from 20 to 300 liters
(5 to 75 gallons).  Other plating salts, such as nickel sulfate, carbon-
ates, phosphates, etc., come in 50-kg  (100 Ib) bags; liquid fluoride,
fluoborate, and sulfamate solutions are stored in plastic or lined steel
containers.  Organic additives for plating baths come in glass or plastic
bottles.  The large drums, 300-1  (75 gal), cylinders of gaseous chemicals
(chlorine, sulfur dioxide, and ammonia, which are used in waste treatment),

                                   SO

-------
and carboys are returned to the supplier, while all other packaging mat-
erial is disposed of with the weekly refuse collection.  Chemical salts
are caught in the linings of bags, and bottles are not rinsed after being
emptied, which causes small amounts of hazardous chemicals to be disposed
of with the packaging.

          Oil Emulsions.  In some process operations, oil emulsions are
used in the final step of the metal finishing operation to provide addi-
tional corrosion protection for the workpieces.  Cutting oils and soluble
oil coolants are used in mechanical operations which are sometimes assoc-
iated with metal finishing shops become part of the shop waste.  These
wastes are handled in waste treatment systems by oil skimmers or precipi-
tated with ferrous or aluminum salts and separated in clarifiers or air-
flotation equipment.  Thus they are a part of the water pollution control
sludge.

          Paints and Paint Solvents.  Paint and paint solvents are in
many ways like oil emulsions and are removed by destroying the emulsifying
agents and separating and settling the solids.  Electropainting operations,
the major source of paint wastes, sometimes use ultrafiltration to elimin-
ate waste discharge from the painting process.  The use of paints, however,
is not a common part of electroplating and metal finishing facilities.

          Stop-Offs.  In some cases, parts are only plated partially or have
different finishes in different areas.  Areas which are not to be finished
or which are to be finished differently are masked.  Masking may be accomp-
lished with inert reusable materials, or tapes or stop-off paints which
are stripped after the process is completed, by either pulling the tape or
dissolving the stop-off with a solvent.  Photo resists and masks are used
in the printed circuit industry.   Stop-offs find their largest application
in hard chrome plating.  Used organic stop-offs, solvents and photo resists
are collected and returned to the supplier while tapes are disposed of
with the weekly refuse.

          Oil to Replenish Hydraulic Units.   The use of large hydraulic-
ally operated plating and finishing machines leads occasionally to oil
spills.  It is customary to soak up such spills with an absorbing material
such as sawdust or corncobs.  Incineration and land disposal are the two
ways of handling such wastes, the latter being most predominant.
                           Degreaser Sludges
          Vapor degreasing is used as a part of the electroplating and
metal finishing operation to remove soils (oils, grease, buffing com-
pounds, etc.) from the parts to be processed.   Degreasers may be small and
manually operated or can be large automated machines.   The type of solvent
used depends on the soil and the material to be cleaned (Table 27).   The
spent solvents are generally recovered by distillation.  A distillation ,
unit may be an integral part of the degreasing unit, or the solvent may
be collected and sealed in drums upon cleanout of the degreaser and re-
turned to the supplier or a scavenger.  The frequency of degreaser cleanout
depends on the type and quantity of soil removed and varies from shop to

                                    81

-------







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shop.  Some criteria have been established to determine when a degreaser
should be cleaned.  Most commonly, the need for cleaning the degreaser is
established when the boiling point of the contaminated solvent is from 5
to 10 degrees above the boiling point of the pure solvent.  In most shops,
experience shows that this will take place at nearly consistent intervals.
The sludge and solids collected at the bottom of the degreasing tank are
removed and disposed of in a landfill.  The solvent is purified by dis-
tillation either in-house or at the supplier's facilities.  Other loss
may occur through leaks or spill.  Vaporization to the surrounding air is
minimal.  The threshold limit is normally 100 ppm in air by volume.


                  Salt Precipitates from Electroless
                       Nickel Bath Regeneration


          Electroless plating is a method by which metals are deposited onto
other metals or nonmetals such as plastics by autocatalytic redox reactions
in solution.  Electroless plating for industrial applications is performed
to provide a uniform coating thickness on all areas of a part (which is not
the case with electrodeposition) , to provide reduced porosity, and to improve
the corrosion and wear resistance resulting from an ultrimicro cyrstalline
alloy of the metal with phosphorus.  No applications are known for arsenic,
chromium, and iron electroless plating.  Catalytic gold and palladium elec-
torless plating are used to a small extent and cobalt electroless plating
finds some application where magnetic properties are desired.  Catalytic
copper electroless plating finds its application mostly in the fabrication
of printed circuits, plating on plastics, and other nonconductors.


          The catalytic nickel electroless plating baths, finding frequent
applications, are based on the reducing properties of the hypophosphite
anion:                    ,-,  .n  /•N°\    -
                                          "       "
                                          -
          [H2P02]~ + H20        >        H" + HPO" + 2H (Catalyst)

               Ni2+ + 2H  (Catalyst) - > Ni° + 2H+

          [H2P02]~ + H  (Catalyst) - » H0 + OH~ + P
A continuous increase in phosphite as indicated by these reactions, causes
the bath to become inoperable, and it must be discarded, as is normally the
case with small installations.  The bath is returned to the supplier for
recovery of valuable nickel.  When production rates are high, however, it
is economically advantageous to regenerate the bath.  Regeneration steps
include the addition of water-insoluble nickel salts, such as hydroxides
or carbonates and the removal of the phosphite ions by ion exchange. Most
successful operational regeneration processes are based on the chemical
precipitation of the phosphite anion.  For example, the addition of calcium
sulfate and hydrated lime to increase the solution pH to about 6 precipi-
tates calcium orthophosphite.  Sodium sulfate which builds up during the
regeneration process is separated by freezing at 0 to 5 C (32 to 42 F)
and removed by centrifuging, filtering, or decanting of the bath.  For
each kg of catalytically deposited nickel approximately 2.5 kg of calcium
orthophosphite and 1.1 kg of sodium sulfate are produced.  These wastes
would be disposed of in a landfill.

                                   83

-------
                            Waste Projections
          Estimates of the total industry and potentially hazardous wastes
expected from the electroplating and metal finishing industry job shops
were derived from the three model plants, the data discussed in Section I,
and the data collected from industry (see Appendix G).
Model Plants
          Because of the paucity of data obtained by the industry survey,
it was necessary to develop a series of model plants to calculate the
quantity of wastes rather than just use the data generated from the survey.

          For the purpose of developing model plants for the electroplating
and metal finishing industry and the projections of total industry and
potentially hazardous waste, certain assumptions and conditions were
recognized.  The principal considerations included the  following:

          Plant size
          Product mix
          Plant operating criteria.

          The selection of plant size was based on the data shown in
Table 2 of Section I, which shows the distribution of plants in terms of
the number of employees.  The size (number of employees) ranges and the
percentage distribution are as follows:

                  Employees                 Distribution Percent

                     1-4                           12.04
                     5-10                          26.69
                    11-25                          30.56
                    26-50                          19.74
                    51-75                           4.20
                    76-100                          3.79
                   101-150                          1.56
                   151-250                          1.09
                   251-500                          0.33

From this table, three model plants were developed.  Plant A represents
the average, or medium, size job shop with a work force of between 26
and 50 employees and would produce about 34 percent of the total output
from the 552 electroplating and metal finishing job shops.  The other two
model plants would represent the manufacturing facilities with fewer or
more employees than 26 to 50, respectively.

          Model Plant B, small shops, encompasses 567 job shops with be-
tween 5 and 10 employees and 646 job shops with an employment of 11 to 25
people.  The combined number of 1,213 shops, just more than half of the
industry total (Table 2), is estimated to produce less than 26 percent of
the total output.  Job shops employing fewer than 5 employees were not

                                    84

-------
included in the model plant for the purpose of projecting waste quantities
for the following reasons:

           (1)  They are estimated to produce approximately 1 percent of
               the electroplating  and metal finishing output.  For
               that reason they generate relatively small quantities
               of waste per plant and are exempted from conforming
               to the effluent limitations guidelines for the electro-
               plating and metal finishing industry in 1977.  Conse-
               quently, these plants do not generate any water pollution
               control waste.

           (2)  Even though process wastes occur in all manufacturing
               operations, no matter what size plant, the disposal
               of these wastes is treated in an entirely different
               fashion.  Anode scrap, plating racks, and other metal-
               lic parts are collected in barrels and sold to scrap
               dealers.  Rejects are returned to the customer.  Anode
               sludge and filter cakes from small portable paper filters
               are rinsed and flushed to the sewer.   The small number
               of employees does not allow for any preplating or post-
               plating operations such as polishing, buffing, grinding,
               etc.  Consequently, none of these process wastes are
               being generated.

           (3)  Since there is no polishing or buffing a degreaser is
               not required.  Oils, waxes, and dirt on the parts to
               be plated are removed entirely by the use of soak and
               electrolytic cleaners.  Degreaser sludges, therefore,
               are not present.

           (4)  Spent electroless nickel plating solutions or baths
               that require regeneration, if used in the 1-4 employee
               plant, would be of small volume and beyond the scope
               of the plant to process and would be discharged to
               the sewer or returned to the supplier.

          Model plant C represents all facilities employing from 51 to
500 persons and consists of 232 shops estimated to be responsible for
less than 40 percent of the total job shop production.   Close to three-
fourths of the 232 shops employ between 51 and 100 employees.

          Thus, model plants were developed for 38 employees (medium or
average size plant), for 16 employees (small size plant), and for 87
employees  (large size plant).

          After the plant sizes were chosen,  the volume of production,
the plating processes to be operated by the plant, and the type of equip-
ment needed for that production rate were determined.  The fact that two-
thirds of all metal finishing involves the deposition of copper,  nickel,
chromium, and zinc and that the majority of products are made of  ferrous
or copper-based alloys was the determining factor in the selection of the
electroplating and metal finishing processes.   Frequently occurring pro-
cesses such as phosphating and anodizing were also considered as  was

                                    35

-------
electroless nickel plating, producing atypical wastes, and these were
included in the medium and large size plants.  It is unlikely that even
the largest size plant would have all the plating and finishing pro-
cesses at its disposal.

          Equipment.   The type of basis metal and the size, shape, and
finish of the workpieces determine the size of equipment needed, the se-
quences of the process operations, and whether the equipment should be
automated.

          Each job shop is likely to serve more than one industry, and
therefore requires equipment adaptable to a continuous change of products.
Under such conditions, small shops are likely to have a large number of
smaller tanks for depositing a variety of metals.  The same preplating or
postplating solutions, such as cleaners, pickles, and chromating solutions,
etc., are often used for more than one plating operation.  The needed
flexibility of processing and the economics of small volume items to be
finished preclude the use of much automated equipment.  As the production
volume of a job shop increases, greater quantities of the same parts,
and different parts being finished by the same process, allow for the
automation of some, if not all, of the production.  The introduction of
automated equipment is equivalent to an increased output per man hour,
but not necessarily in a direct ratio, as can be seen in Table 29.  Two
men produce 120 m^ of Cu-Ni-Cr plating by manual operation whereas four
men produce 320 m2 doing the same operation in an automatic machine.
Although the cictual plating times are the same to deposit the same quan-
tity of metal, the solution volumes of the automated equipment are better
utilized, i.e., larger area plated per unit volume of solution, transfer
times from tank to tank are normalized, and racking and unracking and
drying of the workpieces with specially designed racks for each item
becomes much more efficient.  When the products do not require racking
but can be processed as bulk volume in barrels, production can be signifi-
cantly increased.  A good example of such a process would be the finishing
of ferrous screw machine products.

          Process Steps.  The plant operating criteria were then matched
to the product mix and the process descriptions  (p. 24).  Several assump-
tions were made in selecting the process steps, taking into account old
and new equipment.  For example, three-stage countercurrent rinses would
be found in most modern plants, but the single rinses used in older plants,
or because of the lack of space, would require much greater volumes of
water.  The result is a reduced ion concentration in the waste stream
causing inefficient removal of toxic materials as solid waste.  For two
chromium waste streams, one containing 300 mg/1 and the other 3 mg/1, the
metal removal efficiency would be 99.8 and 83.3 percent, respectively.
if the amount of chromium in the effluent were 0.5 mg/1.  Or, expressed
as a solid waste, the 300 mg/1 waste stream produces about 20 percent
more chromium hydroxide waste.  The water flow rates* were determined on
the basis of the composition of the process bath and a set maximum concen-
tration of 37 mg/1 in the rinses of the plating baths other than chromium,
which was allowed a concentration of 15 mg/1, and rinses after cleaners and
acid dips, for which concentrations of 750 mg/1 were permitted in the last
   Concentrations and water flow rates are based upon the> composition of
   the plating baths and the water flow rates permitted by Effluent Limita-
   tion Guidelines.
                                    86

-------
rinse following each process step.  A rinse factor of 0.7 was used in cal-
culating the water flow to compensate for density, viscosity, temperature,
and transfer time effects.  The cleaner and acid consumptions were based
on general plating technology, requiring that these solutions would be
dumped after losing their effective strengths at some production intervals.
Drag out rates depend greatly on the size and shape of the processed parts,
the transfer time from tank to tank, and the viscosity, temperature, and
density of the solutions, and may vary from 0.14 1/m2 (0.4 gal/1000 ft2)
for vertical well drained parts to more than 8 1/m2 (24 gal/1000 ft2) for
cup-shaped, very poorly drained parts.  Average drag out rates of 1 1/m2
(3 gal/1000 ft2) for rack operations and 1.67 1/m2 (5 gal/1000 ft2) for
barrel operations were selected.

          The correlations among plants with regard to characteristics
and waste generation rates, as reported by industry, were also analyzed
at considerable length, as were any potential correlations of operating
conditions.  The characteristics examined for correlation included:

          Number of employees
          Power consumption
          Installed rectifier capacity
          Area plated
          Plant operating rate.

          From our analysis, no applicable correlation was found.  This
was attributed to the multitude of operating conditions characteristic
of the electroplating and metal finishing industry.  According to the
process descriptions given earlier (see p. 24), more than 600 plating
processes are possible.  Furthermore, each plating process may be differ-
ent or a different number of cleaners may be used; the acids may vary in
composition as well as ionic strength,or may be used with or without
current; and even the plating baths may vary in composition.  A plot of
one characteristic examined, the area plated versus either the Installed
rectifier capacity or power consumption (i.e., actual electricity used),
showed so wide a spread of data points that no relationships among plants
could be developed.  The wide spread in the data would appear to be the
result of interaction of other factors, such as the degree of automation,
the number of process lines, the coating thickness, the varying power con-
sumption rates for different deposits, and the basic efficiency of opera-
tion.

          Nevertheless, the reported industry data were taken into consi-
deration in the design of the model plants.  The average working time per
week was 70 hours.  The production volume of each line was estimated from
that time basis, allowing for down time for solution and equipment main-
tenance, start-up time, etc.  Automated type equipment is likely to have
longer operating times than manual equipment, especially in the small
shops where all plating tanks are not used all the time arid not to full
capacity.  Such variations make it difficult to set up production rates
on an hourly basis.  A 24-hour day was therefore used as the time basis
indicating that equipment may be utilized from a few hours to 24 hours
per day.  The man power assigned to each line would be the determining
factor.


                                    37

-------
          In summary, the following considerations were given to the
development of the model plants:

          •  Plant size
             - specify the number of employees
             - industry production rates
          •  Product mix
             - specify the plating process, consisting of a major
               portion of copper, nickel, chromium, and zink plating;
               with anodizing, electroless nickel, cadmium and other
               finishes represented in minor portion of the product
               mix.
             - select a mix of automated and manual operations com-
               patible with the number of employees
             - specify the base metals to be finished
          •  Plant operating criteria based on the electroplating
             engineering technology, including
             - preplating, plating, and postplating steps
             - solution compositions
             - bath dump rates, spills, and leaks
             - area plated
             - tank sizes or solution volumes
             - solution drag out rates
             - rinse water usage
             - materials consumption
             - plant operating times
          •  Industry reported data from questionnaires
          •  Design the water pollution control systems based
             on chemical treatment technology, the prevailing
             present practice in the industry, and derive the
             sludge production rates
          •  Derive rates of waste generation during production
          •  Determine the degree and type of finishing required
             for the basis metal and derive waste generation rates.

          The average or medium size plant, Model Plant A, is character-
ized by the data given in Table 28.  It consists of nine process lines
with a total production rate of 3400 m2/day (36,576 ft2/day), plating
copper, nickel, chromium, zinc, and cadmium with additional phosphating
of steel, anodizing of aluminum and an electroless nickel plating opera-
tion.  The processing rate differs from the production rate by the number
of coatings steps for each line.  For example, in Line (1) the total pro-
duction rate is 560 m^/day, which is being processed through 3 electro-
deposition baths, namely copper, nickel, and chromium, in succession for
a processed area of 3 x 560 = 1,680 m^/day.  Or in Line (5) where the
production rate of 160 m /day yields a process rate of 2 x 160 = 320 m^/day
taking into account the cadmium deposition and the chromate conversion
coating steps.  Steels, brass, and aluminum are the base metals to be
finished.  Detailed calculations for the operation of the model plant are
given in Appendix B.

          Model Plant B, which is representative of the smaller job shops
with 5 to 25 employees, is defined in Table 29.  Six lines, electrodepositing


                                   38

-------
             TABLE 28.   PLATING OPERATIONS FOR MODEL  PLANT A  (INTERMEDIATE)

                                Representing Job Shops with  26
                            to 50  Employees  (Industry Average)
 Ltne or
 Operation
    Assumed
  Production
     Rate,
mZ/day  ft2/day
               Processing
                Rate,
             m2/day   ft2/day
                        Water
                       Allowed,
                                                                                Employees
                   Rack, Unrack,
  I/day  gal/day    Plating, etc.  Others
1) Automatic Rack
     Cu(CN)-Ni-Cr      560

2) Manual Rack
     Cu(CN)-Ni-Cr      160

3) Automatic Rack
     Zn(CN) +          800

4) Automatic Barrel
     Zn(CN) +
     Chromating        480

5) Manual Barrel
     Cd(CN) +
     Chromating        160

6) Manual Rack
     Hard Cr            80

7) Manual Rack Al
     Anodizing (+
     Bright Dip +
     Nickel - Acetate
     Seal)             600
8) Automatic Barrel
     Zn Phosphating
 400
9) Manual Electroless
     Nickel Rack
     Plating          160
Combined Lines
                    3,400
 6,024


 1,720


 8,608



 5,160



 1,720


   864





 6,456


 4,304



 1,720

36,576
Other Employees:
  Supervision (Plating)
  Supervision + W.T.
  Lab Analysis (W.T. + Plating)
  Rack-Repair-Stripping
  Maintenance
  Misc.  Job in Plating Shop
  Clerical

Subtotal

TOTAL EMPLOYMENT
                    1,680   18,072


                      480    5,160


                    1,600   17,216
                   63,590  16,800


                   18,170   4,800


                   45,950  12,140
                      960   10,320     45,950  12,140



                      320    3,440     16,810   4,440


                       80      864     10,370   2,740
1,800   19,368-


  400    4,304



  160    1,720

7,480   80,464
 54,960  14,520


 24,910   6,580



 12,040   3,180

292,750  77,340
                 1
                 1
                 1
                 1
                 1
                 1
                 2_

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                38
                                                              2

                                                             30
                                                                       8  (see
                                                                       below)
(1)  Based  on  a water use of 80 1/m  (1,964 gal/1000 ft ) of area  processed.
                                               89

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copper, nickel, chromium, zinc, and cadmium, plus aluminum anodizing and
zinc phosphating, have a production rate of 1,440 m2/day (15,488 ft2/day)
and a processing rate of 3,080 m2/day (33,136 ft2/day).   The base metals
to be finished are steel, brass, and aluminum.  Details for plant opera-
tion and waste generation are given in Appendix C.

          Model Plant C, which is representative of the larger job shops
with 51 or more employees, is defined in Table 30.  In this largest plant
copper, nickel, chromium, zinc, cadmium, tin-copper and lead--tin alloys
are deposited in seven lines.  One additional line is for anodizing,
another for phosphating, and a third for electroless nickel plating bring-
ing the total to 10 lines with a production rate of 6,960 m2/day (74,904
ft2/day) or a process rate of 17,120 m2/day (184,240 ft2/day).  In addi-
tion to the usual base metals, steel, brass, and aluminum, zinc die-castings
are also finished.  Calculations for the operation of the plant, materials
consumption, and waste generation are given in Appendix D.
Discussion of Model Plant Design
          The characteristics of the model plant designs are discussed
below.  Figure 5 shows the wastewater streams from each of the nine plat-
ing or finishing lines of Model Plant A and the daily flow rates of the
five combined streams each going to its specific water pollution treatment
system, followed by neutralization and precipitation of the heavy metals.
After liquids-solids separation in the clarifier, 314,530 I/day (83,100
gal/day) of effluent are discharged to a stream or sewer and 835 I/day
(220 gal/day) of sludge with a 20 percent solids content would be disposed
of by landfill means.  Details are given in Section III.

          Each process line is then broken down into process steps.  Line 1,
for example, identified as a Cu-Ni-Cr automatic rack line includes the
following process sequence:

          Hot alkali soak clean
          Single  rinse
          Electrolytic  anodic clean
          Single  rinse
          Sulfuric  acid  pickle
          Single  rinse
          Copper  cyanide  plate
          Countercurrent  rinse,  2  stations
          Sulfuric  acid  dip
          Single  rinse
          Nickel  plate
          Countercurrent  rinse,  2  stations
          Chromium  plate
          Countercurrent  rinse,  2  stations
          Hot-air dry

The drag out rate for an average shaped part was taken to be 12 1/100 m2
(3 gal/1000 ft2).  With a production rate of 560 m2/day (6,024 ft2/day),
the drag out rate is 68.5 I/day (18.1 gal/YdaO for each of the above process

                                    91

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stations.  The hot alkali soak cleaner is made up at a concantration of
60 g/1 (8 oz/gal) of proprietary compound in a tank having a volume of
7,570 liters (2000 gal).  A rinse water flow of 7,850 I/day (2,070 gal/day)
is calculated on the basis of the initial salt concentration,  the drag out
rate, the allowable salt concentration in the rinse following the cleaner,
and a rinsing efficiency of 70 percent.

          The spent cleaner is dumped every 25 working days, containing
75 percent of the original constituents of the bath, 25 percent having
been used up during production.  The proportionate loss to the waste
stream is:
                           Make-up Concentration     Dump  Concentration
                           Weight
                           percent    g/1   oz/gal      g/1   oz/gal

NaOH                        35      21.0     2.8       15.8     2.1
NaSiO-                       25      15.0     2.0       11.3     1.5
Na2CO,                       22      13.2     1.76       9.9     1.32
Na^PO;;|«12H20                 12       7.2     0.96       5.4     0.72


The cleaner dump rate of 2,000 gal/25 days = 80 gal/day is metered into
the water treatment system and when multiplied by the concentration of
the constituent of the bath gives the waste load.  For example, the
sodium hydroxide lost from this process step to waste is 4.76 kg/day or
10.5 Ib/day.  The same calculation is carried out for each constituent
of the process solutions, giving the total concentration of ions; in the
waste streams.  Acids and bases tend to neutralize in the treatment system.
Most anions are discharged in the effluent, and the metals are precipitated
as hydroxides after subtraction of the metal ion concentrations that are
dissolved in the effluent (see Table 31).

          The net results of the model plant sludge waste derivations are
summarized in a brief and simplified form in Table 32.   The detailed cal-
culations supporting the data in Table 33 are given in Appendixes D and E.
The table presents information bearing only on wastes from the water pollu-
tion control system.

          A detailed review of all model process operations produced esti-
mates of other process wastes.   The types and fates of wastes developed
for the medium-size model plant operation are listed in Tables 34 and 35.
It will be noted from the tables that some wastes are considered to ue
recycled or reclaimed.  These assumptions are in accord with current prac-
tices in some shops reflecting practical economics.

          One of the points worthy of discussion is the waste load produced
with each regeneration of the electroless nickel bath.  Electroless nickel
plating was included as representative of the industry and it was further
assumed that the bath would be regenerated in-house.  Because of the large
quantities of precipitated salts from a large volume of bath with a high
rate of production, these process wastes are identified separately in the
table.

          A recapitulation of the significant quantities of process and

                                   95

-------
TABLE 31.  ASSUMED METAL CONCENTRATIONS IN WASTEWATER*
     Metal	Concentration, mg/1
Cu
Ni
Cr
Zn
Al
Cd
Fe
0.5
0.5
0.5
0.5
1.0
0.5
1.0
  *  U. S. EPA - Electroplating Point Source Category.
     Interim Effluent Limitations and Guidelines, and
     Proposed Performance and Pretreatment Standards.
     Federal Register. Thursday, April 24, 1975, Vol.
     40, No. 80, Part II.
                         96

-------
TABLE 32.  CHARACTERISTICS AND SLUDGE PRODUCTION
           RATES OF THE MODEL PLANTS
Number of Employees
Production Rate
Square meters per day
Square feet per day
Wastewater Discharge
Liters per day
Gallons per day
Sludge Production Rate
at 20% Solids
Liters per day
Gallons per day
16

1,440
15,520

146,710
38,760

305.6
80.8
Sludge Production Rate
dry weight, metal hydroxides
Kilograms per day 60.8
Pounds per day 134.4
Metal Hydroxides in Sludges
Cr(OH)3
Ni(OH)2
Zn(OH)2
Fe(OH)2
A1(OH)3
Cu(OH)2
Pb(OH)2
Cd (OH) 2
Sn(OH).
kg/day Ib/day
19.20 42.32
6.88 15.12
4.64 10.16
3.20 7.06
4.16 7.20
2.80 6.24
-
1.12 2.40
-
38

3,400
36,576

314,530
83,100

701
185
140.2
309.2
kg/day Ib/day
34.98 77.22
11.22 24.77
13.60 30.02
14.78 32.62
23.85 52.67
4.38 9.67
-
0.96 2.13
- -
87

6,960
74,904

660,010
175,960

1,616
428
324
715
kg/day Ib/day
78.00 172.24
49.28 108.80
19.92 44.00
28.08 62.08
46.40 96.00
30.08 65.36
9.12 20.24
0.72 1.68
0.72 1.68
                     97

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solid wastes are given in Table 35.  In this table, the various waste
quantities are all expressed as dry weight or as solid materials.
Survey Data
          An analysis of the 88 written responses to this study from the
job shops indicated that 57 facilities generate some form of waste.  Seven-
teen of the responses stated that no wastes were disposed of by landfill,
while 14 responses gave no information whatsoever.

          The types and characteristics of wastes reported by industry are
tabulated in Appendix E.  Of the 90 wastes identified by the respondents,
26 were clearly identified as water pollution control sludges, 14 as resul-
ting from air pollution control, 23 as wastes associated with plating opera-
tions,  26 as coming from other categories of operations, and one was not
identified as to the source or type.  Indications of composition were given
in 26 of the 90 wastes.   These data serve to illustrate the variability of
the wastes, in accord with the previously discussed latitutde of process
operations characteristic of the electroplating and metal finishing industry.

          Those company code numbers containing the "IPC" (Institute of
Printed Circuits) designation exhibit, in general, tendencies to show copper,
lead, tin, epoxy, and fiberglas in their wastes, associated with the pro-
cessing of circuit boards with copper-solder materials.  The balance of the
wastes show a common occurrence of copper, nickel, chromium, and zinc.
Cyanide, lead, and cadmium are also reported in some of the wastes.  Quan-
tities of waste are also highly variable.  Efforts to aggregate or sum the
reported waste quantities are in many cases voided by the absence of one
or more factors, e.g., wet or dry basis, solids content, plant operating
schedules, etc.

          In view of the small fraction of plants reporting and the highly
variable nature of the wastes, these data were judged insufficient as a
basis for the projection of wastes, particularly on a state-by-state basis.
The data supplied by industry serves as a basis for the understanding of the
qualifications which apply to any model plant developed for the industry.


Current Potentially Hazardous Waste (1975)
          The data developed on the waste generation factors from the model
plants and the state and regional distribution of job shops as given in
Section I on Industry Characterization (Table 2) were used to calculate the
quantity of total industry and potentially hazardous wastes destined for
land disposal.  Plants having only 1 to 5 employees were eliminated because
of their exemption from effluent limitations.

          The numbers of facilities in a given state were aggregated into
three size ranges corresponding to the model plants, and are given in
Table 36 by state, EPA region, and nationally.  The waste generation rates
of each of the model plants were then multiplied by the number of plants

                                   100

-------
     TABLE 35.   SUMMARY OF WASTE QUANTITIES DERIVED FROM MODEL PLANTS
                                                                     (a)
                                  16
                                        Plant Size (Employees)
                                                 38
87
                            kg/yr   Ib/yr   kg/yr   Ib/yr   kg/yr   Ib/yr
Water treatment sludge

Process wastes

Degreaser sludge

Total

Electroless Nickel wastes

TOTAL
                            15,200  33,600  35,000  77,140  81,000 178,750

                            12,110  26,710  25,310  55,810  58,580 129,160

                             2.050   4,530   3.590   7.920   4,210   9.290

                            29,300  64,840  63,900 140,870 143,790 317,200

                             None    None   14,625  32,235  14,625  32,235

                            29,300  64,840  78,525 173,105 158,415 349,435
a)  All estimates are for a 250 working day year.
b)  Dry weight of metal hydroxides and precipitates from process solutions.
c)  Includes solid materials generated during the metal finishing operations
    and allows for occluded chemicals  (dry weight).
d)  Amount of trichloroethylene lost as sludge from degreaser operations,,
                                    101

-------
     TABLE  36.   DISTRIBUTION AND NUMBER OF ELECTROPLATING AND METAL
                FINISHING JOB SHOPS USED IN ESTIMATION OF SOLID WASTE
                GENERATION
Plant Size (No. of Employees)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

56
58
0
3
2
2
121

85
98
183

1
11
69
0
8
89

14
26
6
4
7
11
8
8
84

110
47
123
18
144
20
462
38*

31
25
71
0
0
1
128

21
45
66

0
2
23
2
4
31

6
5
2
5
0
8
1
10
37

36
13
101
9
46
8
213
87

6
11
6
0
1
0
24

6
21
27

0
0
11
1
,2
14

1
1
3
2
1
2
2
2
14

24
9
33
4
22
6
98
Total

93
94
77
3
3
3
273

112
164
276

1
13
103
3
14
134

21
32
11
11
8
21
11
20
135

170
69
257
31
212
34
773
*  Includes those for which the  number of  employees  is  not  known.

                                  102

-------
                              TABLE  36.   (CONTINUED)
Plant Size (No. of Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
16

2
1
5
7
46
61

15
14
30
3
62

14
1
0
1
6
0
22

11
80
1
4
96

0
3
10
20
33
1,213
38*

2
1
1
1
14
19

3
0
6
2
11

3
0
0
0
1
0
4

4
34
0
0
38

0
0
1
4
5
552
87

1
0
0
2
8
11

4
7
9
0
20

5
0
0
0
0
0
5

1
15
0
0
16

0
0
3
0
3
232
Total

5
2
6
10
68
91

22
21
45
5
93

22
1
0
1
7
0
31

16
129
1
4
150

0
3
14
24
41
1,997
*  Includes those for which the number of employees is not known.
                                     103

-------
in each size range for each of the states.

          The waste generation factors of the model plants are based on the
U.S. EPA effluent limitations and guidelines*, which are to apply in 1977
and 1983 and on the total production.  To establish quantities for 1975,
various factors had to be taken into consideration.  The adjustment of the
basic 1977 model plant waste quantities to 1975 waste generation levels
involves an allowance for the number of plants that are not currently pro-
ducing water pollution control sludges.  To estimate this situation,
information was gathered from state and local agencies to determine what
degree or what incidence of pollution control currently exists.  These
estimates were greatly influenced by local conditions.  As an example,
platers in New York City are not required to treat before discharge,
while Chicago has existing regulations equivalent to the proposed Federal
effluent limitations.  Such estimates were developed to the best degree
possible for areas (states) containing the larger numbers of electroplating
job shops.  A review of the 88 industry responses accordingly showed that
about 35 percent of the reporting plants produced water pollution control
sludge in 1975.  Of those 88, only small changes in sludge volume or compo-
sition were expected for 1977 because of increased production or changes
in water pollution control equipment.  Despite the viewpoint expressed by
these respondents, it was assumed that the Effluent Limitation Guidelines
will become effective and that most electroplating and metal finishing
facilities will install water pollution control systems on schedule.

          Thus, it is concluded that the significant differences in waste
quantities between 1977 and 1975 will be in the water pollution control
sludge quantities.  Economic conditions in general and data from Figure 1
(see Section I, p. 4) would indicate that the industry will not undergo any
major expansion or reduction.  Consequently, the wastes generated from
electroplating and metal finishing processes other than water pollution
control sludges will remain unchanged between 1975 and 1977.

          Table 37 shows the estimated quantities of the four categories
of waste and of total industry and potentially hazardous wastes destined
for land disposal by the electroplating and metal finishing job shops in
metric tons per year for each state, EPA Region, and nationally.  The
total industry and the potentially hazardous wastes for 1975 is estimated
to be 78,740 metric tons (dry weight).  The major portion of the wastes,
54 percent, are process wastes as indicated in Table 37.  The water pollu-
tion control sludges account for 25 percent of the total, followed by
electroless nickel plating wastes, 15 percent, and 6 percent for degreaser
sludges.  The fact that only an estimated 35 percent of the total job shops
are producing water pollution control sludges in 1975 is the main reason
that the general process wastes associated with all electroplating and metal
finishing operations account for more than half of the total wastes.
   U.S. EPA - Electroplating Point Source Category.  Interim Effluent
   Limitations and Guidelines, and Proposed Performance and Pretreatment
   Standards.  Federal Register, Thursday, April 24, 1975, Vol. 40, No. 80,
   Part II.
                                   104

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                   TABLE 37.  QUANTITY OF TOTAL INDUSTRY AND POTENTIALLY
                              HAZARDOUS WASTES DESTINED FOR LAND DISPOSAL
                              FROM THE ELECTROPLATING AND METAL FINISHING
                              INDUSTRY (JOB SHOPS); METRIC TONS; DRY WEIGHT*,
                              1975
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Water Pollution
Control Sludges

8^-7.77
926.66
1,039.85
15.96
38.99
22.89
2,892.12

879.55
1,667.96
2,547.51

5.32
83.02
960.68
52.85-
148.26
1,250.13

176.33
203.42
141.47
139.23
65.59
213.22
111.51
193.41
1,297.03

1,706.60
664.44
2,827.16
319.41
1,953.28
374.50
7,845.39
Process
Wastes

1,814.25
1,979.51
2,148.49
36.33
82.80
49.53
6,110.91

1,912'.34
3,555.91
5,468.25

12.11
183.83
2,062.10
109.20
315.28
2,682.52

379.98
449.37
299.02
292.15
143.35
452.85
239.35
408.56
2,773.83

3,649.18
1,425.42
5,978.98
680.09
4,196.86
796.16
16,726.69
Degreaser
Sludges

251.35
254.96
280.15
6.15
8.31
7.69
808.61

274.90
450.86
725.76

2.05
29.73
270.33
11.39
39.18
352.68

54.45
68.28
32.11
34.57
18.56
59.69
28.41
56.51
363.97

455.78
180.91
753.67
86.05
552.96
94.98
2,124.35
Electroless
Ni Wastes

541.13
526.50
1,126.13
0.00
14.63
14.63
2,223.02

394.88
965.25
1,360.13

0.00
29.25
497.25
43.88
87.75
658.13

102.38
58.50
73.13
102.38
14.63
146.25
43.88
160.88
745.88

877.50
321.75
1,959.75
190.13
994.50
204.75
4,548.38
Total

3,454.50
3,687.63
4,594.62
58.44
144.73
94.73
12,034.65

3,461.67
6,639.98
10,101.65

19.48
325.83
3,790.36
217.32
590.47
4,943.46

713.14
779.57
545.73
568.33
242.13
872.01
423.15
819.36
4,963.42

6,689.06
2,592.52
11,519.56
1,275.68
7,697.60
1,470.39
31,244.81
These dry weights can be converted to wet weights by applying the following factors:
WPCS - 20; PW - 1; DS - 1; ENiW - 2.
Note:  Total Industry Wastes = Potentially Hazardous Wastes
                                        105

-------
TABLE 37.
               (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Water Pollution Process
Control Sludges Wastes

63.49
17.57
38.85
106.19
643.02
869.12

229.95
272.93
488.25
40.46
1,031.59

252.98
5.32
0.00
5.33
44.17
0.00
307.79

135.87
1,267.35
5.32
21.28
1,429.82

0.00
15.96
150.50
155.40
321.86
19,792.39

133.42
37.42
85.86
227.24
1,380.04
1,863.98

491.90
579.60
1,042.38
86.95
2,200.83

538.37
-12.11
0.00
12.11
97.97
0.00
660.56

293.03
2,708.04
12.11
48.44
3,061.62

0.00
36.33
322.15
343.44
701.92
42,251.18
Degreaser
Sludges

15.49
5.64
13.84
26.36
178.24
239.57

58.36
58.17
120.93
13.33
250.79

60.52
2.05
0,00
-2.05
15.89
0.00
80.51

41.12
349.21
2.05
8.20
400.58

0.00
6.15
36.72
55.36
98.23
5,445.06
Electroless
Ni Wastes

43.88
14.63
14.63
43.88
321.75
438.75

102.38
102.38
219.38
29.25
453.38

117.00
0.00
0.00
0.00
14.63
0.00
131.63

73.13
716.63
0.00
0.00
789.75

0.00
0.00
58.50
58.50
117.00
11,466.00
Total

256.28
75.25
153.18
403.67
2,523.05
3,411.43

882.58
1,013.08
1,870.94
169.99
3,936.59

968.87
19.48
0.00
19.48
172.66
0.00
1,180.49

543.15
5,041.23
19.48
77.92
5,681.78

0.00
58.44
567.87
612.70
1,239.01
73,737.29
      106

-------
          Additional data pertinent to these wastes are included in Appen-
dix E.  These data in Table E-l indicate that 40 percent of this amount
will derive from plants with from 26 to 50 employees, as represented by
the medium size plant.  The larger plants with more than 50 employees will
produce 30 percent of the total waste, as will the large number of the
small plants employing between 5 and 25 people.

          The tabulated data in Appendix E also identify the respective
quantities of water pollution control sludges, process wastes, degreaser
sludges, and electroless nickel plating wastes destined for land disposal
by the job shops falling under the grouping of small, medium, and large
model plants, respectively.

          Table E-6 indicates the quantity of metal constituents from the
water pollution control sludges disposed of by landfill as their respec-
tive hydroxide by state, EPA Region, and nationally in 1975, listed in
decreasing order.

          The land disposal distribution by small, medium, and large job
shops by state, EPA Region, and nationally for each individual metal has
been calculated and is given in Table E-7 through E-16.


Potentially Hazardous Wastes
for 1977 and 1983
          As discussed previously, the waste treatment processes for the
model plants was developed according to the 1977 EPA effluent limitations
and guidelines requiring pretreatment of the plant effluents.  Consequently,
the quantity of the water pollution control sludges was obtained by multi-
plying the waste generation factors of the small, medium, and large model
plants by the respective number of plants in each state.  Process wastes,
degreaser sludges, and electroless nickel wastes were also calculated from
the waste data of the model plants, again through multiplication by the
number of plants in each area.

          The calculated quantity of total industry and potentially hazard-
ous waste destined for land disposal by the electroplating and metal
finishing job shops in metric tons per year in 1977 are given in Table 38.
The 115,390 metric tons (dry weight) represent an increase of almost 50
percent over the 1975 waste quantities, all of it coming from the addi-
tional load of the water pollution control sludge, as shown by Table 39.
Forty-nine percent of the 1977 total waste is water pollution control sludge.
The process wastes account for almost 37 percent, electroless nickel wastes
and degreaser sludge constitute 10 and 4 percent of the waste, respectively.
The concurring distribution in 1975 is 25-54-15-6 percent.

          Additional information regarding the characteristics of these
wastes generated in 1977 also is contained in Appendix E in Tables E-17
through E-32.
                                   107

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                    TABLE 38.  QUANTITY OF TOTAL INDUSTRY AND POTENTIALLY
                               HAZARDOUS WASTES DESTINED FOR LAND DISPOSAL
                               FROM THE ELECTROPLATING AND METAL FINISHING
                               INDUSTRY,(JOB SHOPS); METRIC TONS; DRY WEIGHT*;
                               1977
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Water Pollution
Control Sludges

2,422.20
2,647.60
2,971.00
45.60
111.40
65.40
8,263.20

2,513.00
4,765.60
7,278.60

15.20
237.20
2, 744.S6
151.00
423.60
3,571.80

503.80
581.20
404.20
397.80
187.40
609.20
318.60
552.60
3,554.80

4,876.00
1,898.40
8,077.60
912.60
5,580.80
1,070.00
22,415.40
Process
Wastes

1,814.25
1,979.51
2,148.49
36.33
82.80
49.53
6,110.91

1,912.34
3,555.91
5,458.25

12.11
183.83
2,062.10
109.20
315.28
2,682.52

379.98
449.37
299.02
292.15
143.35
452.85
239.35
408.56
2,664.63

3,649.18
1,425.42
5,978.98
680.09
4,196.86
796.16
16,726.69
Degreaser
Sludges

251.35
254.96
280.15
6.15
8.31
7.69
808.61

274.90
450.86
725.76

2.05
29.73
270.33
11.39
39.18
352.68

54.45
68.28
32.11
34.57
18.56
59.69
28.41
56.51
352.58

455.78
180.91
753.67
86.05
552.96
94,98
2,124.35
Electroless
Ni Wastes

541.13
526.50
1,126.13
0.00
14.63
14.63
2,223.02

394.88
965.25
1,360.13

0.00
29.25
497.25
43.88
87.75
658.13

102.38
58.50
73.13
102.38
14.63
146.25
43.88
160.88
702.03

877.50
321.75
1,959.75
190.13
994.50
204.75
4,548.38
Total

5,028.93
5,408.57
6,525.77
88.08
217.14
137.25
17,405.74

5,095.12
9,737.62
14,832.74

29.36
480.01
5,574.48
315.47
865.81
7,265.13

1,040.61
1,157.35
808.45
826.90
363.94
1,267,99
630.24
1,178.55
7,274.04

9,858.46
3,826.48
16,770.00
1,868.87
11,325.12
2,165.89
45,814.82
*  These dry weights can be converted to wet weights by applying the following factors:
   WPCS - 5; PW - 1; DS - 1; EHiW - 2.

   Note:  Total Industry Waste • Potentially Hazardous Wastes
                                           108

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                                   TABLE  38.
         (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Water Pollution
Control Sludges

181.40
50.20
111.00
303.40
1,837.20
2,483.20

657.00
779.80
1,395.00
115.60
2,947.40

722.80
15.20
0.00
15.20
126.20
O.CC
879.40

388.20
3,621.00
15.20
60.80
4,085.20

0.00
45.60
430.00
444.00
919.60
Process Degreaser
Wastes Sludges

133.42
37.42
85.86
227.24
1,380.04
1,863.98

491.90
579.60
1,042.38
86.95
2,200.83

538.37
12.11
0.00
12.11
97.97
0.00
660.56

293.03
2,708.04
12.11
48.44
3,061-62

0.00
36.33
322.15
343.44
701.92

15.49
5.64
13.84
26.36
178.24
239.57

58.36
58.17
120.93
13.33
250.79

60.52
2.05
0.00
'2.05
15.89
0.00
80.51

41.12
349.21
2.05
8.20
400.58

0.00
6.15
36.72
55.36
98.23
Electroless
Ni Wastes

43.88
14.63
14.63
43.88
321.75
438.77

102.38
102.38
219.38
29.25
453.39

117.00
0.00
0.00
0.00
14.63
0.00
131.63

73.13
716.63
0.00
0.00
789.76

0.00
0.00
58.50
58.50
117.00
Total

374.19
107.89
225.33
600.88
3,717.23
5,025.52

1,309.64
1,519.95
2,777.69
245.13
5,852.41

1,438.69
29.36
0.00
29.36
254.69
0.00
1,752.10

795.48
7,394.88
29.36
117.44
8,337-16

0.00
88.08
847.37
901.30
1,836.75
Total U. S.
                         56,390.60
42,131-91    5,433.66    11,422.24
115,386.41
                                          109

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                   TABLE 39.  QUANTITY OF TOTAL INDUSTRY AND POTENTIALLY HAZARDOUS
                              WASTES DESTINED FOR LAND DISPOSAL FROM THE ELECTRO-
                              PLATING AND METAL FINISHING INDUSTRY (JOB SHOPS);
                              METRIC TONS; DRY WEIGHT*; 1983
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Water Pollutioa
Control Sludges

3,173.08
3,468.36
3,892.01
59.74
145 . 93
85.67
10,824.79

3,292.03
6,242.94
9,534.97

19.91
310.73
3,595.69
197.81
554 . 92
4,679.00

659.98
761.37
529.50
521.12
245.49
798.05
417.37
723.91
4,854.60

6,387.56
2,486.90
10,581.66
1,195.51
7,310.85
1,401.70
29,364.17
Process
Wastes

2,376.67
2,593.16
2,814.52
47.59
108.47
64.88
8,005.29

2,505.17
4,658.24
7,163.41

15.86
240.82
2,701.35
143.05
413.02
3,514.10

497.77
588.67
391.72
382.72
187.79
593.23
313.55
535.21
3,633.72

4,780.43
1,867.30
7,832.46
890.92
5,497.89
1,042.97
21,911.96
Degreaser
Sludges

329.27
334 . 00
367.00
8.06
10.89
10.07
1,059.28

360.12
590.63
950.75

2.69
38.95
354.13
14.92
51.33
462.01

71.33
89.45
42.06
45.29
24.31
78.19
37.22
74.03
476.80

597.07
236.99
987.31
112.73
724.38
124.42
2,782.90
Electroless
Ni Wastes

708.87
689.72
1,475.22
0.00
19.16
19.16
2,912.13

517.29
1,364.48
1,781.76

0.00
38.32
651.40
57.48
114.95
862 . 14

134.11
76.64
95.79
134.11
19.16
191.59
57.48
210.75
977.10

1,149.53
421.49
2,567.27
249.06
1,302.80
268.22
5,958.37
Total

6,587.89
7,085.23
8,548.75
115.38
284.45
179.79
22,801.49

6,674.60
12,756.28
19,430.88

38.46
628.81
7,302.57
413.26
1,134.21
9,517.31

1,363.19
1,516.13
1,056.08
1,083.23
476.75
1,661.07
825.61
1,543.89
9,942.21

12,914.58
5,012.69
21,968.70
2,448.21
14,835.91
2,837.32
60,017.41
*  These dry weights can be converted to wet weights by applying the following factors:
   WPCS -5; PW - 1; DS - 1; ENiW - 2.

   Note:  Total Industry Wastes = Potentially Hazardous Wastes
                                           110

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                                   TABLE 39.
                                                   (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Water Pollution
Control Sludges

237.63
65.76
145.41
397.45
2,406.73
3,252.99

860.67
1,021.54
1,827.45
151.44
3,861.09

946.87
19.91
0.00
19. 9T
165.32
O.CC
1,152.01

508.54
4,743.51
19.91
79.65
5,351.61

0.00
59.74
563.30
581.64
1,204.68
Process Degreaser
Wastes Sludges

174.78
49.02
112.48
297.68
1,807.85
2,441.81

644.39
759.28
1,365 '.52
113.90
2,883.09

705.26
15.86
0.00
15.86
128.34
0.00
865.33

383.87
3,547.53
15.86
63.46
4,010.72

0.00
47.59
422.02
449.91
919.52

20.29
7.39
18.13
34.53
233.49
313.84

76.45
76.20
158.42
17.46
328.53

79.28
2.69
0.00
2.69
20.82
0.00
105.47

53.87
457.47
2.69
10.74
524.76

0.00
8.06
48.10
72.52
128.68
Electroless
Ni Wastes

57.48
19.16
19.16
57.48
421.49
574.76

134.11
134.11
287.38
38.32
593.92

153.27
0.00
0.00
0.00
19.16
0.00
172.43

95.79
938.78
0.00
0.00
1,034.57

0.00
0.00
76.64
76.64
153.27
Total

490.18
141.33
295.18
787.15
4,869.57
6,583.41

1,715.62
1,991.13
3,638.77
321.12
7,666.64

1,884.68
38.46
0.00
38.46
333.64
0.00
2,295.24

1,042.07
9,687.29
38.46
153.85
10,921.67

0.00
115.38
1,110.05
1,180.70
2,406.14
Total U. S.
74,080.10
55,349.05    7,133.03    15,020.46
151,582.40
                                           111

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          Waste projections for 1983 are based strictly on a study per-
formed for the U.S. EPA Effluent Guidelines Division*, since the responses
obtained from the 88 job shops do not project to 1983, naming the proposed
1983 zero discharge limitation of plant effluents as the reason for the
inability to determine or predict water pollution control sludge loads.
Necessary changes in treatment practices are another reason given.  The
above cited report also projects an industry growth of 31 percent from
1977 to 1983.  Consequently, the quantities of total industry and poten-
tially hazardous wastes in 1983 were calculated by multiplying the 1977
quantities estimated by a factor of 1.31.  The quantity of waste by state,
EPA Region, and nationally are summarized in Table 39 for the four desig-
nated waste categories.  The total estimated quantity of waste destined
for land disposal in 1983 is 151,583 metric tons dry weight.  The 38-
employee model plant (or medium sized job shop) represents the group of
plants with the greatest waste load.  Water pollution control sludges are
the most important contributors to that waste load containing large quan-
tities of hazardous metal hydroxides and soluble salts.

          Tables E-33 through E-48 of Appendix E contain additional data for
the projected potentially hazardous wastes for the industry in 1983.

          A summary of all the wastes destined for land disposal by the
electroplating and metal finishing job shop industry for 1975, 1977, and
1983 is given in Tables 40 and 41 for comparing waste loads and ratios of
waste categories from the job shops represented by one of these model
plants:

          Small with an average of 16 employees in plating.

          Medium with an average of 38 employees in plating.

          Large with an average of 87 employees in plating.

          It is estimated that 40 percent of all the potentially hazardous
wastes from the electroplating and metal finishing industry will be pro-
duced by plants located in EPA Region V for the 3 years under discussion
(1975, 1977, and 1983).  Further, more than two-thirds of these wastes
will be produced in EPA Regions I, II, and V.
   Economic Analysis of Effluent Guidelines - Metal Finishing Industry,
   Report No. EPA 230/1-74-032, Sept. 1974, p. VI-8.

                                   112

-------






















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TABLE 41.   TOTAL ESTIMATED HAZARDOUS WASTES FROM 1977
           ELECTROPLATING AND METAL FINISHING JOB SHOPS,
           METRIC TONS,  DRY WEIGHT (50 Week Year)
(1. Model Plant . .
Waste Category Year Small^' Medium*''1''' LargeVJ'
Water Pollution
Control Sludge 1975 6,453.19 6,762.00 6,577.20
1977 18,437.60 19,320.00 18,792.00
1983 24,153.38 25,309.20 24,617.52
Process Wastes 1975
& 1977 14,689.50 13,971.12 13,590.56
1983 19,243.25 18,302.17 17,803.63
Degreaser
Sludge 1975
& 1977 2,486.66 1,981.68 976.72
1983 3,257.53 2,596.00 1,279.50
Electroless
Nickel Waste 1975
& 1977 0.00 8,073.00 3,393.00
1983 0.00 10,575.63 4,444.83
(1) Representative of 1213 job shops with from 5 to 25
and a production of 1440 m /day.
(2) Representative of 552 job shops with from 26 to 50
and a production of 3400 m2/day.
(3) Representative of 232 job shops with more than 50
and a production of 6960 m /day.

Total
19,792.39
56,549.60
72,080.10
42,251.18
55,349.05
5,445.06
7,133.03
11,466.00
15,020.46
employees in plating
employees in plating
employees in plating
                        114

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                                REFERENCES
                          WASTE CHARACTERIZATION
(1)    "Electroplating Engineering Handbook,  Edited by A.  Kenneth Graham,
      3rd Edition,  1971,  Van Nostrand Reinhold Company,  New York.

(2)    "Modern Electroplating",  Edited by F.  A. Lowenheim, John Wiley and
      Sons,  Inc.,  New York,  1974.

(3)    "Metals Handbook",  Eighth Edition, Vol.  2,  Edited  by L.  Taylor,
      American Society for Metals, Metals Park, Ohio, 1964.

(4)    "Metal Finishing Guidebook and Directory",  Metal and Plastics Publi-
      cations, Inc.,  Hackensack, New Jersey, 1975.

(5)    "Plating Chemical Recovery Units for Chrome and Nickel", Corning
      Glass  Works,  Corning,  New York, 1974.

(6)    "Development Document  for Proposed Effluent Limitations  Guidelines  and
      New Source Performance Standards,  Copper, Nickel,  Chromium, and Zinc
      Segment of the  Electroplating Point Source Category", U.S. Environmental
      Protection Agency,  EPA-440/1-73-003, August, 1973.

(7)    "Metal Finishing Waste Treatment in Sweden", B. Goransson and P. 0.
      Moberg, Journal of Water  Pollution Control Federation, Vol. 47,
      No. 4, April, 1975.
                                  115

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                  Ill,   TREATMENT AND DISPOSAL TECHNOLOGY
          The objective of this phase of the study was to identify and des-
cribe the treatment and the ultimate disposal technologies employed by
electroplating and metal finishing job industry shops under the Standard
Industrial Classification (SIC) 3471.  These operations were described in
more detail in the Waste Characterization section of the report.  In this
section, the various treatment and/or disposal technologies and the fate
of the waste materials are identified and quantified on the basis of an
industry survey.  Current treatment and disposal methods are also discussed
and reviewed.

          The methodology employed in treating the data from the industry
survey and the rationale leading to the final selection of the industry
sample are given.  The data were tabulated and assessed to determine the
present state of the art of treatment and disposal technology applied to
reduce the potential hazards of disposal by the industry sample.  The data
were also employed to determine the use of on-site versus off-site treatment
and disposal methods and the types of off-site facilities used for ultimate
disposal, the quantities of wastes involved, and the identity and frequency
of use of those companies that treat and/or dispose of wastes from job shops
on a contract basis.  The services provided by treatment and disposal con-
tractors together with user charges, disposal methods, and safeguards
employed during disposal were reviewed.

          This information provided the basis for determining the three
levels of treatment and/or disposal technology for those potentially hazar-
dous wastes generated from the electroplating and metal finishing industry.
The technology levels identified in this report are the technology currently
employed by typical facilities (Level I), the best technology currently  in
use in at least one location on a commercial scale (Level II), and the
technology level either in operation or being developed necessary to provide
adequate health and environmental protection  (Level III).  Each of the
technology levels has been assessed for adequacy of health and environmental
protection in the framework of 14 factors set forth in the work statement.
              DESCRIPTION OF WASTES DESTINED FOR LAND DISPOSAL
          Although  the potentially hazardous wastes destined  for land
 disposal are  described in  the previous  section  of  the report,  their  charac-
 teristics are summarized here for the convenience  of the  reader.  The
 relationships between these wastes and  other waste materials,  e.g.,  waste-
 water  and spent  plating baths,  also  are discussed  briefly in  a subsequent
 subsection  on treatment and disoosal methods.
                       Water  Pollution  Control  Sludge


          When rinse waters and  spent plating baths are  treated  in wastewater

                                     116

-------
treatment plants, insoluble hydroxides of the metal constituents normally
are produced.  The precipitated solids are dewatered by various means to
levels ranging from less than 5 to more than 20 percent of solids.  The
level of hazard to health and the environment in the water is reduced by
cyanide oxidation, chromium reduction, and heavy metal precipitation;
however, the potential hazard is transferred to the precipitates removed
from solution which are now destined for land disposal.  In the printed
circuit job shops, the waste solutions may be etching waste solutions as
well as those related to plating operations.  Although municipal sewage
plants usually do not accept such solutions without pretreatment, there
are many instances in which the smaller job shops discharge spent baths
directly to the sewer.
                               Process Wastes
          This category of wastes includes plating sludges, waste chemicals,
air pollution control dusts, and miscellaneous solid wastes.  The air
pollution control dusts (including dusts not otherwise specified) are
generated in buffing and polishing operations, grit blasting, and grinding.

          Various other wastes also are included in this category, i.e.,
honing oils, oils from water pollution control, anode scrap, plating racks,
etc.

          The printed circuit segment of the industry generates large
amounts of wastes consisting primarily of scrap pieces of epoxy-fiberglass
composites (other resin systems also may be used) and the dusts from cutting
and boring these materials.  These are sometimes collected as separate
wastes, but are usually combined with the other process solid wastes and
ultimately disposed of to landfill.
                             Degreaser Sludges


          The organic solvents used for removing the grease, oils, and
paint from metal parts prior to electroplating usually are reclaimed and
reused.  Chlorinated hydrocarbons and normal hydrocarbons are used for metal
cleaning.  A combination of organic chemicals is used for paint stripping.
Among these are toluene, xylene, acetone, other ketones, and methylene
chloride.

          When these solvents are reclaimed, the impurities (oil, grease,
paint pigments, etc.) are removed as a sludge which may contain both heavy
metals and traces of the organic solvents.  Such sludges usually are
destined for disposal in a landfill although they occasionally are incin-
erated.
                                  117

-------
                          Electroless Nickel Wastes
          These wastes are generated during the regeneration of electroless
nickel baths.  Although not specifically included as a component of the
wastes produced by plants responding to inquiries made during this study,
they are produced by facilities which include electroless plating operations.
As pointed out previously, most of the successful regeneration operations
are based on the chemical precipitation of the phosphite ion.
                      ACQUISITION AND ANALYSIS OF DATA


                             NAMF Questionnaires
          The information received in the industry survey was used to help
formulate a schematic of the treatment and disposal alternatives used by
the electroplating and metal finishing industry for the waste types it
generates, as shown in Figure 6.  Although wastewater treatment and air
pollution control are identified operations, they are not considered to be
part of the treatment of waste destined for land disposal.  However, any
residual solids collected or generated during the control of water- or air-
borne pollutants have been included in one of the four categories of poten-
tially hazardous wastes.

Method of Data Assembly and Analysis
          Analysis of the data led to the identification of four categories
of potentially hazardous wastes destined for land disposal as described in
the Waste Characterization section.  These are

          (1)  Water pollution control sludges
          (2)  Process wastes
          (3)  Degreaser sludges
          (4)  Electroless nickel sludges.

The selection of these categories is not meant to infer that these are the
only potentially hazardous materials which are discharged from electroplating
and metal finishing operations,  They were selected because it is not the
normally accepted practice of this industry to dispose of some of the other
potentially hazardous materials to the land.

          Among the materials discharged from various plants which normally
do not involve land disposal are spent plating baths (concentrated inorganic
solutions) and spent solvents.  The methods of disposition of these materials
as well as various sludges and solid wastes were identified by some of the
respondents to the data acquisition efforts.

          In most instances, electroless nickel and degreaser sludges were
not separately identified but were included as sludges along with the water


                                    118

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                                                    119

-------
pollution control sludges.  Thus, only two categories of potentially hazar-
dous wastes destined for land disposal were identified by most of the survey
respondents, i.e., "sludges" and "solids".  (These later were subdivided
during the model plant calculations into the four distinct categories listed
earlier because of the significant differences in their characteristics.)

          A breakdown of the industry sample of 91 plants which is based on
the analysis of the raw data is given in Table 42.  Both those waste
materials normally destined for land disposal and those which normally are
not have been included as confirmation that further consideration should not
be given in this study to the spent plating baths and organic solvents.


Results of Analysis of Industry
Survey Data


          Off-Site Versus On-Site Disposal.  Of the 91 job shops that
returned questionnaires, 50 indicated that wastes are generated for treatment
and/or disposal.  The remaining plants either indicated that they disposed
of their wastes by dumping them in the sewer without treatment, or failed
to disclose any treatment; therefore, these shops were removed from the
sample population.  Of the 50 plants making up the sample, 17 (or 34 percent)
disposed of their treated sludges (water pollution control sludge, etc.)
on site, while 33 (or 66 percent) disposed of the treated sludges off site.

          Of the 50 plants, 27 reported disposal of process solid waste
such as dusts, 8 plants (or 30 percent) reported disposal on site, and 19
plants (or 70 percent) reported disposal off site.  These data are presented
in Table 43.

          Although these data indicate that one plant disposed of spent
organic solvents to a special landfill, and two plants used landfills to dis-
pose of concentrated inorganic solutions, these cases were assumed to be
special exceptions to the accepted practice of the industry.  (In one instance
disposal was to a deep mine which certainly is a special case.')  The normal
practice—on the basis of this small sample and discussions with individual
plant operators—is reclamation of both the solvents and the metals or dis-
charge of the concentrated inorganic solution to the water pollution control
circuit.  Because it is not normal practice to dispose of these materials
to the land, no further discussion will be included in this report of their
potential hazardous nature.
                        Safeguards U."ed in Disposal
          The treatment and disposal of potentially hazardous wastes gener-
ated by  the electroplating and metal finishing industry destined for land
disposal have associated dangers of ground or surface water contamination
by toxic materials.  To minimize these dangers, many land disposal sites
have incorporated such safeguard measures as liquid-solid waste mixing
prior to disposal, compaction, daily cover, clay or plastic linings, install-
ation of monitoring wells, etc.  In addition to these measures, certain

                                  120

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                                     121

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additional safeguards could be incorporated into current hazardous waste
land disposal operations.   In order to better characterize the current
electroplating and metal finishing waste disposal practices, and assess the
environmental adequacy of these practices, the usage of special safeguards
employed in the disposal of potentially hazardous wastes was analyzed in
terms of number of locations identified and percentage of total wastes
disposed.  Five special land disposal safeguards were included in this
analysis:

          (1)  Plastic or concrete encapsulation
          (2)  Steel drum storage and disposal
          (3)  Leachate collection and treatment
          (4)  Chemical fixation/solidification
          (5)  Waste inventory, segregation, and mapping.
Plastic or Concrete Encapsulation


          The encapsulation of potentially hazardous wastes in plastic or
concrete is a special disposal safeguard currently being employed for only
the most hazardous wastes, e.g., nerve gas, biological warfare agents,
radioactive wastes, etc.  Plastic encapsulation is accomplished in two
phases:  first, a plastic material is employed to encase the waste and
secure it from escaping into the environment; and second, a steel section
is employed to provide support and maintain the structural integrity of the
disposal unit.  Concrete encapsulation is similar, except the concrete pro-
vides both the waste encasement and the structural support.  Normally, a
hollow concrete chamber (often lined with stainless steel) is filled with
the hazardous waste (either loose or containerized) and then concrete is
poured in to cap and seal the chamber.  Concrete encapsulation is predomin-
antly employed in radioactive waste disposal since the concrete serves the
dual purpose of liquid and solid waste and radiation confinement.

          Analysis of the available data of plating wastes has shown that
this safeguard is not employed in the industry.  One atypical waste dis-
posal contractor was identified who employs concrete encapsulation for the
disposal of small quantities of plating wastes so that the waste is isolated
from the environment.   (The contractor is considered atypical because he
employs abandoned concrete missile silos as his disposal cells,) An approx-
imate estimate of the percentage of the total quantity of plating waste
disposed of with special land disposal safeguards is summarized in Table 44.
For encapsulation this quantity has been estimated to be less than 1 percent.
Steel Drum Burial
          The containerization of potentially hazardous wastes in steel
drums prior to disposal is another safeguard employed.  Both plastic lined
and unlined drums and barrels are used.  Drum burial procedure usually
entails  (1) filling the drum with the potentially hazardous waste, (2) sealing
the drum, (3) transporting the drums to the disposal site, and (4) land
storage  or land burial.
                                   123

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        TABLE 44.  SAFEGUARDS USED AND THE PERCENTAGE OF WASTE
                   DISPOSED OF FROM THE METAL FINISHING INDUSTRY
                                              Estimation of Percent of
                                              Total Waste Disposed of
                      Number of Sites         With Safeguards for the
                        Identified            Electroplating and Metal
Safeguard           Employing Safeguard       Finishing Industry'3)
            1 '—'	1             '                    -

Plastic or Concrete          ]_                          <1
 Encapsulation

Drum Burial                  3                          <4

Leachate Collection          i                          <1
 and Treatment

Chemical Fixation/           3                          <3
 Solidification

Waste Inventorying           Q                      negligible
 and Mapping

     Total                                              <9
 (a)  Estimates based on the percentage of plants, rather than the actual
     quantities, employing the noted safeguards.  The estimate was
     derived as  (1) the percent of plants disposing on-site which employ
     the specific safeguard times the percentage of plating wastes
     estimated to be disposed of on-site (35 percent) plus (2) the per-
     centage of  treatment and disposal contractors employing the specific
     safeguard times the estimate of the percentage of waste disposed of
     off-site  (65 percent).
                                124

-------
          The wastes normally disposed of in this manner are highly toxic
chemicals, wastes which are thought to have future recoverable value, and
thick, gummy wastes which are difficult to treat or simply difficult to
remove from the drums.  The specific application of this safeguard to
plating wastes is, like plastic/concrete encapsulation, quite limited.

          Analysis of the available data shows that no company reported
on-site drum burial and only three waste contractors employ drum burial for
off-site disposal.  Of these three, all report the use of drum burial as
one of many disposal safeguards, but do not report what types of wastes
are being disposed of in drums.  Although all three dispose of plating
wastes (along with many other types of wastes), information necessary to
determine what percentage (if any) of the plating wastes are being disposed
of by drum burial was not available.  These three plants represent approx-
imately 6 percent of the treatment and disposal contractors surveyed.
Assuming that 65 percent of all plating wastes are disposed of off site,
and that these three plants dispose of 6 percent of this by drum burial,
it is estimated that a maximum of 4 percent of the plating wastes are
disposed of by drum burial.
Leachate Collection and Treatment
          Another effective means of preventing ground- or surfacewater
contamination is to collect and treat any leachate leaving the land disposal
site.  Several designs are in operation or under consideration for the
collection of leachates from hazardous waste disposal sites.  Leachate can
be collected by any of the following methods:

          (1)  Sump at the bottom of each disposal cell.

          (2)  Infiltration piping, placed in a gravel bed
               along trenches in the disposal site, leading
               to a centralized collection sump.

          (3)  A trench placed around the perimeter of the
               disposal site to catch any leachate migrating
               horizontally (vertical migration prevented
               by impermeable liners of clay or plastic).

          (4)  Diversion ditches to collect and transport the
               run-off and leachate to the treatment site.

          (5)  Groundwater wells with a dual purpose monitoring/
               leachate collection system.

Once the leachate is collected, it is pumped t :> cither a lined holding t ond
or to a storage tank and then to a lime or ::.->-ist^i Lreac.r.ent. i.. "-k,  The
neutralized effluent can be discharged to the sewer and the precipitated
solids returned to the landfill.

          The benefit of this type of safeguard ic that i<_ provides a iliiai
leachate collection system before the wastes can reach the groundwater.
                                  125

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Of course, this safeguard is a backup measure, and is not expected to be
employed extensively after the initial operational period of the trench or
ramp where the wastes are exposed to the elements.  The benefit of this
safeguard to plating wastes is that substances such as mobile metal ions
from acidified sludges and liquids can be returned to the landfill rather
than escaping into the environment.

          Analysis of the available data has shown that no on-site and only
one off-site disposal operation employs the leachate collection and treatment
safeguard.  It is estimated, therefore, that less than 1 percent of all
plating wastes are disposed of in land disposal sites employing a leachate
collection and treatment system.


Chemical Fixation/Solidification


          The chemical fixation/solidification of potentially hazardous
wastes is a special procedure currently attracting special attention.  The
process involves the mixing of cementing agents such as portland cement,
lime-based mortars, lime-pozzolan cements, certain mixed inorganic-organic
material or proprietary silicate compounds with the aim of producing a
nontoxic, environmentally safe material which is acceptable for landfill.
The mode of operation differs among various companies; one major company,
Chem-Fix, Inc., will bring a mobile treatment van to the plant and treat
semisolid lagoon wastes on site as a service or will sell the process to
the client.  Other operators prefer to transfer the wastes to the treatment/
disposal site for treatment.  After mixing the cementing agent with the
wastes, the mixture is pumped on the land for solidification after which it
is disposed of to landfill or it may be used as fill dirt for surface con-
touring.

          The benefits of this type of waste treatment in general and for
plating wastes specifically are (1) the effective detoxification of poly-
valent metal ion hazardous wastes, (2) solidification for ease of disposal,
(3) decreased rate of generation of leachate, and (4) reduced disposal cost
(because in some states the fixed solidified material is accepted for land-
fill rather than requiring land disposal).

          Analysis of the available data shows that, of those plants reporting,
one plant or 2 percent of the plating plants employ on-site chemical fixation/
solidification treatment and two plants or 4 percent of the treatment and
disposal contractors contacted employ this treatment.  While it is not
possible to absolutely equate the percentage of plants reporting the use of
the process and the percentage of plating wastes being treated or disposed
of by that process, they are approximately in a one-to-one relationship.
Therefore, it was assumed that 2 percent of the on-site disposed of waste
a.'.c t -• 2iv it of the off-site disposed of waste are chemically fixed and
solidified, or approximately 3 percent of all plating wastes are treated by
chemical fixation and solidification.
                                   126

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Waste Inventory, Segregation, and Mapping


          The inventorying of incoming wastes and recording of their storage
location in a segregated section of the disposal site is another special
safeguard.  This safeguard requires that (1) different types of wastes, e.g.,
acids, caustics, polyvalent metal ion sludges or solutions, etc., be iden-
tified upon arrival at the disposal site, (2) that these wastes be segregated
according to type and stored with similar type wastes, and (3) that the
quantity, waste type, toxicity, etc. of each waste and its exact disposal/
storage location be recorded.

          The benefits of this type of disposal safeguard in general and for
plating wastes specifically are (1) potentially toxic elements of a waste
material will not be resolubilized or converted to a more potentially toxic
form  (e.g., heavy metal hydroxides dissolved to soluble ions or Cr+3 oxidized
to Cr+6) by contact with an oxidant or a waste acid or base indiscriminantly
mixed with the wastes, (2) if evidence of leaching is obtained from ground-
or surfacewater analyses, the source of the problem can be identified and
corrective actions taken (i.e., if the hexavalent chrome or cyanide concen-
tration in the groundwater rises significantly, the storage cell where chrome
or cyanide wasL-3 are stored can be excavated and steps taken to eliminate
the problem) , and (3) if the recovery of a specific type of waste (such as
nickel, copper, chrome, zinc, etc.) becomes economically attractive in the
future, then disposal cells can be excavated and the valuable waste material
collected.

          Analysis of the available data for the prevalence of this type of
safeguard has shown that no facility, on-site or off-site, presently employs
inventorying, segregation, and mapping.  However, these procedures are
presently employed in radioactive waste disposal operations, and since poten-
tially toxic chemical wastes are often accepted by radioactive waste disposal
contractors, it appears likely that at least some small but negligible portion
of plating wastes is disposed of in this manner.


Characterization and Environmental Adequacy


          The use of special safeguards in the disposal of plating wastes
is not widespread.  From the estimates presented in Table 4^., It: can be.
seen that less than 9 percent (and very possibly much less) of all plating
waste disposed of has the benefit of these extra precautionary measures.
On the basis of the special safeguard data, plating waste disposal practices
have been characterized as failing to employ the best currently available
disposal methods for potentially hazardous waste.  However, this does no!:
mean that these disposal practices are unsound, or environmentally inadequate.
A more extensive review of the environmental adequacy of current, disposal
practices is presented in a later section.
                                   127

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                Private Contractors and Service Organizations
          Private contractors and service organizations play a significant
role in the treatment and disposal of potentially hazardous wastes generated
by the electroplating and metal finishing industry.  Treatment and disposal
contractors perform for many plants one or all of the following services:
(1) hauling (transportation of liquid or solid wastes to a treatment or
disposal operation), (2) treatment (either the detoxification of poten-
tially hazardous liquid wastes and/or solid waste treatment, including any
of the many methods of dewatering, incineration, or chemical solification),
and (3) disposal to land (placement of liquid or solid wastes in or on the
land).

          In order to completely assess the state of the art of treatment
and disposal technologies employed by the electroplating and metal finishing
industry and to determine the cost to industry of current and future control
practices, it was necessary to analyze the industry for the prevalence of
waste handling by private treatment and disposal contractors and service
organizations.  Analyses included the estimation of the percent of total
number of plants having wastes handled by contractors and the identification
of the following:

          «  Contractors, by name and address
          •  Services provided
          »  Service costs
          •  Ultimate disposal method.

          To obtain this information, data from the following two additional
sources were analyzed:

           (1)  "An Inventory of Hazardous Waste Management Facilities"
               (1HWMF), a draft report authored by D. Farb and S. D.
               Ward, to be issued by the Hazardous Waste Management
               Division, Office of Solid Waste Management Programs,
               United States Environmental Protection Agency.

           (2)  Information supplied by the industry to this study.

          The initial step in the acquisition of additional information
concerning the services provided by the treatment  and disposal contractors
was a  telephone  survey.  The organizations contacted in this manner and
the information which was obtained are presented in Appendix A.  Results
of the survey are  summarized in Table 45.  These data show that approximately
89 percent treat and/or dispose of sludges and  74  percent treat and/or
dispose of liquid  wastes.  On the basis of collection and hauling costs
data obtained through the telephone survey, average handling costs were
estimated  ?t 0.8c/liter  (93c/gal), while average treatment and disposal  costs
were estimated at  approximately 2.6c/liter  ($.10 per gal); the total
collection-treatment-disposal cost averaged to  5.8c/liter  ($.22 per gal).
Nine different treatment and disposal methods were noted in this survey.
Of the major treatment and disposal methods, approximately 51 percent of
those  companies  providing data disposed of liquid  and solid wastes by

                                  128

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TABLE 45.  SUMMARY OF TELEPHONE SURVEY DATA CHARACTERIZING
           WASTE CONTRACTOR OPERATIONS
      Services Provided
         Hauling
         Treatment
         Disposal

      Wastes Handled
         Sludge
         Liquids
         Solids (dust)

      Average Service Costs
         Hauling
         Treatment
         Combined
& Disposal
                                      Survey
                  85 percent
                  83 percent
                  71 percent
                  89 percent
                  74 percent
0.8c/liter (3c/gal)
2.6c/liter (LOc/gal)
5.8c/liter (22c/gal)
      Disposal Methods
         Landfill (unspecified)       51 percent
         Pond or Lagoon              10 percent
         Land Burial                  8 percent
         Deep Well Injection          8 percent
         Incineration                 8 percent
         Discharge to Sewer           6 percent
         Chemical Solidification      4 percent
         Stockpile                    4 percent
         Outside Disposal             4 percent


      *  Percentage not available.
                          129

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landfilling;  ponding and lagooning accounted for 10 percent;  land burial,
8 percent; deep well injection, 8 percent;  and incineration,  8 percent.

          The data obtained from the telephone survey, IHWMF  report, and
the responses to the NAMF questionnaires provided information necessary  to
compute the distribution of services provided, costs, and the treatment  and
disposal technologies (Appendix A); however, the data base was insufficient
to allow, with any confidence, the extrapolation of these data to the entire
industry.  In addition, the reliability of the data was questionable, since
most of the data were completely unsubstantiated (i.e., information was
listed essentially as received by telephone interview and as  such not
verified).  To obtain a better understanding of the treatment and disposal
practices used for potentially hazardous wastes, a limited number of plant
visits to treatment and disposal contractors were conducted.   The objectives
of these visits were to:

          •  Verify and update the information provided in the IHWMF
             report and facilities' resume obtained over the  phone
             relating to noninventoried plants

          •  Observe firthand the operations of different treatment
             and disposal facilities

          •  Assess and document (if possible) those waste-handling
             practices which are environmentally adequate.

          Of the 67 treatment and disposal contractors identified, 41 were
contacted and 23 stated that they would accept visits by contractor personnel.
Because of time constraints, it was not possible to visit all 23 plants;
however,  eleven plant trips were undertaken after the potential visitation
sites were screened.  The criteria for selection of the visited sites are
noted below in order of importance:

          •  Electroplating or metal finishing wastes treated
             and/or disposed

          •  Non-IHWMF plant site

          •  Plant site not previously visited in IHWMF survey

          •  Contractor did not require letters of reference,
             secrecy agreements, or EPA verification, or
             generally did not display an uncooperative attitude.

Of the six non-IHWMF sites allowing plant visits, two were not considered
to be applicable to our study and  the remaining four were visited.  Table
46 is a listing of the names and states of the eleven treatment and disposal
contractors visited.

          All plant sites x^ere contacted by telephone prior to the plant
visit.  At that time the important information on the facilities' resume
was updated, or, in the case of non-IHWMF plants, a  data-acquisition form
was completed.  Therefore, important data items such as contractor name
and address, services provided, service costs, and ultimate disposal methods

                                   130

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      TABLE  46.    TREATMENT AND DISPOSAL CONTRACTORS
                  HANDLING ELECTROPLATING OR METAL
                  FINISHING WASTES  VISITED
 (1)   Chem-Fix,  Inc.,  Pennsylvania

 (2)   Approved  Chemical  Treatment, Inc.,  Michigan

 (3)   Erieway Pollution  Control,  Inc.,  Ohio

 (4)   Koski Construction Company,  Ohio

 (5)   Systech,  Ohio

 (6)   BioEcology Systems,  Inc.,  Texas

 (7)   Conservation Chemical Company,  Missouri

 (8)   Summit National  Corporation, Ohio

 (9)   Valentine Disposal,  Pennsylvania

(10)   Ohio Sanitation  Systems,  Inc.,  Ohio

(11)   Warren County Solid  Waste  Authority,  Pennsylvania
                           131

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were obtained before the visit.  Assessments of the environmental adequacy
were difficult (if not impossible) from the short inspection tours of the
plant facilities (usually not in operation) especially since the site of
ultimate disposal was often different from that of the treatment plant.

          Treatment and disposal practices can vary widely within a state
and often vary markedly from state to state for many reasons (e.g., regula-
tions, availability of land for disposal, etc.).  The existence of these
wide variations in the treatment or disposal technologies places an economic
liability on those areas maintaining tough standards and rigorous enforce-
ment.  In many locations untreated waste is discharged directly into the
municipal sanitary sewer.

          The electroplating wastes received normally come from (1) those
large job shops and captive shops in large companies wishing to maintain
good public relations and  (2) smaller companies which have large, single
"dump" quantities of concentrated hazardous wastes.  Continued growth or
simple maintenance of private contractor operations for the treatment and
disposal of electroplating wastes is dependent on the enactment and enforce-
ment of strict hazardous waste disposal regulations.

          A composite of the treatment and disposal contractor operations
has been prepared through  the analysis of data obtained from the IHWMF
report, telephone and industry survey data, and information obtained during
the plant visits.  Figure  7 is a  schematic representation of this composite
plant.
              DESCRIPTION OF WASTE  TREATMENT AND  DISPOSAL METHODS
                               Treatment  Methods
           Potentially  hazardous wastes  generated  by the electroplating and
 metal  finishing industry are  found  in one  of  three  forms:   (1)  low-solids
 slurry,  (2)  high-solids  sludge, and (3)  solid waste.   Treatment of the
 low-solids slurry is performed by densification or  densification and dewatering
 to  produce a waste more  easily disposed of to the land.  Concentrated
 solutions  of heavy metals may alternatively be treated by  reclamation or
 chemical fixation and  solidification.  High-solids  sludges and  solid wastes
 are sometimes treated  by volume reduction  processes (e.g., incineration) to
 reduce the transportation and final disposal  costs.

           The methods  of treatment  discussed  below  are those used by this
 industry.


 Concentration and Dewatering
           Liquid wastes such as spent plating solutions,  rinse waters,  acid
 baths,  and alkaline cleaners not collected and disposed of by a private
 contractor, reclaimed or sewered,  are treated in an on-site water pollution

                                    132

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FIGURE 7.   COMPOSITE SCHEMATIC OF ELECTROPLATING AND METAL FINISHING
           HAZARDOUS WASTE TREATMENT AND DISPOSAL CONTRACTOR OPERATIONS

                                 133

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control facility.  Those operations that are used to treat the waste by
concentrating the solids produced in the water pollution control facilities
are as follows:  settling and final burial in a permanent lagoon; settling
and periodically removing sludges from a holding lagoon; direct dewatering
either by filtration or centrifugation; settling in a holding tank with
clarification; or settling in a holding tank with clarification followed
by dewatering.

          A brief description of the concentrating and dewatering treatment
technologies used follows:

          Lagooning.  A lagoon is a depression in the land for holding
brackish waters.  Many lagoons are of natural formation; however, the
majority used in waste disposal operations are manmade on specific selected
sites.  The lagoon may be unlined or it may be lined with clay or plastic
sheets which are overlayed with about 1 foot of gravel.

          The. accumulated sludges may be removed and taken to a permanent
landfill or left in the lagoon.  In a permanent lagoon the solids ultimately
are covered when full with about 6 feet of dirt.

          Since capital and land are invested in the lagoon, many plants
remove the settled sludge after several years of operation and dispose of
it, freeing the lagoon for additional service.  The simplest method of
disposal is to transfer the sludge to a landfill.  A safer method is to
chemically or physically fix the sludge by mixing with cement, asphalts,
plastics, or proprietary agents to form a hard-setting, leach-resistant
medium, with the sludge making it more durable for long-term storage.  The
converted mix may be deposited in a wide variety of landfills.


          Direct Dewatering, Including Holding Tanks.  Instead of settling
in a  lagoon over a period of months or years, many plants dewater their
slurries to sludges immediately.  This treatment is used for a variety of
reasons, some of which are as follows:   (1) some states do not allow lagooning;
(2) sometimes lagoons overflow, leak, or break; or  (3) land is not available
or too expensive for lagooning, especially in larger cities.  In many of
these instances, direct dewatering is the only treatment available.  The
degree of dewatering depends on the local situation, especially in relation
to the distance  between the plant and the disposal site.

          The least complex of these treatment methods is similar to lagooning
and is simply a holding tank wherein solids may be concentrated to about  1
to 2  percent.  When dense solutions are necessary, filters and/or centrifuges
must  also be  used, which require a greater penalty in  that more capital must
be invested and  therefore higher overall costs result.  To improve on the
densification of slurries, a thickener or clarifier may be added to the
tank.  This operation increases the solids content to  about 2-3 percent.
A thickener,  of which there are several different types, consists of a
shallow, cylindrical settling tank, equipped with a central feed well,
peripheral overflow collection trough, pump-regulated  sludge discharge
outlet at the bottom, and a slowly revolving, centrally located shaft
equipped with radial arms and plow blades for moving the settled sludge
gently to the  central sludge outlet.

                                   134

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          These thickened slurries may be sent directly to a lagoon or to
a landfill, or may be further treated by filtration or centrifugation.
Slurries may also bypass tank settling and/or thickening and be processed
by dewatering directly by any suitable dewatering process.


          Filtration.  Filtration is the separation of the solid and liquid
phases by means of a porous membrane.  This separation may be effected on a
vacuum-drum filter or a plate-and-frame filter.

          A continuous vacuum-drum type filter is a cylinder whose periphery
forms the filtering surface.  The external surface is generally used for
depositing the solids and is divided into separate compartments.  Each com-
partment is separately connected to an automatic control valve which regu-
lates the period of vacuum for forming and drying the filter cake, and the
application of compressed air for discharging the filter cake.  The slurry
feed deposits a sludge on the external surface of the filter when a vacuum
is applied.  As the porous drum rotates and leaves the feed bath, carrying
with it the sludge, the sludge is dried and finally discharged into a
receiving hopper before the cycle is repeated.

          In a plate-and-frame type unit, a filtering medium is stretched
over a frame provided with channels for the collection and drainage of
solutions, thus allowing the solids to be recovered.  The slurry to be
filtered is forced under pressure into the space between the filter medium
and the frame.  A number of these units in series constitute a plate-and-
frame filter.  Provisions are made for slurry feed to each frame and for
discharge of filtrants from each plate.  When filtration is completed and
feed stopped, the plates and frames are separated, thus allowing the sludge
to discharge to a hopper,  A sludge of 20 to 25 percent solids may be
expected from this mode of separation.
          Centrifugation.  A centrifuge is a machine designed to apply a
centrifugal force to the waste material.  This machine may be used to
separate the liquid and solid phases by allowing the liquid to pass through
a supported filtering medium (cloth screen) to a discharge port while
catching and holding the solids.  When used to separate sludges from slurries
in a wastewater treatment facility, the solids content is increased to about
20 to 25 percent in a basket-type unit wherein the spinning basket, similar
to a household washing machine, discharges water through a peripheral screen.
          Reclamation.  Sludges and liquids from electroplating and metal
finishing wastes contain valuable metals and other materials which may, at
least in theory, be recovered by chemical treatment.

          In determining the practicality of reclamation schemes, the econ-
omic trade-offs and other factors must be considered, e.g., recovery costs
versus virgin materials costs, energy requirements and availability of
energy, and the cost of environmental protection.

          Many of the techniques for materials reclamation are well


                                     135

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developed and available for use when economic factors are favorable or
regulations encouraging reclamation are adopted.   For example, the reclama-
tion of solvents currently is practiced in many cases and techniques for
concentrating aqueous liquids (e.g., reverse osmosis and evaporation) have
been demonstrated.

          Viable techniques for the reclamation of metal values from sludges
have not been developed.  Some research has been conducted on various
recovery techniques, but no sludge recovery methods have been demonstrated
on a commercial scale in this country.
Chemical Fixation/Solidification
          Both sludges and slurries can be mixed with solid-setting materials
to form a body which keeps leaching to a minimum.  Some of those solid-
forming bodies are cement, asphalts, plastics, or proprietary materials.
As practiced, sludges are scooped from a lagoon, mixed with the solid-setting
material and returned to set.  The set product, which forms a friable mix,
is broken up and disposed of in a landfill.  In another practice, spent
pickle liquor, as a slurry, is mixed with a proprietary material which forms
a thickened mass; upon solidification, the mass is broken up and disposed of
in a landfill.

          Incineration.  Incineration is the application of heat in the
presence of oxygen and a combustible fuel to cause burning.  As applied to
the electroplating and metal finishing industry, it is the formation of
reduced volume of process wastes and degreaser sludges via the oxidation of
solvents, sludges, inerts, and metal-containing solid wastes.  Incineration
is not widely practiced in this industry since combustible fuels are not
available or are too costly.  Only two respondents reported the use of incin-
eration in the survey—one for solid wastes and the other for organic liquids.
Current and potential regulatory demands for controlling air pollution from
incineration require more sophisticated and more costly systems which make
reclamation and land disposal the preferred methods.
                              Disposal Methods
          Solid and  semisolid wastes  from  the electroplating  and metal
finishing industry often are destined for  some form of land disposal.  Below
are brief descriptions of these disposal methods found to be  employed by
either the job shops themselves, or by contractors employed to collect and
dispose of the wastes.
 Sewer Dumping or Sluicing
           Some political divisions allow the dumping of untreated wastes
 into the  sewer system upon notification of the sewage plant operating


                                   136

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personnel,  Many of the electroplaters avail themselves of this service,
even though a charge is usually assessed.  However, this method of treatment
is discouraged since plating solutions, when not sufficiently diluted or
neutralized, can cause serious structural damage due to corrosion, and, in
some cases, may even cause blockage of sewer lines.  Plating wastes, especially
those containing cyanides, can create toxic conditions in the sewer circuit,
making working conditions intolerable.  In addition, these wastes may have
a deleterious effect on the operation of the sewage plant, in that primary
sludge precipitation may overtax the filtration capacity, bacterial colonies
may lose or diminish their effectiveness either in primary or secondary
digestion systems, and excess heavy metal ions may be discharged by the
treatment system and enter navigable streams.
Open Dump


          An open dump may be a disposal site owned and operated by private
concerns or individuals where anybody can dump waste materials for a fee.
Operators of open dumps accept residential, commercial, industrial, and
sometimes potentially hazardous wastes when approved by state, EPA, and local
health authorities.  Open dumps also may be owned and operated by an indus-
trial concern  for its own use.  Wastes are compacted when dumped and left
uncovered until the site is completely filled.  Monitoring wells are not
normally employed.
Municipal Landfill


          Municipal  landfills  are  disposal  sites owned  and  operated  by  local
political subdivisions.  The large majority of  the wastes destined for  these
landfills are  of  commercial and residential origin, with the  quantity of
potentially hazardous waste usually  at  a minimum.  With the exception of
compacting with a bulldozer and covering the disposed debris  daily with about
6  inches of dirt, as in  a  sanitary landfill, additional precautions  are seldom
taken  to insure protection of  the  environment.


Special Landfills


          Approved landfills are disposal sites where precautions are taken
in the selection, control, and monitoring of the sites  to insure that
leaching will  be  minimized.  In order to insure long-term protection of the
environment from  potentially hazardous  waste migrations, either horizontally
or vertically, the geological  conditions are appraised  for  favorable
entrapment and storage.

          When the approved landfill is considered to be a  secured landfill,
the following  additional safeguards  are taken.  Where geological conditions
are inadequate to prevent  these migrations, impervious  liners of clay,
asphalt, or concrete are demanded.   Additionally, an inventory and mapping
                                    137

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of the hazardous waste burial site is required so that retrieval (if
necessary) is possible.  Some special and/or secured landfills require
encapsulation in drums or containers which give some degree of control of
leaching.

          The selected site should undergo extensive geological evaluation
for hydraulic connections to ground and surface waters.  Subsoil charac-
terizations should also be made to determine the need for impervious liners
to prevent horizontal and vertical migration of the hazardous constituents.
A characterization of the surrounding groundwater and surface waters before
the site is activated is also required.  Facilities for leachate collection
are essential for liquid, low-solids slurries and/or soluble metal wastes.
In addition, the site should be operated in such a fashion so as to permit
the disposal of similar materials in separate and isolated cells.  The
location of each cell should be identified and mapped and its contents
recorded.  From these records, problem areas could be easily located, and
the wastes contained in these areas could then be removed.  It would also
permit the excavation for recovery of such wastes for resource reclamation.
Since long-term physical protection of the environment is the goal, surveil-
lance and monitoring of the disposal sites, including regular analysis of
ground and surface waters for changes in background levels, are necessary.
There are several designs in operation or under consideration to facilitate
leachate collection (for surveillance and for treatment, if necessary) from
potentially hazardous waste disposal.  Once the leachate is collected, it is
neutralized with a lime treatment to precipitate metal hydroxides.  The
dewatered solids can be returned to the disposal site and the effluent can
be discharged to the sewer.
                      DEVELOPMENT OF TECHNOLOGY LEVELS
          The results of the analysis performed on the identified treatment
and disposal technologies practiced by the electroplating and metal finishing
industry were used to develop three levels of technology for the industry.
The technology includes processes employed for the treatment of a waste
stream from its point of identification to the waste's ultimate disposition.
The three levels of technology are as follows:

          Level I     -  Technology employed by typical facilities,
                         i.e,, a broad average practice of treatment
                         and disposal.

          Level II    -  Best technology currently employed and
                         representing the soundest process from
                         an environmental and health standpoint
                         currently practiced in at least one
                         location on a commercial scale.

          Level III   -  Technology either in operation or being
                         developed necessary to provide adequate
                         health and environmental protection.
                                    138

-------
          In the development of the technology levels, selected factors were
used to assess the adequacy of the technology related to health and environ-
mental protection.  Each level is discussed in detail in the following
sections.  A summary of each level and its assessment is given in Tables
49A through 49D<
                 Prevalent Treatment and Disposal Technology
                                  Level I
          The broad average treatment and disposal technology for those
potentially hazardous wastes destined for land disposal, defined as Level I,
is discussed below for the following four major waste streams:  (1) water
pollution control sludges/solutions, (2) process wastes, (3) degreaser
sludges, and (4) electroless nickel sludges.
Water Pollution Control Sludge
          The technologies employed to separate the sludge from the treated
wastewater used by the 50 job shops in the survey sample are given in Table
47.  The most prevalent treatment technology is solids concentration through
the use of simple settling devices (e.g., lagoons, holding tanks or clarifiers)
to create a 1 to 5 percent solids sludge for disposal.  The disposal methods
employed by job shops for the various waste streams are summarized in Table
48.  The prevalent disposal technology for the water pollution control sludge
(after the solids concentration treatment) is simple land disposal (including
surface and deep burial, open dumps, and municipal landfills).  Sixteen of
the 27 plants (59 percent) which identified their disposal method for water
pollution control sludge employ this disposal method.  Thirty-three of the
50 plants (66 percent) in our survey employ off-site disposal.


Process Wastes


          The prevalent treatment and disposal technology for process
wastes (comprised of dusts, contaminated metal scrap, plating racks, high-
solids sludges, and miscellaneous process solid wastes) is disposal in
municipal landfills.  Seven of the 11 plants (64 percent) which identified
their waste disposal method employ municipal landfills.  Nineteen of the
27 plants reporting (70 percent) dispose of their process wastes off site.


Degreaser Sludges


          The prevalent treatment and disposal practice for solvent wastes
is reclamation.   Fifteen of the 16 plants (94 percent) included in this
survey employ reclamation, sale, or on-site recovery and reuse.  Ten of
the 16 plants (63 percent) employ off-site reclamation/disposal.   When
reclaiming the solvent on site, a potentially hazardous degreaser sludge is


                                  139

-------
     TABLE 47.  TREATMENT METHODS USED BY THE SAMPLED JOB
               SHOPS TO SEPARATE SOLIDS FROM TREATED WASTEWATER

Treatment Method
Lagoon
Holding Tanks
Tank and Clarifier
Clarifier and Dewatering
Direct Dewatering
Unknown
Total Plants
Dewatering Methods
Filtration
Centrifuge
Total Plants
No. of Plants

8
13
4
2
10
13
50(a)

10
2
12
Percent

16
26
8
4
20
26


83
17

(a)   The  number  of shops  reporting  disposal was  50;
     more than one treatment  is  used  in some  shops.
                             140

-------
      TABLE 48.  DISPOSAL METHODS USED BY THE SAMPLED JOB SHOPS
                 FOR SLUDGES AND PROCESS WASTES
   Disposal Method
 Number of Plants  Using Disposal
 	Method for Waste	
 Water Pollution
 Control and Other       Process
	Sludges	Wastes
Permanent Lagoon (on site)
Surface Burial  (on site)
Deep Burial (on site)
Open Dump (on site)
Open Dump (off site)
Municipal Landfill (off site)
Special Landfill (off site)

Recovery and/or Reuse (on site)
Reclamation (off site)
Sell (off site)

Fate Unknown

Off-Site Disposal
On-Site Disposal
     Total Plants
         3
         3
         1
         1
         5
         6
         2
         4
         2

        23

        33
        17
        50
 2
 7
 1
16

19
 8
27
 (a)  Includes two plants which employ chemical fixation/solidifation.
                                141

-------
created,   This waste may be combined with those solvents not reclaimed and
sent to the water pollution control facilities; it is ultimately disposed
of to the land along with the WPC sludge or may be included with the process
waste stream.  Regardless, the prevalent disposal practice for solvent
sludge is nonapproved land disposal.
Electroless Nickel Wastes
          The prevalent practice for disposal of electroless nickel wastes
is disposal to landfills.  They normally are incorporated with the water
pollution control sludges for disposal.


           Evaluation of Prevalent Treatment/Disposal Technology
                                  (Level I)


          The present broad average treatment/disposal technologies employed
by the electroplating and metal finishing job shops and by the printed
circuit job shops were evaluated by a set of 12 factors.  These evaluations
are summarized in Tables 49A (water pollution control sludges), 49B (concen-
trated inorganic solutions), 49C (process wastes), and 49D (solvent/solvent
sludges).  More detailed consideration of those factors affecting the
adequacy of Level I Technology for each waste stream is given in the following
sections.
Water Pollution Control Sludge


          The prevalent treatment/disposal technology for water pollution
control sludge is solids concentration to 1 to 5 percent, followed by simple
land disposal.  The waste is an aqueous slurry of metal hydroxides.  The
Level I technology is considered inadequate to provide health and environ-
mental protection, primarily because of the potential contamination of
groundwater or surfacewater supplies possible with this method of disposal.
Metal hydroxides, when exposed to an acid environment (possible through
contact with organic acids resulting from municipal refuse decomposition),
become resolubilized.  The metal ions can then enter the groundwater
supplies, when water table levels are high or by being carried with rain
water percolating through the land disposal site.
Process Wastes


          The prevalent treatment/disposal technology for process solid
wastes is municipal landfill disposal.  Process wastes are comprised of
solids and semisolids contaminated with toxic metals from the metal
finishing operations.  These wastes are not normally regarded as hazardous
by the industry and are therefore disposed of with nonhazardous plant trash


                                     142

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in municipal landfills.  This disposal method is not considered adequate for
health and environmental protection because of the potential for ground
water or surface water contamination.  Toxic metals included in the process
wastes can become solubilized through contact with organic acids present in
the disposal site.  The metal ions can be carried with rain water percolating
through the disposal site and into the groundwater supply.
Degreaser Sludges


          The prevalent treatment/disposal technology for spent solvents is
reclamation.  The solvents used in metal cleaning operations become contam-
inated with toxic metals.  These metals are removed in the reclamation
operation and transferred to a solvent sludge.  The treatment/disposal
technology for solvent wastes is considered adequate for health and environ-
mental protection.  However, the prevalent disposal practice for solvent
sludges, simple land disposal with the process wastes or water pollution
control sludges, is considered inadequate because of potential groundwater
or  surfacewater contamination.  Metal oxides  or hydroxides in the waste can
become solubilized in an acid environment and be carried with percolating
rain water to groundwater supplies.  Any residual solvent also is potentially
hazardous.
              Evaluation of Best Technology Currently Employed
                                 (Level II)
          From the technologies identified in the survey sample, the soundest
process from an environmental and health standpoint currently in use in at
least one location on a commercial scale was selected as the best technology
currently employed (Level II technology).  Evaluations of the treatment/
disposal technologies are summarized in Tables 49A through D for water
pollution control sludge, concentrated inorganic solutions, process wastes,
and solvent/solvent sludges, respectively.  More detailed consideration of
the Level II technologies' adequacy is described below for each waste stream.


Water Pollution Control Sludges


          The best treatment/disposal technology for the water pollution
control sludge involves (1) solids concentration, (2) dewatering to greater
than or equal to 20 percent solids, and  (3) disposal in an approved sanitary
landfill.   The additional safeguards above the Level I technology include
the dewatering operation which produces a high-solids (increase from 1 to
5  to 20 percent solids), lower volume, sludge cake.  The most important
additional  safeguard is the change from simple land disposal (surface
burial, open dumps, municipal landfills, etc.) in Level I technology to an
approved sanitary landfill for Level II technology.  An approved sanitary
landfill involves a disposal site where precautions have been taken in the
areas of site selection and leachate control and monitoring.  Disposal of
                                    150

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water pollution control sludges in such a. disposal site is considered
adequate for short-term disposal,  Long-term protection, however, cannot
be assured since surface run-off and rain water can still percolate through
the disposal area, leading to leachate formation.  If the impervious barriers
placed in the bottom of the landfill should become ruptured, break, or
otherwise fail, no means are available to collect the leachate for treatment
or excavate the problem hazardous waste.
Process Wastes


          The best treatment/disposal technology for the contaminated solid
and semisolid process wastes is disposal in an approved sanitary landfill.
As noted  in the best technology section for WPC sludges, an approved sanitary
landfill  is considered adequate for short-term disposal.  However, because
such  facilities do not include the means for  leachate  collection and treat-
ment, waste segregation  and mapping, long-term protection of  the environment
cannot be assured.
 Degreaser  Sludges


           The prevalent  treatment/disposal  technology  for  solvent wastes  is
 reclamation; it  is  also  considered  the best practice.   Reclamation  of
 solvent wastes is considered  adequate to  provide health and  environmental
 protection.

           The best  treatment/disposal technology for solvent sludges is
 disposal in an approved  sanitary  landfill.  This disposal  method is considered
 adequate for short-term  disposal.   Long-term  protection, however, cannot  be
 assured because  of  the lack of  facilities for leachate collection and  treat-
 ment,  waste segregation  and mapping.


                 Evaluation of  Treatment/Disposal  Technology
                      Considered Adequate  for  Health and
                     Environmental Protection  (Level IIIj


           The  technology identified here  may  be identical  to the two
 previously cited technology levels  or it  may  be more or less sophisticated.
 The identified technology may include pilot or bench-scale processes.   In
 any case,  the  technology must provide adequate health  and  environmental
 protection,

           The  technology identified as adequate in this study consists
 principally of the  present best technology  described in the  previous section
 with some  modifications  in the  preparation  and operation of  approved sanitary
 landfills,

           The  level of technology considered  adequate  for  each waste stream
 has been evaluated  for 12 factors in Tables 49A through D.   The adequate


                                     151

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disposal practices are discussed briefly for each waste stream below.


Water Pollution Control Sludge
          The treatment/disposal technology considered environmentally
adequate for the water pollution control sludge includes solids dewatering
and disposal in a secured sanitary'landfill.  A secured sanitary landfill
employs the basic site selection, and leachate control procedures described
for an approved sanitary landfill with the additional safeguards discussed
in a previous section of the report.
Process Wastes
          The treatment/disposal technology considered adequate for health
and environmental protection for process wastes is disposal in a secured
sanitary landfill.  As noted previously for water pollution control sludges,
a secured landfill includes modifications to an approved landfill to provide
additional safeguards to assure long-term environmental protection.
Degreaser Sludges
          Reclamation of spent solvents is considered both the best and
the most environmentally adequate treatment/disposal technology.

          The disposal practice considered environmentally adequate for
solvent sludge wastes is disposal in a secured sanitary landfill.  As noted
earlier, the modification of the best disposal practice, approved landfill
disposal, to the secured classification allows assurance of long-term
protection of health and the environment.
                                  152

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                             IV.   COST ANALYSIS
                        INTRODUCTION AND METHODOLOGY
          This section presents a cost analysis of the treatment and dis-
posal techniques of those potentially hazardous wastes generated in the
electroplating and metal finishing industry which are destined for land
disposal.  The electroplating and metal finishing wastes are grouped into
four distinct waste streams:

          (1)  Water Pollution Control (WPC) Sludges
          (2)  Process Wastes
          (3)  Degreaser Sludges
          (4)  Electroless-Ni Bath Treatment Sludge.

          The engineering approach method of cost analysis was used to
generate waste treatment and disposal costs.  The engineering approach
involves the estimation of capital and average operating costs on a one-time
basis without any regard to the life of the project.  The entire capital
cost is amortized to obtain annualized capital costs.  No consideration is
given to cash flows, incremental costs, or expected project benefits.

          The simulation technique of cost estimation using three different
sized model plants was employed.  The detailed descriptions of the various
electroplating and metal finishing operations, together with the calculations
related to the different quantity of waste generated in the 16-man, 38-man,
and 87-man model plants are presented in Apoendixes B, C, and D, respectively.

          For estimating the model plant operating costs, capital costs for
various items of equipment for the WPC sludge dewatering, storage of the
several wastes, etc., were derived from literature or trade sources.
Equipment cost data were adjusted to show December, 1973, costs using the
Marshall and Stevens Equipment Cost Index published periodically in
Chemical Engineering (McGraw-Hill, Inc.).  All capital and operating costs
for the model plants were based on December, 1973, dollars.  For estimating
model plant operating costs, a 10-year straight line depreciation (i.e.,
10 percent per year) was applied to the capital investment cost for the
waste dewatering and waste storage equipment.  An annual interest charge
of 10 percent was also applied to the capital investment on this equipment.
Labor costs for sludge dewatering and handling of the several stream wastes
were based on a charge of $8/man hour.  Annual maintenance costs were
estimated to be 5 percent of the capital investment costs, while annual
costs for taxes and overhead were determined to be equal to 0.8 percent of
capital equipment costs.  The principal items influencing the capital and
operating costs for waste disposal contractors and/or landfill operators
include those for land, site development, equipment, depreciation, interest,
equipment rental, labor, power, maintenance and repair, materials, admin-
istration, and overhead.

          The following sections of the report provide considerable data,


                                   153

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gathered from many sources, on contractor charges for hauling wastes,
contractor charges for combined hauling-treatment (if any)-disposal of
wastes, landfill operating costs, and landfill fees.  The manner in which
these data were used to arrive at representative waste treatment and dis-
posal costs for the different treatment-technology levels is discussed
below.
                   Contractor Treatment and Disposal Costs


Versar, Inc. Survey for EPA
          A survey of approximately 50 hazardous waste treatment and dis-
posal contractor companies, which collectively represent all sections of
the continental United States, was made in early 1974 by Versar, Inc. for
the Office of Solid Wastes Management Programs, EPA, Washington, D.C.*
Information gathered included the type of operation (hauling, treatment,
and/or disposal), type of waste (sludges, liquids), service cost, and
ultimate disposal facility used.  Of the 50 contractors, 18 (36 percent)
supplied service cost estimates for hauling, treatment, and/or disposal
activities.  Most of the cost figures were expressed as cents/gal; however,
a few others used mixed units such as $/cu ft, $/lb of specific substance,
$/mile per truck, etc.

          Most electroplating and metal finishing facilities pay a fee to
the private contractors for handling sludges, dusts, and other wastes.
The fees paid are not the actual cost of handling waste, but they represent:
the charges imposed on the customer by the contractor.  The charges include
the contractor's expenses plus overhead and profit.

          Table 50 contains the data on contractor fees for waste handling
which were derived from the Versar, Inc. survey.*  Although the available
data and descriptive information are limited, some generalizations can be
made about the various categories.
          Hauling.**   As would be expected,  "Hauling" is the only category
which includes a mileage rate.  Data are too  limited to permit mileage
generalizations.   In addition to the mileage  fee, a "Hauling" fee may be
charged on  a per-gallon basis, ranging  from 0.26 to 0.79C per liter  (1  to
3
-------
Footnote ** (from previous page):

          Most of the data obtained from the Versar study and other surveys
or contacts on charges for hauling, treatment, and disposal of hazardous
wastes were of a general nature.  The charges for hauling, treatment and
disposal were mostly expressed on a cost/unit volume of waste basis.
Because of the general nature of the data and lack of specific information
on the waste characteristics, there was no reliable method for converting
data on cost/unit volume of waste to data on cost/unit weight of waste,
cost/unit weight of product, or cost/unit area product processed.  These
same comments generally apply to cost data for the several landfills (pre-
sented later in the cost section)  where costs were usually expressed as
cost/metric ton of waste.  Because of the lack of specific information on
the wastes, it was not possible to reliably convert data on cost/unit weight
of waste to data on cost/unit weight of product or cost/unit area product
processed.

          The relationship between cost/unit volume of waste and cost/unit
weight of waste or cost/unit area of product processed, which was developed
from model plant data for the treatment and disposal of electroplating and
metal finishing wastes, is presented and discussed in the latter part of
the cost section of this report.
                                  155

-------















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          Treatment and Disposal.*  Table 50 shows that for "Treatment and
Disposal" the fee structure is somewhat more complicated.  Mileage rates
are no longer apparent, but the data suggest some firms are giving more
serious consideration to toxic versus unspecified wastes.  For example, an
Ohio firm charges 1.3C per liter (5c per gallon) of waste plus $5.51 per
kilogram ($2.50 per pound) of cyanide (CN~) handled and $2.76 per kilogram
($1.25 per pound) of hexavalent chromium handled.  This seems to be inde-
pendent of the concentrations of cyanide and hexavalent chromium in the
materials accommodated.

          For the most part, though, "Treatment and Disposal" fees seem
independent of the waste's toxicity and range from 0.53 to 5.38C per liter
(2 to 20c per gallon) with an average of about 2. AC per liter (9£ per gallon),
          Combined.*  Most contractor firms seemed to prefer and charge a
flat fee for "Hauling" plus "Treatment and Disposal" of the wastes as
opposed to separating the two operations.  The firms surveyed also seemed
to place more emphasis on special charges for toxic wastes.  For cyanide
wastes, the fees ranged from 2.6 to 40.Oc per liter (10<: to $1.51 per gallon);
no specific concentration of cyanide was indicated.  One firm charges $2.65
per kilogram ($1.20 per pound) of cyanide sludge.  Given this wide range
of variations, the average fee is estimated to be around 13.2<; per liter
(50
-------
              TABLE 51.  SUMMARY OF AVERAGE WASTE HANDLING FEES
                                                               (a)
Waste or Waste Handling Activity
                                            Average Fee Charged
Metric Units
Equivalent Units
A.  Nonspecific Faste

     Hauling

     Treatment and Disposal

     Combined Hauling-Treatment-
        Disposal
               (c)
B.  Toxic Wastev '
Q.53c/liter(b)   2c/gal(b)

2.Jc/liter       8.6c/gal
2.9c/liter       He/gal
$2.71 to  ...
 $5.51/kg(d)
$1.25 to
 $2.50/lb
                                                                (d)
 (a)  Data were derived from Versar, Inc. survey for EPA cited in Table 50,

 (b)  An additional mileage fee may also be charged.

 (c)  This usually refers to chromium and/or cyanide wastes.

 (d)  The charge generally refers to a kilogram or pound of chromium
     and/or cyanide independent of overall waste character or volume.
     An additional fee per unit volume of waste handled may also be
     charged.
                                   158

-------
(Including collection) cost was estimated at about 2.6c per liter (10c per
gallon), and the combined collection-treatment-disposal cost averaged 5.8c
per liter (22
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to develop the relationships between waste treatment and disposal costs
and items such as area processed, sludge amount, plant size, etc., which
are presented later in the main body of the report.
                          Costs of Landfill Disposal
          In order to estimate the additional cost that contractors would
charge for an approved sanitary landfill, it was necessary to determine the
representative operating costs for a simple or municipal sanitary landfill
operation.  Aside from the sludge dewatering, the most important difference
affecting the overall waste treatment and disposal costs is the landfill
cost.  Considerable data on how landfill costs vary with the size of the
operation and site characteristics are presented below.

          Table 54 provides a range of fixed landfill costs for three sites
ranging in capacity from 27 to 544 metric tons per day (30 to 600 tons per
day).*  Additional data on the areas and overall fill capacities for the
three sites are given in the footnotes to the table.  It should be noted
that there is considerable spread in the individual and total costs for the
three sites.  For example, the total unit costs ranged from $0.84 to $1.94
per metric ton ($0.76 to $1.76 per ton) and the range was even greater for
the individual unit costs for the three sites because of their dependence
on the particular site characteristics.

          The principal operating-cost items for sanitary landfills such
as those cited immediately above are:

          (1)  Personnel
          (2)  Equipment
               (a)  Operating expenses — gas, oil, etc.
               (b)  Maintenance and repair
               (c)  Rental, depreciation, or amortization
          (3)  Cover material — material and transportation
          (4)  Administration and overhead
          (5)  Miscellaneous tools, utilities, insurance,
               maintenance to roads, fences, facilities,
               drainage features, etc.

The operating costs (land excluded) for Sites 1, 2, and 3 were about $1.92,
$2.76, and $1.49 per metric ton ($1.75, $2.50, and $1.35 per ton), respec-
tively.*  The average operating costs for landfills in metropolitan Wash-
ington, D.C. were indicated to be about $3.03 per metric ton ($2.75 per
ton).*

          Figure  9  presents a range of capital and operation-maintenance
(O&M) costs (excluding land costs) for sanitary landfills in the Minnea-
polis, Minnesota, area for 1972.*,**  Quantities are expressed in tons of
net sludge cake per day.  As can be seen from Figure  9,  the curves of the
*   See Table 40, Footnote (a) for reference.
**  "Process Design Manual for Sludge Treatment and Disposal", U. S. EPA,
    EPA 625/1-74-006, Washington, D.C., October, 1974.

                                   163

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                    QUANTITY (WET METRIC TONS/DAY)
                        91
907
9072
                                             1000
                       QUANTITY (WET TON/DAY)
                                                          4  6
                       0.01
                    10,000
  FIGURE  9.   CAPITAL AND 0/M COSTS  FOR SANITARY LANDFILLS
              NOTES:
                1. Minneapolis. Mar., 1972. ENR Construction Cost Index of 1827.
                2. Amortization'of 7% for 20 years.
                3. Labor rate of $6.25 per hour.
                4. Quantity assumes 6-day work week.
                5. Wet sludge must be considered for cost per ton.
                6. Source: U. S. P. H. S. and Stanley Consultants.
(a)  Stanley Engineers,  "Sludge Handling and Disposal, Phase I, State
     of the  Art", Report to Metro  Sewer Board of Twin Cities Area,
     November 15, 1972.
(b)  "Process Design Manual For Sludge Treatment and Disposal", U.S.
     EPA,  EPA 625/1-74-006, Washington, D.C., October, 1974.
(c)  Burd, R. S., "A Study of Sludge Handling and Disposal", Report  for
     FWPCA,  Department of the Interior, by the  Dow Chemical  Company,
     Publication WP-20-4 (May 1968).
                                  166

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total cost (excluding land) and O&M costs versus quantity of wet cake per
day were almost straight lines in a log-log plot.  The O&M costs varied
from about $1.10 to $4.40 per metric ton ($1 to $4 per ton) of wet cake,
depending upon the size of the landfill operation.  Other investigators
have reported landfill costs (1968) from $1.10 to $4.40 per metric ton
($1 to $4 per ton) of dry solids.*,**

          Figure 10 shows a range of operating costs (1970 values) to be
expected as a function of the size of the sanitary landfill operation.
Some economies of scale accrue in the size range from 0 to about 182,000
metric tons (0 to 2000,000 tons) per year.  Beyond 182,000 metric tons
(200,000 tons) per year, the unit operating costs seem rather stable.  Fig-
ure 11 presents data somewhat similar to that shown in Figure 10, but sup-
plies additional detail.  For instance, in addition to minimums, maximums,
and averages, Figure 11 suggests the nature of the cost differences to be
expected for different landfill operations, based on the characteristics of
the sites and the equipment employed (1969 values).

          In summation, based on the data from various sources presented
above, the estimated operating and maintenance costs for sanitary landfills
range from about $1.10 to $5.50 per metric ton ($1 to $5 per ton).  In some
instances, there may be an additional estimated capital cost (excluding
land) in site development, facilities, etc. of about $0.44 to $1.55 per
metric ton ($0.40 to $1.50 per ton).
                           Sanitary Landfill Fees
Estimation of Costs for A
Simple or Municipal Landfill
          According to the Versar, Inc. survey and BCL contacts, the Los
Angeles County Class I disposal sites will take almost any liquid or solid
waste; there are no treatment facilities.  Liquid wastes are generally mixed
in with the refuse.  The charges for hazardous wastes are usually the same
as for nonhazardous materials.  Table 55 shows the fees charged by several
of the Los Angeles County landfills for different types of wastes.  The
rates shown in the table had been in effect from 1970 to 1972, and were
scheduled for increases as indicated in Footnote (a) of Table 55 in July,
1974.  Accordingly, because of the long period of time between rate increases
at the site, the proposed July, 1974, fees were considered for this report
to be representative of December, 1973, charges.

          Assuming bulk-density values ranging from 1.10 g/cc to 1.4 g/cc
for the electroplating and metal finishing wastes, the landfill charges on
a volumetric basis (at $3.31 per metric ton of liquid wastes) are tabulated
below:
*   "Process Design Manual for Slucge Treatment and Disposal", U. S. EPA,
    EPA 625/1-74-006, Washington, B.C., October, 1974.
**  Burd, R. S., "A Study of Sludge Handling and Disposal", Report for FWPCA,
    Dept. of the Interior, by the Dow Chemical Co., Publ. WP-ZO-4 (May, 1968)

                                      167

-------
   7.00
  6.00
   500
 ?*
 o
•o
I
   4.00!
 &3.00
 to
8
   2.00
   I.OO
                         Metric Tons/per Year

               90,720     181,440     272,160      362,880     453,600
                            Lo
                              Upper
ver Co
      lost E
st Ran
      angel
ge Le\
      evel
el
       0       100,000     200,000    300,000    400,000    500,000
                             Tons per Year


             FIGURE 10.   RANGE OF SANITARY LANDFILL
                         OPERATING COSTS(a,b)


(a)   Reference:   Updated from "Sanitary Landfill  Facts", Thomas J.
     Sorg and H.  Lanier  Hickman,  Jr.,  1970, PHS Publication No. 1792.
(b)   Based on 6-day work week.
                                168

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     Filling  Rate, Metric Tons  per Average Working  Day
   $350
                 181
363
544
726
   $300 —
            0  One dozer operating
            20 Two dozers operating
            OS Dozers or\d scroper
            DRS Dozers, ripper, scroper
                                        •  Estimated by others
                                           (or Denver orea
                                       — Maximum, overage and
                                        minimum costs based on
                                        characteristics of sites
        0         200        4OO        600        600       IOOO

              Filling  Rote,  Tons  per  Average  Working Day
 Note:   Chart shows how cost  of ownership and  operation
         of equipment relates  to the required filling rate.


   FIGURE  11.   ESTIMATED  SANITARY  LANDFILL OPERATION
                 AND MAINTENANCE COSTS(a)
(a)  Reference:  Public Works,  100  (3):79, March  1969,
     as cited by: Bond, R. G.,  Straub,  C.  P., and Prober,
     R.,  editors, Handbook of  Environmental Control,
     Volume II, Solid Waste, CRC Press,  Cleveland,  1973.
                              169

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         Electroplating and                      Landfill Charge	
       Metal Finishing Wastes                 cents/liter    cents/gal

        Waste - (Bulk density 1.1 g/cc)           0.36          1.38
        Waste - (Bulk density 1.3 g/cc)           0.43          1.63
        Waste - (Bulk density 1.4 g/cc)           0.46          1.75


          Based on the Los Angeles County landfill fees (which are considered
low) and the estimated capital and operating costs for landfills cited ear-
lier, it was estimated that 0.8<; per liter (3.0£ per gal) would be repre-
sentative of nationwide landfill fees paid by the contractors who handle
wastes produced by the electroplating and metal finishing industry for
disposal in a simple or municipal sanitary landfill.
Estimation of Level II
Technology Landfill Fees


          The best technology currently employed, that was identified by
the BCL survey and discussions with electroplaters, waste-handling contrac-
tors, and government (national, state, county, etc.) personnel for the
disposal of electroplating and metal finishing wastes, was represented by
the disposal of the potentially hazardous wastes in an approved sanitary
landfill.  One of the sites that was identified was the Ventura County
(California) landfill.

          The Ventura hazardous waste landfill site was selected with
special care and has a clay-type soil.  Some of the features of the approved
Ventura sanitary landfill operation are as follows:

          (a)  Site geology, hydrology, and monitoring meet all
               State requirements for Class I landfills.

          (b)  Waste burial is mapped; a grid of prior disposal
               is maintained to avoid undesirable mixing inter-
               actions.

          (c)  Contents of waste streams are determined and
               screened for acceptability before disposal.

          (d)  All site run-off is collected.

          (e)  Liquid wastes are mixed with soil rather than
               indiscriminate refuse.

          (f)  Special attention is given to disposal of hazardous
               wastes by landfill personnel.

          The charge for the Ventura landfill is $8.45 per metric ton of
waste ($7.70 per ton) plus $1.00 for the first 0.9 metric ton ($1.00 per
ton) and $0.66 on each additional metric ton ($0.60 per ton).  There is

                                    171

-------
also a $25.00 application fee charged to the hauler for each new waste
received (fee covers chemical analyses and other administrative costs).
The combined charges amount to about $9.25 per metric ton ($8.40 per ton)
of waste.  For a waste with a bulk density of 1.3 g/cc, the landfill
charge on a volumetric basis amounts to about 1.2c per liter (4.54c per
gallon).

          The ratio of the Ventura landfill charge to the Los Angeles
County landfill charge for a waste of bulk density of 1.3 g/cc is 1.20/0.43
or 2.8.  Assuming that the overall landfill charges nationwide for a simple
or municipal landfill are about 0.8c? per liter (3.0c per gal), a represen-
tative charge for an approved sanitary landfill disposal site would be about
2.8 times greater or 2.24<: per liter (8.4c per gal).  Thus a premium cost
of about 1.44$ per liter (5.4
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Xi -H X! I-i XI -H
H CO H 4J H CO


x— x X-N x*"s
Cfl Xl O
s_/ s_x ^— /
173

-------
          These charges were used to generate the waste hauling, treatment,
and disposal costs for the model plants and also to project the nationwide
costs for the years 1975, 1977, and 1983 (expressed in December, 1973,
dollars) for treatment and disposal of electroplating and metal finishing
wastes.
                   Capital and Operating Costs for Waste
                 Treatment and Disposal at Three Technology
                        Levels for Three Model Plants
Introduction
          The estimated investment and annual operating costs for the
overall treatment and disposal of potentially hazardous wastes destined
for disposal on land at the three technology levels for three model plants
are shown in Table 57.  Detailed descriptions of the electroplating and
metal finishing operations carried out in the 16-man, 38-man, and 87-man
plants are presented in Appendixes B, C, and D, respectively.  Data on
workpiece-area processed, and also on the type and quantity of different
wastes generated in the model plants are also presented in these appendixes,
Water Pollution Control (WPG) Sludges
          For Level I Technology for the model plants, the water pollution
control (WPG) sludge containing 5 percent solids was assumed to have been
produced by the use of clarifiers and/or settling tanks.  The production
of the 5 percent solids sludge was considered to have been part of the
wastewater treatment operation and its costs.  The 5 percent sludge was
assumed to be essentially free of cyanides, hexavalent chromium, or other
wastes requiring special treatment.  The principal item of equipment
involved with this sludge at the electroplating and metal finishing plants
is the storage vessel.

          For Level II and III technologies for the model plants, the WPG
stream underflow from a clarifier containing 2 percent solids was dewatered
to a 20 percent sludge with a centrifuge.  The production of the 2 percent
solids underflow was considered to be part of the wastewater treatment
operation and its costs.  Dewatering to produce the 20 percent solids
sludge was considered to be part of the sludge handling and disposal cost.
Centrifuge Size and Cost Calculations


          The calculations used to determine the size of the centrifuge
needed for producing the 20 percent sludge is illustrated using data from
the 38-man model plant.

          From Table 35 and data on the wastewater treatment presented in

                                     174

-------
Appendix C, the quantity (dry weight) of metal hydroxides and other preci-
pitates or solids in the water pollution control sludge (20 percent solids)
is 35,000 kg/year or 140 kg/day.  The bulk density of the solids in the
WPG sludge was estimated to be 2.8 kg/liter.

          The total weight of the sludge (20 percent solids) was calculated
as follows:

                    140 kg/day     -,„„ ,  /,
                    - -  - *•  =  700 kg/day .
The sludge consists of:

          150 kg/day solids
          560 kg/day water.

The volumes occupied bv the solids and water portions of the sludge,
respectively, are as follows:
                     2.8 kg/liter

                     -—- ,"•/,."*—  = 560 liters/day water.
                     1.0 kg/liter                 *
The total volume of the 20 percent solid sludge produced by the centrifuge
is:
                     50 + 560 = 610 liters/day  (161.2 gal/day).

The bulk density of the 20 percent sludge was calculated to be 1.15 g/cc.

          The volume of 2 percent solids underflow that has to be centri-
fuged daily was calculated as follows:

                                = 7000 kg/day
                     Volume of solids = 50  liters/day

                     Weight of solids = 50 x 2.8 =  140 kg/day

                     ,71     f         7000 kg/day  - 140 kg/day
                     Volume of water = 	°~,—77:	a	L =
                                             1 kg/liter
                       6860 liters/day

                     Total Volume = 6860 -t- 50 = 6910 liters/day
                       or 1826 gal/day.
                                  175

-------
TABLE 57.  DETERMINATION OF ESTIMATED CAPITAL AND OPERATING COSTS FOR WASTE HANDLING AND DISPOSAL AT
Capital Investment



Technology
Model Treatment
Plant Level
16-Man I



16-Man II



16-Man III



38-Man I




38-Man II




38-Man III




87-Man I




87-Man II




87-Man III









Waste Stream' '
WPC Sludge (&%: Solids, BD(b) 1.033 g/cc
Process Wastes (BD 1, 5 g/ct)
Degreaser Solvent Sludge (BD 1. 5 g/cc)
Combined Waste Streams
WPC Sludge (20":,, Sol., BD 1.15 g/cc)
Process Wastes (BD 1.5 g/cc)
Degreaser Solvent Sludge (BD 1.5 g/cc)
Combined Waste Streams
WPC Sludge (20T,, Sol. , BD 1. 15 g/cc)
Process Wastes (BD 1 5 g/cc)
Degreaser Solvent Sludge (BD 1. 5 g/cc)
( ombined Waste Streams
WPC Sludge (5?> Sol. , BD 1. 033 g/cc)
Process Wastes (BD 1. 5 g/cc)
Degreaser Solvent Sludge (BD 1 5 g/cc)
Electroless-Ni Sludge (BD 1.45 g/cc)
Combined Waste stream^
WPC Sludge (20'> Sol. , BD 1. 15 g/cc)
Process Wastes (BD 1. 5 g/cc)
Degreaser Solvent Sludge (BD 1 5 g tc)
Electroless-Ni Sludge (BD 1.45 g/cc)
Combined Waste Streams
WPS Sludge (2('l', Sol. , BD 1. 15 g/cc)
Process Wastes (BD 1 5 g/cc)
Degreaser Solvent Sludge (BD 1 5 g/cc)
Electroless-Ni Sludge (BD 1.45 g/cc)
Combined Waste Streams
WPC Sludge (&;",> Sol., BD 1.033 g/cc)
Process Wastes (BD 1 5 g/tc)
Degreaser Solvent Sludge (BD 1. 5 g/cc)
Electroless-Ni Sludge (BD 1.45 g/cc)
Combined Waste Streams
WP( Sludge (207,, Sol., BDl.lSg/cc)
Process Wastes (BD 1 5g,cc)
Degreaser Solvent Sludge (BD 1. 5 g/cc)
Electroless-Ni Sludge (BD 1.45 g/cc)
Combined Waste Streams
WPC: Sludge (2 07,, Sol , BD 1.1 5 g/cc)
Process Wastes (BD 1. 5 g/cc)
Degreaser Solvent Sludge (BD 1. 5 g/cc)
Electroless-Ni Sludge (BD 1.45 g/cc)
Combined Waste Streams
Annual in
Amount Installed
of Waste Centrifuge
Material'0' System
Metric Cost(d),
m'i Ton $
295 304.7 None
8.1 12.15
1.4 2.10
305 319.0
66. 3 76.25 7, 1 11
8.1 12.15
1.4 2.10
76 90. 50 7, 15,'
66.3 7(,.25 7, IV
8.1 12.15
1.4 2.10
76 90.50 7 IV
678 700.4 N'one
16.9 25.35
2.4 i. 60
20. 2 29. 29
718 751 (,
153 176.0 19, MMI
16.9 25. )5
2.4 t.0'0
20.2 29.29
193 2 (1.2 I'1, '""
15) 176.0 19. v"
16.9 25.35
2. 1 t.60
20.2 29.29
193 234.2 19 ''""
1 569 1,020.3 None
)9. 1 53.05
2. •< 4. 20
20. 2 29. 29
1 Gil 1,712.9
i53 406 0 '3, 7'"'
!9.1 53.05
2.3 4.20
20.2 29.29
415 493.1 (8,711"
353 406.0 48.7""
39. 1 5t
2.3 4.20
20. 2 29. 20 ~
415 493.1 '3,7""
Equipment



Waste Storage
Vessel
Capacity,
m3
28
1.7
0.9
-
7. 1
1.7
0. 9
-
7. I
1.7
0.9
-
-,7
3 4
1 4
'i 7
-
1)
3.4
1.4
5.7
-
1.4
3 4
1 4
5 7
-
142
7. 1
-. 0
5.7

Cost,
$
3, 100
600
400
4, 100
1,200
600
4111
2, 200
1, 200
600
400
2, 200
4, 501
800
">00
1, OlHi
6, 800
1, 81 iO
8n(i
-)0(i
1, 000
4, Id"
1, 800
8(i"
50(,
1, u()H
4, 10"
7,90,'
1, 200
60"
1, OOd
10,700
28
7. 1
2 o
1.7
-
28
7. 1
2 0
5 7
-
3, Id"
1. 2""
6""
1, 000
i, 900
3, 10"
1, 200
600
' , ooo
5, 9(io
Annual
Depreciation
Cost (at 10';',,
of Cap.
Irn.)(el,
$
310
60
40
41o
83 5
60
40
935
835
60
4o
9.35
4 10
80
50
100
680
2, 130
80
50
100
2, 360
2. 130
80
->u
100
2, 360
790
120
60
luO
i, mo
\ 130
120
60
I.HI
5, 460
">, 180
120
60
loo
5, 460
    (a)  The model plant operations were based on 2-50 working days per year.  The descriptions and details of the
        various electroplating and coating operations,  along with processing rates for the lo-man,  3S-man,  and
        87-man model plants are presented in Appendices C,  B, and D respectively.  All cons are in December
        1973 dollar..
    (b)  The BD (bulk density) of each of the four stream sludges was estimated taking into account the amount*;
        and densities of different materials that make up the particular steam ua^tes.
    (c)  The volumes of waste material to  be hauled awa> and disposed b> the contractor were calculated using  the
        bulk densities and the amounts of wastes generated in  the model plant4; as shown in Table "U  (page 73).
    (d)  The procedures  used to calculate the different sized centrifuges required in the model plants  and also to
        estimate the installed cost  of the overall centrifuge c)stems are illustrated in the text of thi";  section of the
        report.   The upper curve of Figure 13 shows the basic  centrifuge unit costs m December 197 i dollars.
                                                                176

-------
THREE TECHNOLOGY LEVELS FOR THREE DIFFERENT SIZED ELECTROPLATING AND METAL FINISHING MODEL  PLANTS>,
$
310
60
40
41o
835
60
40
935
835
60
40
935
450
80
50
100
680
2, 130
80
50
100
2.360
2, 130
,30
50
100
2,360
790
120
60
100
1,070
5, 180
12o
60
100
),4oO
>, 180
12 U
GO
luu
5.46o



Annual
1 abor < osr
(at $8/Hr),
$
2, 000
400
2oO
2 Gl 0
2, 000
400
200
2, 600
2, (JIM
400
200
2, 600
3. oOO
600
300
400
4, 300
3, ooo
600
30i
400
4,300
3, 000
GOO
300
400
4, 300
4, 000
800
400
600
i, 800
4, 000
800
100
600
5, 300
4, OOil
800
400
600
',, 800


Annual
Annual Maintenance
Power < ost Tost (at S"/,-
(at 2if /Kwhn, of ( ap Inv ),
$ $
155
30
20
2o5
300 420
30
20
3oo 470
3 00 420
,30
20
300 470
225
40
— 25
- 5o
340
520 1,065
40
25
50
520 1, 130
520 1,065
40
- 25
50
520 1, ISO
395
60
30
-.0
535
810 2,590
60
30
50
810 2,730
810 2, 590
60
30
50
810 2,730

Annual
Taxes and
Overhead
( at 0 . 8T of
( ap Inv.),
$
25
5
5
35
65
5
5
75
65
5
5
75
35
5
5
lo
55
170
5
5
10
190
no
5
5
10
190
65
lo
~t
10
90
415
10
5
10
440
415
10
5
10
440
Annual
( ontractor
Waste
Hauling
and
Disposal
< liarge.(f)
$
10, 570
290
50
10.910
3, 325
405
70
3, 800
5,425
660
110
6, 195
24, 345
605
85
725
25,760
7, 655
845
120
1, 015
9,635
12, 495
1. 380
195
1, 650
15, 720
56 330
1, 405
100
725
58, 560
17.715
1, 960
140
1.015
20. 8.30
28. 905
3.200
2,30
1, 650
33, 98"



Costs for Handling
and
Total
Annual
Cost,
$
13, 370
845
355
14,570
7,785
9oO
375
9, 120
9,880
1,215
415
11,510
23, 505
1,410
515
1, (85
31,315
1(,,G70
1,050
500
1,075
20. 545
21, 510
2,135
G25
2,310
26,030
02. i70
2, 515
1,55
1 , 585
07, 125
15,390
), 070
(,95
1,875
41, 530
17,030
4, 110
735
. 510
54, 085
Disposal of

Cost,
$/ metric
ton
43.88
69.55
169.05
45.67
102.10
79.01
178.57
100.77
129.57
100.00
197.62
127. 18
40.70
55. G2
143. OG
47.29
41.94
91.72
G5.09
152.73
57.19
37.72
122.22
8G.19
173.01
73.37
113.71
38.48
42.33
155.95
54.11
39. 19
88. 4o
52. 34
105.43
64.0'J
33. (3
115.90
7 (.49
13C.90
35. 9o
109. 79
Wastes

Cost,
t/m2
Processed^'
1.74
0.11
0. 05
1.89
1.01
0. 12
0.05
1. 18
1.23
O.lu
0.05
1. 1-9
1.52
0.07
0.03
0.07
1.70
0.89
0.09
O.OS
0.09
1. 10
1. 15
o. 12
0. 1 t
0. 12
1 42
1.40
0. 1)1;
0.02
0.01
1. 57
o. 81
0. 07
0. 02
(,.04
0. 97
1. 10
0 111
0.02
0. Oo
1. 23
    (<•) A  10-)ear straight-line depreciation (i.e., 10"',,/)r) was applied to the unestniem cost lor the waste-
       dewatenng and/or waste storage equipment.  An interest charge of 10 percent  wa^ applied to the capital
       investment for equipment.
    (0 This represents the total annual fee paid by the olectroplater/metal finisher to the contiactor tor collecting,
       hauling,  handling and landfill disposal of the wastes.  The contractor charges for total handling and disposal
       of wastes in Level I, II,  and III Technology landtilli are shown in Table 56.
    (g) The annual processing rates for the 16-man,  i3-'iian and 37-man plants are 770,000,  1, 370,000 and
       4,280,000  m2/yr respectively.
                                                              177

-------
          The centrifuge size was calculated on the basis of a total
operating time of 8 hours per day.  The capacity of the centrifuge required
was as follows:
                  6910
                  8(60)
           = 14.40 liters/min (3.80 gal/min) .
Allowing for a 40 percent oversize for safety, the rating of the centrifuge
unit required is:

                  14.40 (1.40) = 20.16 liters/min (5.33 gal/min) .

Using Figure 12, the estimated capital cost of the centrifuge unit was
$15,000.  The total installed cost of the overall centrifuge system, inclu-
ding piping, pump, etc., was arrived at by applying a factor of 1.3 to the
basic centrifuge unit cost.  The installed cost of the centrifuge system
was:

                  $15,000 x 1.3 = $19,500 .

Similar calculations were made for sizing the centrifuge units required for
the 16-man and 87-man model plants.

          A vacuum filter, or some other type of filter unit could be
employed instead of the centrifuge to dewater the sludge to a 20 percent
solids content.  The equipment costs and operating costs for the filter
units would be closely comparable to those for centrifuges.
Contractor Waste Treatment
and Disposal Costs
          Contractor hauling, treatment, and off-site landfill disposal of
electroplating and metal finishing wastes (destined for disposal on land)
was employed at the three model plants for the three technology levels.
Such contractor treatment and disposal of wastes had been identified as
the prevalent practice in the industry.  The wastes from all four streams
[i.e., water pollution control (WPC) sludge, process wastes, degreaser
sludge, and electroless Ni-bath treatment sludge] were considered poten-
tially hazardous and were handled and disposed of in the same manner.

          The contractor charges for combined hauling, treatment, and
disposal of the wastes, as indicated earlier in this section of the report,
were as shown in the tabulation below:
Technology
  Level
    I
   II
  III
           Disposal
Simple or Municipal Landfill
Approved Landfill
Secured Landfill
Contractor Waste Hauling,
Treatment, and Disposal
	Charge	
 3.6c/liter (13.6c/gal)
 5.0c/liter (19.0c/gal)
 8.2c/liter (31.0e/gal)
The same charge was applied to wastes from the different streams, since the
wastes from all streams were considered potentially hazardous.
                                    178

-------
                         Flow, liters/min
   0    7.6   15.1  22.7  30.2  37.9  45.4  53.0  60.6  68.1   75.7
                            8    10    12
                            Flow, gal/min
14    16
18    20
               FIGURE 12.  CENTRIFUGE CAPACITIES AND COSTS

                           Upper curve shows adjusted costs to
                           December, 1973, using M&S factor of
                           350
                           338
                               = 1.04.
References:  Zievers, J.F., Finisher's Management, Vol. 18, No. 2,
             Feb. 1973, pp. 51-54.

             M&S Equipment Cost Index, Chemical Engineering, Vol. 82,
             No. 3, Feb. 3, 1975, p. 120.

                                   179

-------
Discussion of Model Plant Costs for
Handling and Disposal of Wastes
          The total annual costs for handling [which includes costs for
dewatering of the WPC sludges, storage of the various wastes and sludges
at the electroplating plant site, contractor collection, and hauling and
chemical treatment (if any) of wastes] and contractor disposal of the
model plant wastes in landfills are shown in Column 16 of Table 57 for
Technology Levels I,  II, and III.  The unit cost based on cents per unit
area processed (expressed as cents per m  processed), as given in Column
20, provides a useful means of comparison of waste handling and disposal
costs for the three different sized plants at the three technology levels.
Unit costs for handling and disposal of wastes on a volumetric basis, i.e.,
cents per liter and cents per gallon, are given in Columns 17 and 18,
respectively.  Unit costs for handling and disposal of waste on a weight
basis, i.e., dollars  per metric ton, are given in Column 19.

          Using the model plant data presented in Table 57, the contractor
charges for hauling,  treatment, and disposal of wastes were developed for
converting from costs/unit volume of waste to costs/weight of waste and
costs/area product processed.  The contractor charges for combined hauling,
treatment, and disposal of electroplating and metal finishing wastes for
different technology  levels are summarized in the tabulation below:

                                 Average Contractor Waste Hauling,
                                 Treatment and Disposal Charges	
Technology                                         $/       $/1000 m
  Level        Disposal	  <:/liter   c/gal  metric ton  Processed
    I       Simple or Munici-
            pal Landfill         3.6     13.6     34.30        13.90
   II       Approved  Landfill    5.0     19.0     41.95         5.00
  III       Secured Landfill     8.2     31.0     68.45         8.15
          Summarized estimated costs for treatment and disposal of indivi-
dual and combined stream wastes at three technology levels for the three
different sized electroplating and metal finishing model plants are presented
in Table 58.  This table permits easy comparison of treatment and disposal
costs for particular types of wastes at different technology levels in
different sized plants.

          Plots of the annual costs versus model plant size and the unit
costs per area processes versus plant size for handling and disposing of
the wastes at the three treatment technology levels are shown in Figure 13.
It is readily apparent from Figure 13 or Tables 57 and 58 that the costs
for handling and disposing of the wastes for Level I technology are signi-
ficantly higher than those for Levels II and III for all the model plants.
The reason for this apparent anomaly is the fact that Level I technology
involves the handling and disposal of WPC sludges containing 5 percent
solids as opposed to WPC sludges containing 20 percent solids for Technology
Levels II and III.  Dewatering the sludge from 5 to 20 percent solids
results in a 4.4-fold reduction in the volume of sludge, and accounts for
the significantly lower overall handling and disposal costs for Levels II


                                   130

-------

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o
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181

-------
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                                                                      w
                                                                      o
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                                                                      o
                                                                      w
                                                                      H
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-------
and III.  The Level I costs were greater than the Level II and III costs,
even though the contractor charges for the combined treatment and disposal
of wastes for Level I were 3.6c per liter ($34.30/metric ton or $/1000 m
processes) as opposed to contractor charges of 5.0C per liter ($4L.95/
metric ton or $/1000 m  processed) and 8.2<: per liter ($68.45/metric ton or
$/1000 m  processed) for Levels II and III, respectively.  As expected, the
waste handling and disposal costs for Level II technology were lower than
those for Level III technology, with the cost difference being accounted
for by the higher contractor charge for disposal in a secured landfill.

          The following are generalized comments regarding the costs for
treatment and disposal (T&D) of the individual and combined stream wastes
for different technology levels for different sized model plants  (Tables
43 and 44") :

          A.  WPG Sludge

              (1)  Costs for treatment and disposition of the WPC sludges
                   constituted more than 80 percent of the total  costs
                   for treatment and disposition of combined stream wastes
                   irrespective of treatment technology level or  plant size,

              (2)  For all plant sizes, costs for T&D of WPG sludge were
                   highest for Level I technology, intermediate for Level
                   III, and lowest for Level II.  The reasons for this
                   cost-treatment level pattern were discussed in the
                   preceding paragraph of this report.

              (3)  T&D costs, expressed as $/metric ton, decreased slightly
                   with increased plant size for all technology levels.
                   The lower costs are the result of lower unit costs in
                   the larger plants for handling, dewatering (Levels II
                   and III), and storage of the WPC sludges prior to their
                   being hauled away for treatment and disposal, by a con-
                   tractor.

          B.  Process Wastes

              (1)  T&D costs for process wastes increased with treatment
                   technology level primarily because of the higher costs
                   associated with the disposition of wastes in a secured
                   landfill (Level III) as opposed to disposition ir, an
                   approved landfill (Level II-intermediate cost), or in
                   a simple or municipal landfill (Level I-lowest cost).
                   The bulk density of the process wastes is the same for
                   the three technology levels.

              (2)  T&D costs for process wastes decreased slightly with
                   increased plant size at all technology levels.  The
                   lower costs are attributed to the lower unit  costs in
                   the larger plants for handling and storage of the
                   process wastes prior to their being hauled away for
                   treatment and disposal by a contractor.
                                   183

-------
              (3)  T&D costs for process wastes, irrespective of treatment
                   technology level or plant size, constituted 11 percent
                   or less of the total costs for treatment and disposition
                   of the combined waste streams for a plant.

          C.  Degreaser Sludge

              (1)  T&D costs for degreaser sludge wastes increased with
                   treatment technology level mainly because of the higher
                   costs associated with disposition of the wastes in a
                   secured landfill (Level III)  as opposed to disposition
                   in an approved (Level II) landfill or in a simple or
                   municipal (Level I) landfill.

              (2)  T&D costs for degreaser sludge wastes, irrespective of
                   plant size or technology level, were relatively small
                   and amounted to about 4 percent or less of the total
                   costs for treatment and disposition of the combined
                   stream wastes.

          D.  Electroless Nickel Sludge

              (1)  T&D costs for electroless nickel sludge increased with
                   treatment technology level primarily because of the
                   higher costs associated with disposition of the sludge
                   in the higher level landfills.

              (2)  T&D costs for the electroless nickel sludge, irrespective
                   of treatment technology level or plant size, amounted
                   to less than 9 percent of the total costs for treatment
                   of the combined stream wastes from any of the plants.

          E.  Combined Streams

              (1)  For all plant sizes, costs for T&D of the wastes from
                   the combined streams were highest for Level I technology,
                   intermediate for Level III, and lowest for Level II.
                   T&D costs for the WPG sludge stream account for 80
                   percent or more of the costs for treatment and disposi-
                   tion of the combined stream wastes in any of the plants,
                   so that comments made above under (A) for WPC sludge
                   costs also generally apply to the costs for the combined
                   stream wastes.

          As indicated above, because of the significantly larger volumes
of waste generated in the water pollution control (WPC) stream in comparison
to the other waste streams, the costs for handling and disposing of the WPC
sludge ranged from about 80 to 93 percent of the costs for the combined
waste streams irrespective of treatment technology level.  Accordingly, the
use of in-process controls, such as save rinses, or the use of techniques
such as evaporation, reverse osmosis, or ion exchange for the recovery of
dragout chemicals, offers the most promise for reducing the quantity of
sludge and thereby cutting the costs related to the treatment and disposal
of the WPC sludges at all treatment levels.
                                      184

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                  National Costs  for Treatment and Disposal
            of Electroplating and Metal Finishing Wastes  for  1975
          The projected quantities of the various wastes  (destined  for
land disposal) to be generated nationally in the different plant  size
categories for 1975 are presented in Table 59.  The quantity of waste in
the 16-tnan plant category includes those facilities having 4 to 25
employees; the 38-man plant is representative of plants having 26 to 50
employees; and the 87-man plant covers plants with more than 50 employees.

          The annual cost data for the treatment and disposal of  the various
waste streams in the model plants for the three technology levels,  as
presented in Table 43, were used in conjunction with the waste stream load
data to determine the unit costs for the treatment and disposal of  wastes
in each plant-size category, as shown in Table 44, Columns 4, 5,  and 6.
Multiplying the unit-cost (expressed in $/metric ton of waste as  indicated
in Footnote (d) of Table 59) values in Column 6 by the projected  quantity
of waste shown in Column 3 gives the national cost for the treatment and
disposal of that particular waste in all U. S. plants in that size  category
for a particular technology level.

          The total costs for the treatment and disposal, at the  three
technology levels, of WPG sludges, process wastes, degreaser sludges, and
electroless nickel sludges for all U. S. job shops for 1975 are shown on
an individual-stream and combined-stream basis at the bottom right  of
Table 59.  The costs were highest for the Level I technology, intermediate
for Level III technology, and lowest for Level II technology.  The  reasons
for this cost-technology level pattern are the same as those that had been
presented and discussed in the previous subsection of the report entitled
"Discussion of Model Plant Costs for Handling and Disposal of Wastes".

          In the "Economics Characteristics" subsection in the "Industry
Characterization" section of this report, it was indicated that the value
added in the electroplating and metal finishing industry (job shops) was
$749,100,000 for 1972."  Assuming an inflation value of six percent to
convert the 1972 value to December, 1973, dollars, the value-added  figure
becomes $794,000,000.  The ratios of waste treatment and disposal costs
at the different technology levels to the value-added statistic for the
industry range from 1.83 to 2.60 percent for 1975 (Table 60).**  The signi-
ficantly lower ratio value of 1.83 percent for Level II technology  as opposed
to 2.60 percent for Level I technology results from the fact that the amount
of WPG sludge hauled away for disposal in Level II technology is markedly
less than for Level 1 technology.  This is primarily because the WPG sludge
is dewatered to a solids content of 2.0 percent in Level II technology as
opposed to a solids content of 5 percent for Level I technology, which
significantly lowers handling and disposal costs for Level II technology.
The ratio value for Level III technology is 2.26 percent,  which is  inter-
mediate between the ratio for Level I and Level III technologies.   Although
Level III technology employs dewatering the WPC sludge to the same  solids
content as Level II technology,  the higher costs of overall treatment and
    "Economic Analysis of Effluent Guidelines - The Metal Finishing Indus-
    try", EPA 230/1-74-032, September, 1974, page VI-8.
    For this calculation, it was assumed that the production data for 1975
    were similar to  those for 1972 for which value-added data were available.
                                   185

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            TABLE 60.   COMPARISON OF WASTE TREATMENT AND DISPOSAL
                       COSTS  TO VALUE  ADDED STATISTIC FOR THE
                       ELECTROPLATING  AND METAL FINISHING INDUSTRY
                       FOR DIFFERENT TREATMENT TECHNOLOGY LEVELS(a)


Annual
Value Added
Statistic,
Year dollars
1975(a) 794,000,000
794,000,000
794,000,000

National
Waste
Treatment
and
Disposal Cost,
dollars /year
20,628,000
14,506,000
17,982,000


Treatment
Technology
Level
Level
I
II
III
Ratio of Waste
Treatment and
Disposal Costs
to Value Added
Statistic Ex-
pressed as a
Precentage
Value , percent
2.60
1.83
2.26
(a)   Costs are expressed in terms of constant December,  1973,  dollars.
                                  189

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disposal for Level III technology over Level  II  technology  arise  from the
higher cost of using o secured landfill  for L':v,,Te]  IIT  as  opposed  to a less
costly approved landfill ror Level II..   The above  rat Jus  of waste treatment
and disposal cost fo value added sho*w' that the waste  '-reatmerit  and disposal
cost constitutes an important segment of the  overall  production costs in
the electroplating and metal finishing industry.
                                 190

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                                APPENDIX A

                   METHODOLOGY FOR ACQUIRING INFORMATION


          For many years Battelle has worked with the electroplating and
metal finishing industries in the development and improvement of electro-
plating techniques and in the assessment of environmental control technology,
Much of the information acquired during those past studies was available for
the current investigation of hazardous waste management practices.(a.ajbb,cc;
As a preliminary step in the acquisition and analysis of the data, this
initial data base was reviewed and the pertinent information from it has
been included.

          However, from the beginning of the study, the need for much more
detailed data was recognized and steps were taken to procure these data.
The first such step was to seek the cooperation and involvement of the
appropriate industrial organizations.  Both the U.S. Environmental Protec-
tion Agency and Battelle had approached these organizations prior to the
beginning of the study and were assured of their intent to cooperate.


                             Industry Survey


          Following the award of the contract, a meeting was held on
August 1, 1974, with the following trade associations to develop a method
for interaction and data acquisition:  the National Association of Metal
Finishers (NAMF), the American Electroplater's Society (AES), the Metal
Finishers Suppliers' Association (MFSR), and the Institute of Printed
Circuits (IPC).  One of the objectives of that meeting was to review a
draft data-acquisition form which had been developed by Battelle for the
survey of the  industry.  During the meeting it was agreed that the data-
acquisition form should be revised and field tested before it was mailed.
It also was agreed that the NAMF would mail out the data-acquisition form
to provide the broadest possible coverage of the entire electroplating
and metal finishing industries.

          The mechanism of the industry survey consisted of mailing about
7,000 of the data-acquisition forms shown in Figure A-l by NAMF through the
Association's  headquarters office; the return of the completed questionnaire
to that office; the removal of identifying information; the attachment of
a code number; and the forwarding of anonymous information to BCL.  The
mailing list used was known only to the NAMF office.

          Battelle received 131 forms, 24 of which were marked "no plating
done".  Of the remaining 107 forms, 79 were from job shops, 26 were from
captive shops, and two were from shops which classified themselves as both.
Of the 107 forms, 38 reported no wastes or gave no etitry on the form.  Of
the 69 forms containing entries dealing with wastes, the entries varied in
detail from only the. name and the source of the waste to detailed presen-
tations of quantities and analyses.  Most respondents gave some information

                                   A-l

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                 SOLID WASTE DISPOSAL OUliSTIONNAIRG
Company Name
Address 	
Telephone I  >.
Code No.  	
          (Code Number to be filled in by NAMF)


Thus page will be kept by the NAMF, and will not be given to the Environmental Pro-
tection Agency or the contractor working for the EPA.
The following questions are directed at obtaining information on
     (1)  Wastes from electroplating or metal-finishing op^ra.'ons.
     (2)  Waste-  destined for disposal on  land (for example, sludges) not
          including ordinary paper and trash.
Tills questionnaire  is being sent to both job shops and captive shops. Only those wastes
from cleaning, electroplating, acid treatments, and similar processes are considered here.
Wastes from painting, lacq-'ering, or other ogranic coatinr processes are not in  "uded.
Disposal Contractors Used

Name        	   	
Address      	
Service	
Type of Waste	
                   FIGURE A-l.   NAMF  QUESTIONNAIRE
          (NOTE: THIS FORM TO BE RETAINED BY NAMF OFFICES)
                                    A-2

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CONFIDENTIAL   'I HIS IS 1RADF. SIX/UKI INFORMATION - CONFIDF.N 11 \L
             Qucslioniiairc Code Number	(by NAMF)
             Geographical Location	
             State	
Plant Operations and Charactcnstics
   Type of Plant:   Job Shop	  	Captive	
   Your Standard Indu  ual  Classification (if known) SIC No	
   Number of Employees: Total Plant	Metal Finishing Production	
Production Char,  eristics
Type of Process: (Plcai.e check as many as apply)
   Electroplating	   Phosphating	  Hot Dipping	
   Anodi/.ing	   Bright Dipping	  Debarring	
   Electrolcss Plating	    Chemical Polishing	  Passivating_
   Chromating	    Dying	Lead Stripping.
•Metals Deposited	
Metals and Materials Purchased Monthly for Metal Finishing and Electroplating (please
list in pounds/month or gallons/month)
Metal Anode..                               Metal Salts or Oxides
   Copper	
   Zinc	
   Chromium.
   Nickel	
   Tin	
   Cadmium	Acids, Solvents, Alkaline Cleaners	
   Lead	
Other	
Total Volume of Sales of Plating Facility, dollars per month.
Power Consume .1 Monthly for Metal Finishing	
Installed Rectifier Capacity.	Average Operating Level, % of Rated,
Estimated Square Feet Plated Monthly	
Plant Operating Rate	Hrs/day	days/week
Age of Tlating Plant Equipment (Range or Average)	
     Metal Finishing Production	
      Metal Finishing Waste Trcatment_
Types of Other Operations on Plant Site_
                                         A-3

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Pic.ise j'.ivc itil'.tim.ilion mi ;i|| imlir.t i i.il w.rli's hoin yum dci liopLiliin1, pi,ml I)I'.SI IN'I',1)
K)K DISPOSAL ON LAND, hut not including p.ipei ;IIH! genual Irish. Tins will most
likely include information on sludges from wnler ticatmcnt, sludges 1'iom sumps, waMC
or spent chemicals, spent solvents, used abrasives, fi'  >r aides, baglio.  e dusts, or other
wastes wlu'ch would be disposed of in a landfill or du.np.
Type of Waste
(sludge, dust .spent
 chemicals, or other)
1.
2.
3.
4.
Source
(water pollution control,
 air pollution control,
 finishing, plating, or
 other)
Quantity*
(gallons/day —
 pounds/month)
   If a sludge, please indicate wet or dry basis, or, if wet, percent solids.
Please indicate any planned or estimated changes in wastes from electroplating or metal
finishing destined for land disposal in the future.
Will there be new or increased amounts of sludges from water treatment because of
water pollution con'rol regulations? (Scheduled for 1977 and 1983)
                    Yes	No	
If   'ssible, please give estimates of industrial wastes destined for land disposal in 1977
and 1983.
                          Estimated Futu-e Waste, in 1977
 3.
 4.
      of Waste
 Source
Quantity (Pk-ase indicate
amount if possible, or
more or less, or same)
 Please indicate if possible, the reason for any change in amount of sludges or other
 wastes to be disposed of (for exa;;>ple, water pollution control, increased production,
 process changes, or recycle of waste)	
                                          A-4

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                        Estimated Future W;istcs in I9S3

                                                      General Intimate
Type of Waste              Source                     Quantity (More, less. \.r £j
1.	  .	
2.	
3. 	  	  	
4.	  	

If changes in quantities of wastes from electroplating or metal finishing destined for
land disposal are expected, what is the reason for the change? For example:  increased
production, installation of water j -llution control equipment, installation of sludge
drying equipment, etc.
                                          A-5

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C'luractciislKx ol  .ill ii .!i>-iti.il Wash's limn Hei.ltl.iliii|', .mil Mclal Fin: .Inn);
Destined for l,;iiul Disposal (except misa'llaneons liasli). I'leasc use lolloping sliccts
and indic.iic what is known, concentrations, present, absent, not analyzed, or esti-
mated ranges (each column is  for a different waste).
                        Characteristics of Wastes (Present)
Type of Waste
Source of Waste*
Units of Concentration
   (wt 7o, mg/l,ppm)
   Asbestos
   Arsenic
   Beryllium
   Cadmium
   Calcium
   Chiormum(+6)
   Cluomium (total)
   Copper
   Cyanide
   Iron
   Lead
   Magnesium
   Mercury
   Nickel
   Selenium
   Zinc
   Other Metals
   Solvents
    Cleaners
      Phosphates         	   		
      Sulfates	   	      	  	
      Oils & Greases      	   	   	  	
      Soaps	   	  	
      Water Content      	   	   	  	
  * Examples of Sources of Waste would be waste-water treatment plant, sludge drier,
  some particular sump, etc.
                                       A-6

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Please indicate cliaiaeteiistics of wastes from electroplating .11 id metal limshing des-
tined for disposal on land expected in 1977 (i_ach column is for a sep.irjtc w.iste).
If concentrations cannot be predicted, indicate as present, absent, major, minor etc.
Type of waste            	   	   	   	
Source of Waste*         	   	   	   	
Units of Concentration   	   	   	   	
   (wt %, mg/l,ppm)
   Asbestos              		
   Arsenic               	   	   	   	
   Beryllium            	   	   	   	
   Cadmium             	   	   	   	
   Calcium              	   	   	   	
   Chromium (+6)        	   	   	   	
   Chromium (total)      	   	   	   	
   Copper               	   	   	   	
   Cyanide	   	
   Iron                  	   	   	   	
   Lead		
   Magnesium            	   		
   Mercury	
   Nickel               	   		
   Selenium             		
   Zinc                 	   		
   Other Metals
   Solvents
   Cleaners
     Phosphates         		
     Sulphates          	   		
     Oils & Grease       	   		
     Soaps              		
     Water Content      	   		
   Examples of Sources of Waste would be waste-water treatment plant, sludge drier,
   some particular sump, etc.
                                      A-7

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                       Characteristics of Wastes (1983)
Type of Waste
Source of Waste *
Units of Concentration
  (wt %, mg/l,ppm)
  Asbestos
  Arsenic
  Beryllium
  Cadmium
  Calcium
  Chromium (+6)
  Chromium (total)
  Copper
  Cyanide
  Iron
  Lead
  Magnesium
  Mercury
  Nickel
  Selenium
  Zinc
  Other Metals
   Solvents
   Cleaners
     Phosphates
     Sulfates
     Oils & Grease
     Soap5;
     Water Content
   Examples of Sources  of Waste would be waste-water trc. tment j hnt, sludge drier,
   some paiticular sump, etc.
                                       A-8

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  I'lc.isc i'ln.'i'l\ nil I) Links ;i|>jt!u';ilik' lo W.r.li1:. lioin IK-i. ln>|>l.iliii[- <>i Mcl.il 1 u
                  Waste Treat menIs Now Used Ik-fore Disposal
                         on Land or to As .-id Dumping
Sludae
Dewater.
   Filter
   Incineration  	
Encapsulate   	
Fixed in Cement 	
Recovery and Reuse
Other (specify)  	
Waste Dusts
Incineration   _
Open Burning _
Bag or Package_
Other (Specify),
Waste Ashes (from inciner-
ation)
Package (Bag or Drum)	
Other (specify)  	
Method of Disposal (please check all blanks applicable)
Type of Waste	
Source of Waste          	   	
On-Site Disposal         	   	
Off-Site Disposal         	   	
Company o\ ned Off-Site	
Sewer	
Lagoon                 	   	
Open Dump	
Mine Disposal           	   	
Covered Liiid Fill	
Hauled by your truck     	   	
Hauled by contractor     	   	
Incinerator              	   	
Deep Well Injection       	   	
Recovery and Reuse	
Sale                    	   	
Municipal Dump         	   	
Other (specify)          	   	
Liquids
Organic
   Reclaim
   To Reclaimer .
   To Wastewater
     Treatment
   Incineration
Inorganic   	
   To Reclaimer	
   To Wastewater
     Treatment .
Recovery and
   Reuse   	
                                         A-9

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                                   COSTS
Please provide iiiforiiuitioii on cosls associated with the treatment or disposal ot solid or
other wastes DLST1NLD FOR LAND DISPOSAL. The information sought would prob-
ably include such things as sludge driers, incinerators, private sludge lagoons, etc. Costs
of water pollution control equipment arc NOT being sought.
Cost for Contractor Disposal Service (including sludge removal costs but not paper or
   general trash)
   Cost Basis (cents per gallon, dollars per ton, etc.)	
   Monthly Costs, dollars per month	
Costs for Waste Treatment Equipment (for example, sludge driers, lagoons, etc.)
   Type of Equipment	
   Type of Waste Treated.
(a)    Capital Imestment Costs*                 Year Costs Incurred
      Design Costs  		
      Purchase of land and materials  		
      Site preparation  		
      Construction and installation (includes equipment) ..	
      Start-up Costs		
      Losses due to downtime (product,,-n halts during installation)
      Total Capital Costs  		
      Debt/Equity Ratio**		
      Purchase or Truck(s)		
(b)   Operating Costs                          Year of cost figures*   	
      Cost of Capital***   		
        Interest rate applied _ 	
      Maintenance
      Labor   		
      M...  ,:s   		
        Chemicals  		
        Replacement parts  		
      Testing and Analysis		
      Insurances  		
      Taxes   	 	
      Administrative Costs  		
      Energy' and Power Costs   	 	
      Truck Fuel Costs	 	
      Total Operating Costs 	  	
                                           A-10

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(c)   Savings
     Productivity increases (crcdii "i  	
     Revenues on by-products or recycle savings
(d)   Net Operating Costs	
(e)   Estimated equipment life expectancy	
     Depreciation Scheme Used	
      Length of time for depreciation	years
(f)    Total solid-waste trt  • ment and disposal costs as percentage of total costs of the
      electroplating and metals-finishing costs	
*     1973 cost figures are prefera 1 or indicate year of investment.
**    Debt — amount of money borrowcd/equity=total amount of money invested.
***   Financ 1 charges whic?1 are computed as the cost of capital times the capital
      expenditures.  The cost of capital should be bai -d upon a weighted averag  of
      the separate costs of debt and equity.
              Would you be w:"ing to receive a plant
              visit by the contractor personnel
                   Yes  	 No
              If "Yes" please supply:
              Comp:v.y Name
              Address 	
              Telephone Number
             Person To Be Contacted
                                        A-ll

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on the number of employees, etc., relative to the industry characterization.
However, in many cases the responses were not sufficiently consistent to
allow correlation of the activities or rationalization of units.
          Survey of Private Contractors and Service Organizations
Identification of Contractors,
Services, Costs,  and Disposal Methods


          The identification of waste treatment and disposal contractors
and service organizations, the services provided, the service costs, and
the treatment and disposal methods employed often required direct contact
with these organizations, in addition to analysis of the industry data and
data from the report "An Inventory of Hazardous Management Facilities"
(IHWMF).  To obtain more complete contractor information, a telephone
survey was conducted.  The survey questions were patterned after the
facilities' resume" found in the IHWMF report plus questions regarding the
acceptability of a plant visit by program personnel.  Plants included in
the IHWMF report which were contacted were asked to verify the accuracy
and update the data previously provided.  A copy of the data-acquisition
forms used during the telephone survey is included in this report as
Figure A-2.  Time made it necessary to limit the total number of contacts
to those facilities likely to provide the most relevant information.
This was accomplished by applying a screening or selection criterion to
potential contacts.

          Early in the program, before responses to the NAMF data acqui-
sition forms came in, the only source of information was the IHWMF report.
The 65 facilities covered in this report received the bulk of the initial
investigative effort.  All treatment and disposal contractors listed in the
IHWMF report which met the following criteria were contacted by telephone
(or contact was attempted):

          •  The  plant site had  not  been previously  visited  by
             another  HWMD contractor.

          •  Wastes accepted  fell  into  the  range of  waste materials
             typically  produced  in electroplating and  metal  finishing
             operations  (e.g.,  heavy metals in solution or in sludges,
             cyanide  wastes,  acids,  caustics,  solvents, chlorinated
             hydrocarbon degreasers, and alkaline cleaners.)

          As the project progressed, the names of an additional 42 treat-
ment and disposal contractors from  the indistry response  (NAMF data acqui-
sition form) became available.  All contractors handling potentially
hazardous wastes who were identified before January 13, 1975, were contacted
(or contact was attempted); later,  a one-page follow-up form (See Figure
A-3) was sent to 23 NAMF contacts to obtain additional information.
                                   A-12

-------
                Solid Waste Disposal Questionnaire
Company Name

Address

Telephone No.
The following questions are directed at obtaining information on

          (1)  Wastes from electroplating or metal-
               finishing operations

          (2)  Wastes destined for disposal on land
               (for example, sludges) not including
               ordinary paper and trash.

This questionnaire is being sent to both job shops and captive shops.
Only those wastes from cleaning, electroplating, acid treatments, and
similar processes are considered here.

Wastes from painting, lacquering, or other organic coating processes
are not included.
              FIGURE A-2.  DATA ACQUISITION FORM USED IN BCL
                          TELEPHONE SURVEY
                                 A-13

-------
Would you be willing to receive a plant
visit by the contractor personnel
   Yes              No
If "Yes" please supply:
Company Name
Address
Telephone Number
Person To Be Contacted
                    A-14

-------
                   Geographical Location_
                   State           	
 Plant Operations and Characteristics
  Type of Plant:  Job Shop	Captive_
  Your Standard Industrial Classification  (if known) SIC No.
  Number of Employees:  Total Plant	 Metal Finishing Production
.Production Characteristics
Type of Process:   (Please check as many as apply)
  Electroplating	 Phosphating	Hot Dipping	
  Anodizing	Bright Dipping	Deburring	
  Electroless Plating	 Chemical Polishing      Passivating	
  Chromating	Dying	lead Stripping	
Metals Deposited	
Metals and Materials Purchased Monthly for Metal Finishing and Electroplating
(please list in pounds/month or gallons/month)
Metal Anodes                            Metal Salts or Oxides
  Copper		
  Zinc
  Chromium_
  Nickel	
  Tin
  Cadmium	Acids, Solvents, Alkaline Cleaners_
  Lead	:	     	
Other
Total Volume of Sales of Plating Facility, dollars per month_
Power Consumed Monthly for Metal Finishing	
Installed Rectifier Capacity	Average Operating Level, 7. of Rated_
Estimated Square Feet Plated Monthly	
Plant Operating Rate	hrs/day	days/week
Age of Plating Plant Equipment (Range or Average)	
     Metal Finishing Production	
     Metal Finishing Waste Treatment_
Types of Other Operations on Plant Site_
                                    A-15

-------
Please give information on all industrial wastes from your electroplating

plant DESTINED FOR DISPOSAL ON LAND,  but not including paper and general trash.

This will most likely include information on sludges from water treatment,

sludges from sumps, waste or spent chemicals, spend solvents, used abrasives,

filter aides, baghouse dusts, or other wastes which would be disposed of in a

landfill or dump.
Type of Waste
(sludge, dust, spent
chemicals, or other)
1..
2..
3.
Source
(water pollution
control, air pollution
control, finishing,
plating, or other)
Quantity*
(gallons/day •
pounds/month)
4.
*  If a sludge, please indicate wet or dry basis,  or,  if wet,  percent solids
                                   A-16

-------
Please indicate any planned or estimated changes in wastes from electroplat
or metal finishing destined for land disposal in the future.
Will there be new or increased amounts of sludges from water treatment
because of water pollution control regulations? (Scheduled for 1977 and
1983)  Yes	  No	
If possible, please give estimates of industrial wastes destined for
land disposal in 1977 and 1983.
                    Estimated Future Wastes in 1977

Type of Waste                    Source                Quantity (Please indj
                                                       amount if possible, c
                                                       more or less, or same
1..
2..
3..
4.
Please indicate if possible, the reason for any change in amount of sludges
or other wastes to be disposed of (for example, water pollution control,
increased production, process changes, or recycle of waste)	
                                 A-17

-------
                     Estimated Future Wastes In 1983
                                                       General Estimate
Type of Waste                  Source                  Quantity (More,  Less,Same)
1.	           	      	
2.
3..
A.
If changes in quantities of wastes from electroplating or metai. xj.nishing
destined for land disposal are expected, what is the reason for the change?
For example:  increased production, installation of water pollution control
equipment, installation of sludge drying equipment, etc.
                                A-18

-------
Characteristics of all Industrial Wastes from Electroplating and Metal Finishing
Destined for Land Disposal (except miscellaneous trash).  Please use following
sheets and indicate what is known, concentrations,  present,  absent,  not analyzed,
or estimated ranges (each column Is for a different waste).
                       Characteristics of Wastes (Present)
Type of Waste            	  	  	  	
               *
Source of Waste          	  	  	  	
Units of Concentration
  (wt %, ng/1, ppm)
  Asbestos
  Arsenic
  Beryllium
  Cadmium
  Calcium
  Chromium (+6)
  Chromium (total)
  Copper
  Cyanide
  Iron
  Lead
  Magnesium
  Mercury
  Nickel
  Selenium
  Zinc
  Other Metals
  Solvents
  Cleaners
     Phosphates          	  	  	  	
     Sulfates            	  	  	  	
     Oils & Crease       	  	  	  	
     Soaps               	  	  	  .	.
     Water Content       	      .-,...    ____________	
 *  Examples of Sources of Waste would be wastewater treatment  plant, sludge drier,
    somo particular sunm.  otr.
                                         A-19

-------
                                       8
                           Characteristics  of Wastes  (1977)
 Please indicate characteristics  of wastes  from electroplating and metal finishing
 destined for disposal  on land  expected  in  1977 (each column  is for a separate
 waste).  If concentrations cannot be  predicted, indicate as  present, absent,
 major, minor, etc,
 Type of Waste            	  	  	  	
•Source of Waste          	  	
 Units of Concentration
   (wt 2, mg/1, ppm)
   Asbestos
   Arsenic
   Beryllium
   Cadmiuni
   Calcium
   Chromium (+6)
   Chromium (total)
   Copper
   Cyanide
   Iron
   Lead
   Magnesium
   Mercury
   Kickel
   Selenium
   Zinc
   Other Metals
   Solvents
   Cleaners
      Phosphates
      Sulfates
      Oils & Crease
      Soaps
      Water Content
 *  Examples of Sources  of U';istc would  be waste-water treatment, plant,  sludge drier,
    some particular sump,  etc.
                                       A-20

-------
                                      9

                         Characteristics of Wastes  (1983)
Type of Waste
               *
Source of Waste
Units of Concentration
  (wt 7., mg/1, ppm)
  Asbestos
  Arsenic
  Beryllius
  Cadmium
  Calcium
  Chromium (+6)
  Chromium (total)
  Copper
  Cyanide
  Iron
  Lead
  Hagnesiun
  Mercury
  Rlckei
  Selenium
  Zinc
  Other Metals
  Solvents
   Cleaners
     Phosphates
     Sulfates
     Oils & Crease
     Soaps
     Water Content
*  Examples of Sources of Waste would be waste-water treatment plant, sludyc drier,
   some particular sump, etc.
                                       A-21

-------
                                        10
   Please check all blanks applicable to Wastes from Electroplating or Metal Finishing

                      Waste Treatments Now Used Before Disposal
                             on Land or to Avoid Damping
  Dewater
                               Waste Dusts
                               Incineration
                            Organic_
    Filter
    Incineration,
  Encapsulate	
Open Burning	
Bag or Package	
Other (Specify),
                                                             Reclaim
  Fixed  in  Cement
  Recovery  and Reuse_
  Other  (specify)	
Waste Ashes.(from inciner-
atisra)
Package  (Bag or Drum)	
Other (specify	
  To Reclaimer	
  To Wastewater
    Treatment	
  Incineration,
Inorgan ic	
Method of Disposal (please  check all  blanks  applicable)
                                                             To Reclaimer	
                                                             To Wastewater
                                                               Treatment	
                                                             Recovery  and
                                                               Reuse
Type of Waste	
Source of Waste              __,	
On-Site Disposal             	-
Off-Sitp. Disposal	
Company owned Off-Site	
Sewer                        	
Lagoon                       •—•	
Open Dump                             ••
Mine Disposal                	
Covered Land Fill            	
Hauled by your truck         	
Hauled by contractor         	
Incineration	
Deep Well  Injection          	
Recovery and Reuse           ____——
Sale                         	
Municipal  Dump               	
Other(spccify)               —	
*  Please supply information  on page 11
                                         A-22

-------
                               11
Disposal Contractors Useo






Name           	




Address        	




Service        	




Type of Waste  	
                               A-23

-------
                                       12
                                        COSTS
Please provide information on costs associated with the treatment or disposal of
Solid or other wastes DESTINED FOR LAND DISPOSAL.  The information sought would
probably include such things as sludge driers, incinerators,  private sludge
lagoons, etc. Costs of water pollution contol equipment are NOT being sought.
Cost for Contractor Disposal Service (including sludge removal costs but not
  paper or general trash)
  Cost Basis (cents per gallon, dollars per ton, etc.j	
  Monthly Costs, dollars per month	
Costs for Waste Treatment Equipment (for example,  sludge driers, lagoons, etc.)
  Type of Equipment	
  Type of Haste Treated	
(a) Capital Investment Costs"                   Year Costs incurred	
    Design Costs	
    Purchase of land and materials 	
    Site preparation	.	
    Construction and installation (includes equipment)
    Start-up Costs 	  .....
    Losses due to downtime (production halts during installation)_
    Total Capital Costs		
                      **
    Debt/Equity Ratio    	  	
    Purchase of Truck(s)  	  	
(b) Operating Costs                        Year of cost figures*
                   ***
    Cost of Capital      		
      Interest rate applied
    Maintenance
    Labor  	
    Materials  	
      Chemicals  	
      Replacement parts  .  .
    Testing and Analysis .  .
    Insurances 	
    Taxes  	
    Administrative Costs .  .
    Energy and Power Costs  .
    Truck Fuel Costs   . .  .
    Total Operating Costs  .
                                  A-24

-------
                                      CODE  # 	
                                    Questions  Concerning
                              Wastes Destined  for  Land Disposal
 1.   Job  Shop 	                       2.  Captive Shop

 3.   Metal  Finishing Processes Operated 	
 4.   Metals Deposited by Electroplating
 5.   Number  of Production Workers in Metal Finishing
 6,   Do you  treat wastewater before discharge?     Yes 	  No

     a.  If  yes, describe type of treatment   .	
 7.   Do  you  discharge wastewater to a sewer?       Yes 	  No

     a.   If  yes, where does sewer go? 	
                                                            Other Process
                                                            Wastes  (Dusts,    Spent Baths,
                                                            Abrasives,        Concentrated
                                             Solvents        Anode Bags, etc)  Solutions
 8.   Quantity/Month

 9.   Disposal Method

     a.   Sewer

     b.   Contractor/Hauler

     c.   Lagoon

     d.   Landfill

     e.   Reclaimer

     f.   General Trash
10.  Disposal  Cost per Month
     (include  sewer charges, if paid)
     a.   Sewer  costs

     b.   Hauling Costs
11.   Please  attach a copy of available data on analysis  of  sludges and name the chemicals
     in the  wastes listed above (solvents,  etc)  or describe classification as to origin
     and frequency below.	
                  FIGURE A-3.   FOLLOW-UP  TELEPHONE  QUESTIONNAIRE
                                          A-25

-------
          Telephone Survey.  The selected treatment and disposal contractors
were contacted by telephone over a period of 5 weeks.  The IHWMF- and
industry-identified sources dominated the list of attempted contacts.
Attempts were made to contact all 25 IHWMF-identified companies meeting
the selection criteria; 23 plants were contacted, 16 agreed to permit a
visit by contractor personnel, and 7 of the latter were visited.

          On the returned NAMF data acquisition forms, as originally
received by the contractor, the name of the electroplater or metal finisher
supplying data was removed (as agreed).  However, the name of the waste
contractor was also removed.   Upon written request to the NAMF this con-
tractor information was supplied to the program.  As the names and addresses
of contractors were received, they were screened and selected facilities
were contacted (or contact was attempted).   The names of 26 industry-
identified comparies were eventually received (including the names of 5
companies for which there was insufficient information to make a contact) ;
Battelle representatives attempted to contact 11 companies but of these
companies 4 agreed to a visit, and 2 were visited.  The other 15 companies
were not contacted because the industry survey was received late in the
program.  However, through the one-page NAMF follow-up questionnaire, 13
additional waste contractors were identified and one site was visited.
Industry contacts with electroplaters and waste contractors identified 2
additional treatment and/or disposal operations.  Both of the latter were
contacted; one agreed to a visit and was visited.

          The results of the telephone survey plus other information
obtained on identified treatment and disposal contractors are presented in
Table A-l.  The information identified for each plant was divided into
The information identified for each plant was divided into four areas:
(1) services provided (hauling, treatment, and/or disposal), (2) type of
wastes handled (sludge, liquids, solids), (3) service costs, and (4)
ultimate disposal method.
                                    A-26

-------
                                    TABLE A-1.  INFORMATION ON PRIVATE CONTRACTORS WHO
Contact Summary
Company
Number
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Identi-
fication
EPA Source
Region Number'8' Company Name
I 1
Mil 1
IV
II 1
III 1
III, V, 1
IX
III 1
IV, VI 1
V 1
V, VII 1.2
V 1,2
V 1,2
V 1.2
V 1
V 1
V 1
V 1
V 1
VI 1
VI 1
IX 1
IX 1
IX 1
Crago Company, Inc.
Rollins Environmental
Services
Recyclind Laboratories
American Recovery Corp.
Nuclear Engineering Co.
Chem-Fix, Inc.
Petrolite Corporation
Hyon Waste Management
Services, Inc.
Conservation Chemical Co.
Approved Chemical
Treatment, Inc.
Environmental Waste
Control, Inc.
Nelson Chemical Company
Erieway Pollution
Control, Inc.
Koski Construction Co.
Systech
Rogers Laboratories
Waste Research & Recla-
mation Co., Inc.
U. S. Pollution Control,
Inc.
BioEcology Systems, Inc.
Casmalia Disposal Site
Chancellor & Ogden, Inc.
Richmond Sanitary
Services
Contact
Attempted
by BCL
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Company
Contact Response to
Made by Visit Request
BCL
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Ye
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
Yes
BCL



Yes(c)
Yes(c)
Yes
No
Yes
No
Yes(e)
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
Yes
Yes(c>

(c)
EPA



Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes

Yes
Yes
No
No
Yes
No


Company
Visited
No
No
No
No
No
No
No
No
Yes
Yes
No
No
Yes
Yes
Yes
No
No
No
Yes
Yes
No
No
23
                         Wes Con, Inc.
Yes
       Yes
                                                                       Yes
                                                                               No
                                          A-27

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HANDLE ELECTROPLATING AND METAL FINISHING WASTES
Type of Operation
Haul
Yes
Yes
Yes
Yes
Yes
No
No
No
No
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
No
No
Yes
Yes
No
Treat
No
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
Dispose

Yes
Yes
Yes
Yes
No
Yes
Yes
Yes
Yes
No
No
Yes
Yes
Mo
No
No
Yes
Yes
Yes
Yes
Yes
Yes
Wsste Types
Hauled, Treated,
or Disposed
Sludges
H-T
H-T-D
H-T-D
H-T-D
H-D
T
T-D
T-D
T-D
H-T-D

H-T
T-D
H-T-D


D
D
T-D
H-D
H-D
D
Liquids
H-T
H-T-D
H-T-D
H-T-D
H-D
T
T-D
T-D
T-D
H-T-D
H
H-T
H-T-D
H-T-d
T
H-T
H-T
H-T-D
H-T-D
T-D
H-D
H-D
D
Service Cost Ultimate Type of
Treatment and Disposal Facility
Hauling Disposal Combiner' Landfill Other-Specify

1^/gal/ 10-20tf/ga! x Incineration
100 mi
Incineration
x Lagoon
$1/mi/ $1.25/ft^ x Land burial
truck
4d/gal Land cover
^194/gal x Deep-well injection
3-7d/gal ' x
3d/gal x Deep-well injection'd'
CN--10d/gal
10-20d/gal x
Sewer
$1 .20/lb CN- x Sewer
16d/lbCrO3
x Chemical solidification
landfill cover
Lagoon
$2.50/lb CN~ Piped to city water
$1 .25/lb Cr+6 treatment plant
+ 5
-------
                                                                                              TABLE A-1.
Contact Summary
Company
Number
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
EPA
Region
X
X
I
II
III
V
V
V
V
V
V
V
V
VI
IX
IX
IX
IX


III
IV
Identi-
fication
Source
Number'3'
1
1
2
2
2
2
2
2
2
2
2
4
3
4
2
2
2
3,1
2
2
2
2
Company Name
Resource Recovery Corp.
Westerh Processing Co.
Environmental Waste
Removal, Inc.
Gcariello
Jimon Wrecking Co.
Interstate Pollution
Control
Pollution Corporation
of America'9'
Frinks Sewer Service
Peter Wallin Company
Summit National Services
Valentine Disposal
Warren County Solid
Waste Authority
Ohio Sanitation
Systems, Inc.
Industrial Wastes Sonics
International Corp.
Oscar Erickson
J. & M. Filtering
Capri Pumping Service
Industrial Tank, Inc.
Pats Carting (NAMF-163)
Smithen Sanitation
(NAMF-629)
Bradford Sewerage Works
Golden Strip Septic
Tank Service
Contact
Attempted
by BCL
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
No
No
No
No
Company
Contact Response to
Made by Visit Request
BCL BCL EPA
Yes Yes Yes
Yes No No
Yes No Yes
No
Yes Yes Yes
Yes NA(h) MA
Yes NA NA
No(f)
Yes Yes Yes
Yes Yes Yes
Yes Yes Yes
Yes Yes Yes
Yes
Yes (c)
Yes Yes Yes
No
Yes Yes Yes




Company
Visited
No
No
No


No
No
No

Yes
Yes
Yes
Yes
No

No

No




46




47
V




V
Morris Roth




City of Mansfielc!
No




No
                                                  A-29

-------
SContinuef')
W'sste Types

Type
Hsu!
Yes

Wo

Yes



of Operation
Treat
No

Yds

Yes

Dispose
Yes

No

Yes

Hauled,
Treated,
c Disposed
Sludges


T

H-T-D

Liquids
R-D

T

H-T-D

Service Cost Ultimate Type of
Treatment and Disposal Facility
Hauling Disposal Combined Landfill Other-Specify
2.5d/gal x Ponding
Drum burial
Claims no discharge
or land disposal
~ 1 5d/gal Stock pile sludges
on land
 Yes   Yes   Yes
 Yes   No    Yes
                         H-D
                        H-D
                                 H-T-D
                                            15-20d/gal
                                                Ship sludges to
                                                outside disposal
 Yes   No    NO
                                 H-T
                     34/gal    64/gal
                        94/ga!
Trucks wastes to
outside disposal
 Yes   Yes

 Ye:   No    Yes

 No    No    Yes
         H-T

H-D     H-D

D
                                          x     Incinerator-residues
                                                landfilled
                                          x
 Yes   Yes   Yes
            Yes
H-T-D   H-T-D
$30/hr   $5/ton
         landfiMed
                                                                    Deep-well injection
 Yes   Yes   No

       Yes

 Yes   Yes   Yes
                                 H-T-D
                                 H-T-D
                             24/gal
                                            2-5c/gal
                                               Ponding; Drum burial;
                                               Incineration
             Yes
                        H

                        H
                                                    A-30

-------
                                                                                                        TABLE A-1.
Company
Number
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
EPA
Rei on
V
V
V
V
V
V
IX
IX
IX
1
II
II
II
II
III
IV
V
V
V
V
Identi-
fication
Source
Number'3'
2
2
2
2
2
2
2
2
2
3
3
3
3
3,1
3
3
3
3
3
3
Company Name
H & H Industries
Region's Rubbish
Udulite Corporation
Browning Ferrous
Industries
Apple Canton "Egg"
Busco
Tandy Pumping Service
M. C. Nottingham
(NAMF-339)
George F. Cagey
Hitchcock Gas Engine Co.
South Side Car: ng
Jamaica Ash & Rubbish
Air Vac
Chemtrol
Lundmark Septic, Tank
Rubin Construction Co.
Burrows Sanita*'on
George Miller & Sons
Regional Services, Inc.
Wayne Dean
Contact Summary
Company
Contact Contact Response to
Attempted Made by Visit Request Company
by BCL BCL BCL EPA Visited
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
No
(a) Identification Source Number.
   (1) Farb, D. and S. D. Ward, "An Inventory of Hazardous Waste Management Facilities", USEPA, OSWM
      (draft report).
   (2) National Association of Metal Finishers (NAMF) questionnaire.
   (3) BCL questionnaires.
   (4) Contact with  plater, metal finisher, or private contractor.
(b) Showed reluctance to allow visit -  but did not refuse.
                                                        A-31

-------
 (Continued!
  Type of Operation
 Haul  Treat Dispose
  Yes

  Yes
               Wsste Types
             Hauled, Treated,
              or Disposed
            Sludges   Liquids
                                                           Service Cost
                               Treatment and
                     Hauling    Disposal      Combined
     Ultimate Type of
     Disposal Facility
Landfill
            Other-Specify
 Yes    Yes   Yes
                          H-T-D    H-T-D
 Yes

 Yes

 Yes

 Yes
             H

             H
 Yes

 Yes

 Yes

 Yes

 Yes

 Yes   Yes   Yes

 Yes   Y  ,

              Yes
            H

            H
                     T-D

                     H-T
 Mo

 Yes
Yes

No
D

H
(c) Requested letter from EPA before allowing visit.
(d) Gary, Indiana, plant.
!e) Kansas City, Missouri, plant.
(f) When contact attempted, no telephone listinr "ould be found.
(g) Sold to Browning Ferrous Industries.
(h) NA  = Not applicable — contractor does not handle wastes characteristic of electroplating or metal-
   finishing wastes.
                                                        A-32

-------
                 APPENDIX B - MODEL PLANT A (38 EMPLOYEES)

                 PART I.  TOTAL INDUSTRY WASTES FROM MODEL
                 ELECTROPLATING AND METAL FINISHING PLANT
                                 INTRODUCTION
          The many metals that are deposited from aqueous solutions of
different anionic species and concentrations on a multitude of basis
materials (metallic or nonmetallic), requiring different process steps in
the production operations appears to make the task of designating a plant
as a "model plant", very formidable.  The theoretical development of such
a plant, of course, must have some basic pertinent factors incorporated,
in order for the data that is derived from this plant to be meaningful and
applicable to the "industry" as a whole.

          The selection of the plant operations was made from the knowledge
that at least two thirds of all metal finishing involves the deposition of
copper, nickel, chromium, and zinc.  The majority of products are made of
ferrous or copper-base alloys.  Other important operations, such as phos-
phating, electroless nickel plating, and anodizing, were also made part of
the plant production because they are frequently occurring processes with
large size installations, and they also pose specific waste treatment
problems.  Precious metals deposition processes have been omitted from the
plant because where these metals are used in significant quantities,
recovery rather than disposal  is practiced.  Of course,  preplating operations
still produce wastes, but these are not significantly different to handle
than the wastes generated from the preplating operations of the included
processes.  The final determination of how many processes could be operated
in the model plant was the limitation of its size.

          Average plant size was found from the data on Industry Charac-
terization to be one having from 25 to 50 employees.  In the model plant,
the type and quantity of work is believed to be sufficiently carried out
by 30 production employees.  Twelve people are used for pre- and post-
plating operation such as grinding, polishing,  etc.  A total of eight
management, supervisory, and clerical personnel were added to complete the
plant capabilities.

          The following calculations and discussions are divided into two
units,  each one being an entity in itself so that conclusions arrived from
each unit may be applied to the "industry" in part or as a total.  The two
units are

           (A)  Determination  of  the quantity of waste generated  in
               an  electroplating and metal  finishing facility  that
               uses combined  chemical treatment and neutralization/
               precipitation  techniques, and
                                    B-l

-------
          (B)  Determination of the quantity of waste generated in
               an electroplating and metal finishing facility from
               mechanical pre- and postplating operations, solution
               and equipment maintenance, and from organic solvents.


          (A)  DETERMINATION OF THE QUANTITY OF WASTE GENERATED IN
         AN ELECTROPLATING AND METAL FINISHING FACILITY THAT USES COM-
    BINED CHEMICAL TREATMENT AND NEUTRALIZATION/PRECIPITATION TECHNIQUES
                           Model Plant Operations


          A summary description of the nine processing lines in the plant,
along with a description of the work assignments for the 30-man plant and eight
supervisory employees are provided in Table 8-1.  The assumed production
rate presented in the second column of the table shows the physical work-
piece area processed in each line.  The processing rate reflects the number
of operations [i.e., the number of different metallic plates or coatings
applied to the same part (e.g., Cu-Ni-Cr plating = three operations; zinc
plate plus chromating = two operations)] carried out on a workpiece.  The;
water volume used for the rinsing operations from the divided processing
streams for acid/alkali, cyanide, and chromium is summarized for each line.

          Detailed diagrams and descriptions of the nine processing lines
in the model plant are presented in Table B-2, lines one through nine.  Data
on bath volumes, bath composition, dump frequency, drag out, rinse water
flows, etc., for the various cleaning, pickling, plating, and other
processing steps are given.  The rinse water use is calculated from the
assumption that a certain maximum quantity of dissolved solids, generally
37 mg/1 in rinses following metal-electrodeposition steps and 750 mg/1 for
rinses following cleaning and dipping operations, has been established as a
good rinsing practice(B~l).  The water volume is then dependent on the
number of rinses and how they are arranged, i.e., countercurrent or single,
as well as the solution drag-out rate.  Drag-out rates may vary more than
one magnitude, depending on size and shape of the part and rack, and
solution viscosity.  In the calculations that follow, a drag-out rate of
1.0 and 1.75 1/m2 area processed (3 and 5 gal/1000 sq ft) for rack and
barrel plating respectively has been assumed for the purpose of taking
into account the multitude of simple- and complex-shaped parts that are
processed through a plating line.  No allowances were made for the use of
save rinses of any kind so that the loss of plating chemicals from solutions
would be near its maximum.  A rinsing efficiency factor of 0.7 is used to
take into account solution effects which are different from those obtained
when the parts are moved in water only.  This factor is commonly applied
in practice.

          As an example, for a cleaning solution having a make-up concen-
tration of 8 oz/gal (60,000 mg/1) consisting of a proprietary cleaner used
in a rack-plating line processing 560 m^/day (6024 sq ft/day), the drag out
is 3.0 gal/1000 sq ft x 6.024 sq ft/day = 18.1 gal/day.
                                    B-2

-------
TABLE B-l.   MODEL ELECTROPLATING PLANT OPERATIONS
Assumed Employees
Line Production Processing Rack, Unrack
or Rate, Rate, Plating,
Operation m^/day
1) Automatic Rack
Cu(CN)-Ni-Cr 560
2) Manual Rack
Cu(CN)-Ni-Cr 160
3) Automatic Rack
Zn(CN) +
Chromating 800
4) Automatic Barrel
Zn(CN) +
Chromating 480
5) Manual Barrel
Cd(CN) +
Chromating 160
6) Manual Rack
Hard Cr 80
7) Manual Rack Al
Anodizing (+
Bright Dip +
Nickel - Acetate
Seal) 600
8) Automatic Barrel
Zn Phosphating 400
9) Manual Electroless
Nickel Rack
Plating 160
Combined Lines 3,400
Other Employees
Supervision (Plating)
Supervision + W.T.
Lab Analysis (W.T. + Plating)
Rack-Repair-Stripping
Maintenance
Misc. Job in Plating Shop
Clerical
Subtotal
Total
ft2/day m2/day ft^/day etc.
6,024 1,680 18,072 7
1,720 480 5,160 3
8,608 1,600 17,216 5
5,160 960 10,320 3
1,720 320 3,440 1
864 80 864 1
6,456 1,800 19,368 6
4,304 400 4,304 2
1,720 160 1,720 2
36,576 7,480 80,464 30

1
1
1
1
1
1
2
8
38
Others









8 (See
Below)


                      B-3

-------
                TABLE B-20  LINE 1, AUTOMATIC RACK Cu(CN)-Ni-Cr

          Drag out:               3.0 gal/1000 sq ft
          Area plated per day:    6024 sq ft
          Drag out rate:          300 x 6.024 = 18.1 gal/day
          Work pieces plated:     Steel 70 percent
                                  70/30 Brass 30 percent
Process Steps
          (1)  Hot Alkali Soak Clean
                   Cone.          8 oz/gal
                   Tank volume    2000 gal
                   Dump cycle     25 days
(2)   Single Rinse,  flow =        (j     = 2070 gal/day

(3)   Electrolytic Anodic Clean [same as (1)]

(4)   Single Rinse,  flow = 2070 gal/day

(5)   Sulfuric Acid  Pickle
         Cone.          45 g/1
         Tank volume    500 gal
         Dump cycle     10 days

(6)   Single Rinse,  flow = ^(75°) (o!?)'^ = 155°

(7)   Copper Cyanide Plate
         Cone.          CuCN    5.0 oz/gal
                        NaCN    7.0   "
                        NaOH    0.5   "
                        Na2C03  2.0   "

(8)   Countercurrent Rinse   i    ono1/2
                          -
\1
)
                   2 stations, flow - \                   = 1400 gal/day

          (9)  Sulfuric Acid Dip
                   Cone.          107 g/1
                   Tank volume    500 gal
                   Dump cycle     10 days

         (10)  Single Rinse, flow = ^75^)      '   = 369°
  60,000 is total salt concentration, mg/1
    18.1 is the drag out rate, gal/day
     750 allowable salt concentration in rinse, mg/1
     0.7 rinsing efficiency of 70 percent
                                    B-4

-------
               TABLE B-2.  LINE 1  (Continued)
(11)   Nickel Plate
          Cone.          NiSO,-6H,0   40 oz/gal
                              -6H0    6   "
(12)  Countercurrent Rinse
tercurrent Rinse   (,ft nnn\l/2 / „ A
2 stations, flow = \~  £   )    I Q7j =  212° 8al/day
(13)  Chromium Plate
          Cone.          CrO_   45 oz/gal
                                 0.45 oz/gal
(14)  Countercurrent Rinse
          2 stations, flow = l^i^l   (i^-1 . 3900 gal/day
                           B-5

-------
                 TABLE B-2.  LINE 2, MANUAL RACK Cu(CN)-Ni-Cr

          Drag out:               3.0 gal/1000 sq ft
          Area plated per day:    1720 sq ft
          Drag out rate:          3.0 x 1.72 = 5.16 gal/day
          Rinsing efficiency:     70 percent
          Work pieces plated:     Steel 70 percent
                                  70/30 Brass 30 percent
Process Steps
          (1)   Hot Alkali Soak Clean
                   Cone.           8 oz/gal
                   Tank volume    600 gal
                   Dump cycle     25 days

          (2)   Single Rinse     ,fi  nnnws
                   Rinse  flow =                - 590 gal/day
          (3)   Electrolytic Anodic Clean
                   Cone.           8 oz/gal
                   Tank volume    300 gal
                   Dump cycle     20 days

          (4)   Single Rinse
                   Rinse flow « same as (2)  = 590 gal/day

          (5)   Sulfuric Acid Dip
                   Cone.           45 g/1
                   Tank volume    200 gal
                   Dump cycle     10 days

          (6)   Single Rinse     ,,   nnnws i M
                   Rinse flow - (46?  = 450 gal/day
          (7)   Copper Cyanide
                   Cone.           CuCN      5.0 oz/gal
                                  NaCN      7.0   "
                                  NaOH      0.5   "
                                  Na2C03    2.0   "

          (8)   Countercurrent Rinse

                   Rinse
          (9)   Sulfuric Acid Dip
                   Cone.          107 g/1
                   Tank volume    200 gal
                   Dump cycle     10 days

         (10)   Single Rinse     (    OOOU5
                   Rinse flow = < °^Q)(0.7)     = 105°
                                    B-6

-------
             TABLE  B-2.  LINE 2  (Continued)
(11)   Nickel  Plate
          Cone.          NiSO,'6H 0     40 oz/gal

                        IT -on    ^       C   II
                        rU JDU,,           D

(12)   Countercurrent Rinse, 2 stations

          Rinse  flow = I—r^	)    I  *7 j = 610 gal/day

(13)   Chrome  Plate
          Cone.          CKL      45   oz/gal
                        H2SD4     0.45   "

(14)   Countercurrent Rinse, 2 stations

          Flow
       t\l/2 /    \
-is-2)    (oHr)= 1UO gal/day
                          B-7

-------
                 TABLE B-2.  LINE 3,  AUTOMATIC RACK ZINC (CN)

          Drag out:                3.0 gal/1000 sq ft
          Area plated per day:    8608 sq ft
          Drag out rate:          3.0 x 8.608 = 25.8 gal/day
          Rinsing efficiency:     70  percent
          Workpieces plated:       Steel
Process Steps
          (1)  Electrolytic Anodic Clean
                   Cone.          8 oz/gal
                   Tank volume    500 gal
                   Dump cycle     15 days
          (2)  Single Rins
          (3)  Concentrated Hydrochloric Acid Dip
                   Cone.          Ill g/1
                   Tank volume    250 gal
                   Dump cycle     25 days
          (4)  Single Rinse,  flow =             '    = 546° §al/day
          (5)  Caustic Dip
                   Cone.          NaOH   1 oz/gal
                   Tank volume    250 gal
                   Dump cycle     5 days

          (6)  Zinc Cyanide Plate
                   Cone.          Zn as metal    40 g/1
                                  NaOH           90  "
                                  NaCN           90  "

          (7)  Countercurrent Rinse, 2 stations
                   _.      f220.00oV/2 /25.8\   OQ_n   . ..
                   Flow = I— ^ - I    I~o7f I =      §al/day

          (8)  Chromate Dip
                   Cone.          Na Cr907'2H 0  2 oz/gal
                                  HN03       l   1 oz/gal
                   Tank volume    250 gal
                   Dump cycle     5 days

          (9)  Countercurrent Rinse, 2 stations

                   Flow .     zoo/2       . 880 gal/day
                                   B-8

-------
                TABLE B-2.   LINE 4,  AUTOMATIC BARREL ZINC (CN)

          Drag out:                5.0 gal/1000 sq ft
          Area plated per day:    5160 sq ft
          Drag out rate:           5  x 5.16 = 25.8 gal/day
          Rinsing efficiency:      70 percent
          Workpieces  plated:      Steel
Process Steps
          (1)   Hot Alkali Soak Clean
                   Cone.           8 oz/gal
                   Tank volume    600 gal
                   Dump cycle     10 days
          (2)   Single Rinse,  flow =                = 2950 gal/day
          (3)   Concentrated Hydrochloric Acid Dip
                   Cone.           Ill g/1
                   Tank volume    200 gal
                   Dump cycle     15 days
          (4)   Single  Rinse,  flow =             '    = 546° g*l/day
          (5)   Caustic Dip
                   Cone.           NaOH  1  oz/gal
                   Tank volume    200 gal
                   Dump cycle     5 days

          (6)   Zinc Cyanide Plate
                   Cone.           Zn as  metal    40 g/1
                                  NaOH           90  "
                                  NaCN           90  "

          (7)   Countercurrent Rinse, 2 stations

                   wl      f220,OOoV/2 f25. 8\   OQC_    . 7j
                   Flow = I — - 1     ~~    =  2 50  Sal /day
          (8)   Nitric  Acid  Dip
                   Cone.           50  g/1
                   Tank volume    200 gal
                   Dump cycle      5 days

          (9)   Chromate Dip
                   Cone.           Na  Cr20'2H20   2  oz/gal
                                  HNO            1  oz/gal
                   Tank volume    200 gal
                   Dump cycle      5 days

         (10)   Countercurrent  Rinse,  2 stations

                   Flo. =(^4'Z fef) -  880  gaZ/day
                                  B-9

-------
                TABLE B-2.  LINE 5, MANUAL BARREL CADMIUM (CN)

          Drag out:               5.0 gal/1000 sq ft
          Area plated per day:    1720 sq ft
          Drag out rate:          5 x 1.72 = 8.6 gal/day
          Workpieces plated:      Steel
Process Steps
          (1)  Cathodic Alkaline Clean
                   Cone.          8 oz/gal
                   Tank volume    400 gal
                   Dump cycle     10 days
          (2)  Single Rinse, Flow =               = "°
          (3)  Hydrochloric Acid Dip
                   Cone.          Ill g/1
                   Tank volume    200 gal
                   Dump cycle     10 days
          (4)  Single Rinse, Flow =                = 182° §al/day
          (5)  Caustic Dip
                   Cone.          NaOH  15 g/1
                   Tank volume    200 gal
                   Dump cycle     5 days
          (6)  Single Rinse, Flow =         ^.6) = 25Q gal/day
          (7)  Cadmium Plate
                   Cone.          Cd        2.66 oz/gal
                                  NaCN     13.3    "
                                  NaOH      1.9    "
                                  Na2C03    7.0    "

          (8)  Countercurrent Rinse, 2 stations
                                       f   \
                                        ^4)= 880 gal/day
                           \ -"   /    \U. //
          (9)  Chromate Dip
                   Cone.          Na_Cr,,0'2H70  2 oz/gal
                                  HN03           1 oz/gal
                   Tank volume    200 gal
                   Dump cycle     10 days

         (10)  Countercurrent Rinse, 2 stations
                          /      \l/2 /   \
                   Flow = f—^—|    I T-^T ) = 500
                                   B-10

-------
            TABLE B-2.  LINE 6, MANUAL RACK HARD CHROMIUM

          Drag out:               3.0 gal/1000 sq ft
          Area plated per day:    864 sq ft
          Drag out rate:          3 x 0.864 =2.60 gal/day
          Rinsing efficiency:     70 percent
          Workpieces plated:      Steel
Process Steps
          (1)  Cathodic Alkaline Clean
                   Cone.          8 oz/gal
                   Tank volume    200 gal
                   Dump cycle     20 days
          (2)  Single Rinse, flow =                = 300 gal/hr
          (3)  Anodic Sulfuric Acid Treatment
                   Cone.          960 g/1
                   Tank volume    200 gal
                   Dump cycle     60 days

          (4)  Two Series Rinses   .  ,      .
                   Flow = l^»"wl   l^~^l = 1880 gal/day
                          \       i   \   /
          (5)  Chromium Plate
                   Cone.          CrO,,      45   oz/gal
                                  H-SO,      0.5 oz/gal

          (6)  Countercurrent Rinse,  2 stations
                          •       \l/2 /     \
                   Flow = (—^5	J    [ Q":7 )= 560 gal/day
                                  B-ll

-------
                   TABLE B-2.   LINE 7,  MANUAL RACK ANODIZING

          Drag out:               3 gal/1000 sq ft
          Area plated per day:     6456  sq ft
          Drag out rate:          3 x 6.456 - 19.37 gal/day
          Rinsing efficiency:      70 percent

          Three save rinses on bright dips to recover 80 to 90 percent
          of drag out.   The adjusted value of 206 g/1 is used.  The
          saved solutions are  sold for fertilizer.

          Workpieces:             Aluminum
Process Steps
          (1)  Hot Alkali Soak Clean
                   Cone.          8 oz/gal
                   Tank volume    800 gal
                   Dump cycle     15 days

          (2)  Single Rinse, flow = ^50) ffiy)'3^ = 220° §al/day

          (3)  Caustic Etch
                   Cone.          NaOH      53 g/1
                   Tank volume    400 gal
                   Dump cycle     7.5 days
          (4)  Single Rinse, flow - ^(750) (O       = 196° Sal/day

          (5)  Nitric Acid Desmut
                   Cone.          100 g/1
                   Tank volume    400 gal
                   Dump cycle     20 days
          (6)  Single Rinse, flow =          ^7) '     = 368° §al/day
          (7)  Bright Dip
                   Cone.          ^^A.     67 percent by volume
                                  HML       3 percent by volume

          (8)  Countercurrent Rinse, 2 stations

                          /206,000\1/2/19.37\   9n8n   . ,.
                   Flow = I—-r*	I    I       1 = 2080 gal/day
          (9)  Anodize
                   Cone.          H SO      165 g/1
                   Tank volume    3000 gal
                   Dump cycle     20 days
                                  B-12

-------
          TABLE B-2.  LINE 7  (Continued)
(10)  Countercurrent Rinse, 2 stations
          F10B . (ISfiSS!)"   (1H1) - 1840 gal/day
(11)   Nickel Acetate Seal
          Cone.           Ni(C2H 02)-4H20     10 g/1
          Tank volume    400 gal
          Dump cycle     5 days
                        B-13
(12)   Single Rinse,  flow =              '   = 2?6°

-------
        TABLE B-2.   LINE 8,  AUTOMATIC BARREL ZINC PHOSPHATING

          Drag out:                5  gal/1000 sq  ft
          Area plated  per day:     4304 sq ft
          Drag out  rate:          5  x 4.304 = 21.52 gal/day
          Rinsing efficiency:      70 percent
          Wbrkpieces:              Steel
Process Steps
          (1)   Hot Alkali Soak Clean
                   Cone.           8 oz/gal
                   Tank volume    250 gal
                   Dump cycle     20 days
          (2)   Single Rinse,  flow =   (jgp) ()'     = 246°

          (3)   Hydrochloric Acid Pickle
                   Cone.           75 g/1
                   Tank volume     250 gal
                   Dump cycle     10 days
          (4)   Single Rinse,  flow =   (yj     = 3080  gal/day

          (5)   Zinc Phosphate
                   Cone.           H^PO.-Zn (PO,)       42  g/1
                   Tank volume    250 gal      ^
                   Dump cycle     15 days

          (6)   Countercurrent Rinse, 2 stations

                   _.     /42,000\1/2 (2l.52\    1A/n
                   Flow = (—37 — i    \~o77~7  =

          (7)   Hot Dip Seal
                   Cone.           Cr03      0.25  g/1
                   Tank volume    250 gal
                   Dump cycle     5 days
                                   B-14

-------
              TABLE B-2.  LINE 9, MANUAL ELECTROLESS RACK NICKEL
Drag out:
Area plated per day:
Drag out rate:
Rinsing efficiency:
Workpieces plated:
                                  3 gal/1000 sq ft
                                  1720 sq ft
                                  3 x 1.72 = 5.16 gal/day
                                  70 percent
                                  Steel
Process Steps
          (1)  Hot Alkali Soak Clean
                   Cone.          8 oz/gal
                   Tank volume    200 gal
                   Dump cycle     10 days
(2)   Single Rinse,  flow
          (5)
          (6)
                          ^50) (fi
          (3)  Hydrochloric Acid Dip
                   Cone.          240 g/1
                   Tank volume    200 gal
                   Dump cycle     15 days
(4)  Single Rinse, flow
                                    (24°°
                                      ((0
     Electroless Nickel Plate
         Cone.          NiSO,'7H_0
                        NaH_P0'2H
                           f\ o o   o

     Countercurrent Rinse, 2 stations
                                                     59° Sal/day
                                                      2360 gal/day
                                                   30 g/1
                                                   10  "
                                                   10  "
                                              - 330
                                   B-15

-------
          The water use required for a single station rinse following the
cleaning is
          Having a countercurrent rinse with two tanks would reduce the
water use to
         /60,OQO\1/2 /18.1\
         ^750  ;     \o.?;-
                             = 230 gal/day = 875 I/day.



                          Waste-Treatment Procedures


Principal Considerations
          All the processing rates and material  balances will be presented
on a daily basis for the model plant.  This will permit ready conversion
of the data and results to another time basis if desired.

          Combined chemical treatment and neutralization/precipitation
techniques will be employed in the model plant.  The dumps will be presumed
to be metered in at a designated rate into the the rinse streams.  The main
plating baths will not be dumped; however, the alkaline cleaners and dips,
chromating, anodizing, and phosphating baths are dumped on a periodic
basis (see Figure B-l).

          The rinse waters and dumps from the various processing operations
on the lines will be segregated into three main streams as follows:

          (1)  Cyanide
          (2)  Chromium
          (3)  Acid/Alkali.

A schematic diagram showing materials flow as well as the overall waste-
treatment scheme for handling the effluents from the model plant electro-
plating and metal finishing plant is presented in Figure B-l.

          Although many of the alkaline cleaners used in electroplating
plants are proprietary mixtures, the individual cleaner compositions
employed in the model plant (Table B-3) are considered representative of
actual practice.  The particular cleaner composition used will be indicated
in the calculations carried out on the individual lines.

          It will be assumed that 25 percent of the alkaline cleaner ingre-
dients are used up in reactions with greases, oil, etc., softening water,
breaking up esters, etc., to form precipitates or other materials which
settle out as sludges.  In the model plant, these sludges will be included
with the liquid cleaner dumps going to the waste-treatment plant.  These
sludges will be considered to represent a portion of the overall solid
waste in the underflow from the clarifier.

                                    B-16

-------


Cyanide 1
4


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                               B-18

-------
Calculations Related to Cleaners,
Acid Dips, and Processing Baths
That Are Periodically Dumped
          The calculations that follow deal with cleaners, acid dips,
caustic etches, and other processing baths that are used up during the
overall electroplating and metal finishing operations carried out on the
various process lines; the spent baths are periodically dumped, according
to the schedules of Table B-2.

          Detailed calculations are given for the process steps of line
one (Table B-2) to exemplify the assumptions made and to illustrate the
general techniques employed in material balance relevant to rinsewaters and
the dumps of the various processing solutions.
                         Hot Alkali Soak Clean
          Make-up concentration = 8 oz/gal = 60 g/1
Cleaner Constituent (Table B-3)

Sodium hydroxide, NaOH
Sodium metasilicate, Na.SiO-
Sodium carbonate, Na~CO~
Trisodium phosphate, Na3PO,-12H 0
Surfactant
          Drag out rate:
          Dump cycle:
          Tank volume:
          Dump rate:
                                                Composition
Original
Weight
Residual
75 percent
Percent g/1
35
25
22
12
6
21.0
15.0
13.2
7.2
3.8
oz/gal
2.8
2.0
1.76
0.96
0.5
fi/1
15.8
11.3
9.9
5.4
2.9
oz/gal
2.10
1.50
1.32
0.72
0.38
18.1 gal/day = 68.5 I/day
25 days
2000 gal = 7570 1
80 gal/day = 303 I/day
Daily Amounts of Cleaner Constituents
in Drag Out and Dump Stream
          NaOH:  80 gal/day dump rate x 2.10 oz/gal of NaOH = 168 oz/day
                              = 10.40 Ib/day =4.70 kg/day

          Na2C03:   (80)(1.32) = 106 oz/day = 6.64 Ib/day = 3.04 kg/day

          Na2Si03:   (80)(1.50) = 120 oz/day = 7.52 Ib/day = 3.44 kg/day

          Na3P04«12H20:  (80)(0.78) = 62.4 oz/day = 3.92 Ib/day = 1.76 kg/da:
                                    B-19

-------
                        Electrolytic Anodic Clean
                      CSteel and Nonferrous Metals)
          Make-up concentration = 8 oz/gal = 60 g/1
Cleaner Constituent

Sodium hydroxide, NaOH
Sodium metasilicate, Na
Sodium carbonate, Na^CO"
Trisodium phosphate, Na^PO -12H0
Surfactant

          Drag out rate:
          Dump cycle:
          Tank volume:
          Dump rate:
                                                 Composition
                                             Original
                      	    Residual
       Weight                 75 percent
       Percent  g/1  oz/gal  g/1  oz/gal
                                            35
                                            40
                                            13
                                            10
                                             2
               21.0
               24.0
                7.8
                6.0
                1.2
2.8
3.2
1.04
0.80
0.16
                                  18.1 gal/day = 68.5 I/day
                                  15 days
                                  1000 gal = 3785 1
                                  66.7 gal/day = 252 I/day
15.8
16.8
 5.9
 4.5
 0.9
2.10
2.40
0.78
0.60
0.12
Daily Amounts in Drag Out
and Dump Stream
          NaOH:  (66.7)(2.10) - 140 oz/day - 8.72 Ib/day = 3.92 kg/day

          Na2C03:  (66.7)(0.78) = 3.28 Ib/day = 1.52 kg/day

          Na SiO.:   (66.7)(2.4) - 160 oz/day = 10.0 Ib/day = 4.56 kg/day

          Na3P04-12H20:  (66.7)(0.60) = 32 oz/day = 2.48 Ib/day = 1.12 kg/day
                          Sulfuric Acid Pickle
          Drag out rate:
          Dump cycle:
          Tank volume:
          Dump rate:
18.1 gal/day = 68.5 I/day
10 days
500 gal = 1895 1
50 gal/day = 190 I/day
          The original acid concentration of 6 oz/gal (45 g/1) will be
maintained by fresh additions of acid to the tank twice a day; the acid
added will be equivalent to the acid leaving in the drag out.

          It will also be assumed that 15 percent of the acid will be used up
in pickling the metal parts being processed which are 70 percent steel
and 30 percent brass (70 percent Cu, 30 percent Zn).

          According to the reaction

                o     +  	    24-
                                    B-20

-------
one gram of steel (Fe)  reacts with 1.76 g of H SO,  having a molecular weight
of 98.08 g/mole.   Similarly,  1 g 70/30 brass reacts with 1.53 g of K^O, for
a molecular weight of 64.09 g/mole, determined as follows

                   Cu - 63.54 g/mole x 0.70 percent = 44.48
                   Zn - 65.38 g/mole x 0.30 percent = 19.61

                                        70/30 brass = 64.09

The amount of 85 percent (38.25 g/1) of the unreacted sulfuric acid that
leaves in the dump and drag out stream is as follows:

          (Dump rate + Drag out rate in gal/day)(H^SO, cone, in g/1)
             (3.785 1/gal)

          (50 -f 18.1) (38.25) (3.785) = 9859 g/day = 9.859 kg/day = 21.76 Ib/day

The amount of various metals  in the dump and drag out stream which have been
dissolved with 15 percent (6.75 g/1) of the acid

          (50 -t- 18.1) (6.75) (3.785) = 1740 g/day = 1.740 kg/day = 3.84 Ib/day

of sulfuric acid, are

          (1740)(0.70) = 692  g/day = Q>692 kg/day = 1>528 Ib/day of iron
              J_ • / D


          (1740) (0.30) = ,.    ,.   ^239 g/day = 0.239 kg/day
              1.53           g/  y \            =0.528 Ib/day of copper
                                           g/day = 0.102 kg/day
                                                 = 0.224 Ib/day of zinc
                             SuIfuric Acid Dip
                          (After Cu(CN) Plating)


          This dip will be assumed to dissolve a negligible amount of
copper plate; no fresh additions  of acid are made.

          Drag out rate:          18.1 gal/day = 68.5 I/day
          Dump cycle:             10 days
          Tank volume:            500 gal = 1895 1
          Dump rate:              50 gal/day = 190 I/day

The quantity of acid going to the dump and drag out stream is as  follows:

          (50)(107)(3.785) = 20250 kg/day = 20.25 kg/day = 44.70 Ib/day of
            sulfuric acid
                                    B-21

-------
Calculations Related to Chemical
Losses from Plating Baths


          Drag out with the workpieces and racks constitutes  the  major  loss
of chemicals from the plating baths.  The quantities  removed  in the  rinse
tanks following plating are fed continuously to the waste  treatment  system
in the appropriate waste streams, i.e., nickel bath constituents  to  acid-
alkali stream, copper cyanide bath constituents to the cyanide stream,  etc.
The calculations that follow give the losses of each  bath  constituent as
illustrated:


          Copper cyanide bath, Line 1, make-up concentration

             Copper cyanide, CuCN      =  5.0 oz/gal
             Sodium cyanide, NaCN      =  7.0 oz/gal
             Sodium hydroxide, NaOH    «  0.5 oz/gal
             Sodium carbonate, Na9CCL  =  2.0 oz/gal.
                                 £-  ~J

The hourly loss by drag out of copper cyanide (CuCN)  is then

          [Bath concentration, oz/gal] x [7.5] x [Drag out, I/day]

          = (5.0 oz/gal)(7.5)(68.5 I/day)

          = 2569 g/day = 2.569 kg/day = 5.671 Ib/day  of copper cyanide

where 7.5 is the factor converting oz/gal to g/1:

          1 oz  x 28 35 -^ x   l gal  - 7 S &
          1 gal X 2b"^ oz X 3.785 1  " 7'5 1

The quantity of the  other  copper bath constituents  dragged out and going to
the same waste treatment stream is:

          NaCN:  (7.0)(7.5)(68.5) = 3597 g/day = 3.597 kg/day = 7.939 Ib/day

          NaOH:  (0.5)(7.5)(68.5) = 257 g/day = 0.257 kg/day = 0.567 Ib/day

          Na2C03:   (2.0)(7.5)(68.5)  = 1028 g/day = 1.028 kg/day = 2.268 Ib/day

The calculated losses  for  the nickel plating bath are :

          NiS04-6H20:   (40)(7.5)(68,5) = 20550 g/day = 20.55 kg/day

                                                     = 45.36 Ib/day

          MC12-6H20:   (6.0) (7.5) (68.5)  = 3083 g/day = 3.083 kg/day

                                                     = 6.805 Ib/day

          H3B03:   (5.0)(7.5)(68.5)  = 2569 g/day = 2.569 kg/day = 5.671 Ib/day
                                   B-22

-------
           Most nickel plating installations would consist of a semibright
nickel bath followed by a bright plating bath with a direct transfer from
the first to the second bath without rinsing.  Consequently, the single drag
out loss calculated suffices.  Organic additives contained in the waste have
been omitted from the calculations because their low concentrations are not
captured in the precipitates of the waste treatment system unless a carbon
filter is used to polish the final plant effluent.

           Drag out losses from the electroless nickel rinse of Line 9 are
5.2 gal/day or 19.7 I/day for a total nickel concentration of

           6.3 g/1* x 19.7 I/day = 124 g/day = 0.272 Ib/day.

The rinse stream of 230 gal/day (871 I/day) is treated separately from the
acid-alkali rinses, since a higher pH of 13.0 is required to destroy the
nickel complex.  The wastes that occur from the regeneration of the electro-
less nickel bath are discussed later in the section on bath maintenance.

           The losses from the chromium plating bath by drag out are

           Cr03:  (45)(7.5)(68.5) = 23,119 g/day = 23.119 kg/day = 51.04 Ib/day

           H2S04:  (0.45)(7.5)(68.5) = 231.2 g/day = 0.231 kg/day = 0.51 Ib/day.

Cyanide-containing solutions are carried off to the treatment plant in a
separate stream for destruction of the cyanide, requiring a calculation for
the total cyanide in the raw wastes from the plant to determine the quantity
of treatment chemicals needed and the quantity of waste produced.  In the
case of the copper plating bath of Line 1, for example, the quantity of
cyanide present in the rinse stream is calculated as before times a factor
describing the fraction of CN present in each salt

    from CuCN:  (5.0)(7.5)(68.5)(0.291) = 747.5 g/day = 1.65 Ib/day of cyanide

    from NaCN:  (7.0)(7.5)(68.5)(0.531) = 1907 g/day = 4.22 Ib/day of cyanide.

Factors for other cyanide-containing chemicals are not needed in the calcu-
lations because metal content rather than metal cyanide content is given in
the description of other plating baths in Table B-2.  The metal content of
the respective cyanide salt is calculated just as above with the multiplying
factor relating the metal portion of the salt as shown for copper of Line 1

    from CuCN:  (5.0)(7.5)(68.5)(0.71) = 1824 g/day = 4.03 Ib/day of copper.

           Applying the above procedures for calculating metal ion content
and anion content (CN, SO,, etc.) for each of the plating baths yields the
total amount of materials that must be reacted in the waste treatment system.
The respective amounts are shown in Tables B-4 through B-6.
*  NiSO   -7H?0 Concentration = 30 g/1 = 6.3 g/1 Ni.

                                     B-23

-------
Cyanide Destruction
           The destruction of cyanide will be carried out using chlorine
(C19) and caustic soda (NaOH) at a pH of about 9 to 10.  The theoretical
quantity of chlorine required is 3.62 Ib per pound of sodium cyanide or
6.82 Ib per pound of cyanide according to the following equation:

           2 NaCN + 5 C12 + 12 NaOH— »Na2CO  + 10 NaCl + NZ + 6 E^.

Allowing 10 percent excess Cl~, 7.50 Ib or 3.40 kg Cl? per Ib or kg CN is
required.  For a total CN-content of 31.95 Ib/day the amount of chlorine
required is:

           •51 ac lb CN    7.5 Ib C10   _.Q , lbCl0        , kg_Cl0
           31.95 —5 -  x  T ..2 = 239.6 — - - 2 or 108,6 — 5 - 2 .
                  day      1 lb CN            day             day

           From the same equation, and again allowing for a 10 percent
excess, 326 lb of NaOH will be required per hour to destroy the cyanide.
If used as a 50 weight percent solution, which contains 6.36 Ib/gal NaOH,
the volume required is :
              636 Ib/gal       '

It is also possible to carry out the cyanide destruction process using  lime.
instead of caustic.  The theoretical ratio of lime  [Ca(OH)7]  to caustic
(NaOH) required for neutralization is:

                   Ca(OH)_2  =   74'10  -  =  o 926
                   2NaOH        2(40.01)            '
The quantity of lime required is:

           326 x 0.926 - 301.9  Ib/day  of Ca(OH)2  .

The same results would be obtained if  one were  to  substitute  12 NaOH for
6 Ca(OH)~ in the above equation.


Chromium Reduc t ion
           The reduction of hexavalent chromium  to  trivalent:  chromium in  the
waste stream will be carried out using sulfur  dioxide  (SO  ) gas  at  a  solution
pH from 2.5 to 3.0.  From the equation,

                2 CrO  + 3 S02—> Cr2(S04)3

the theoretical quantity of SO.,  required per pound  or  kg of CrO   is 0.961 lb
or 0.435 kg.  With a chromium content of 52 percent in CrO.,,  the amount of
S02 required is   ' ••„•  = 1.85 lb or 0.84 kg per  lb  or  kg o^ Cr.   The  use  of
2.1 lb or 0.92 kg ScL is required when the gas is fed  in excess  of  10 percent.

                                    B-24

-------
           Using the example of the chromium plating bath of Line 1, as
given in Table B-2, the drag out loss is 23.06 kg/day =50.9 Ib/day of
CrO ,  which, when multiplied by 0.52, gives 11.99 kg/day or 26.47 Ib/day
of hexavalent chromium in the waste stream requiring

           11.99 x 0.84 = 10.07 kg/day or 22.23 Ib/day of S02.

Equivalent calculations were carried out for the chromium baths of Lines 2
and 6 and the CrO. hot dip step in Line 8.  The chromium lost from the
chromating steps following zinc and cadmium deposition has been included
in the drag out and dump calculations presented in Appendix A-2, Lines 3,
4, and 5.  These rinse and dump solutions also contain dissolved electro-
deposited zinc or cadmium.  These quantities are calculated from the com-
bined daily dump and rinse volumes times the metal ion concentration     ,
dissolved in solution by 1/2 of the nitric acid concentration.  Total Cr
from the seven lines including dumps is as follows:

   25.54 + 7.57 + 3.81 + 1.088 + 0.872 + 0.432 + 0.027 = 39.34 Ib/day
                                                       = 17.82 kg/day.

The total flow of streams is as follows :

    3900 + 1100 + 560 + 930 + 920 + 320 + 50 = 7780 gal/day = 29,450 I/day.

The average Cr   concentration of the combined streams and dumps equals

           17,820,000 mg/day  =        ,
            29,450 I/day        ™* mg/i  '

In addition to the Cr   these streams also carry

           Zn = 0.648 + 0.520 = 1.17 Ib/day = 0.53 kg/day

           Cd = 0.56 Ib/day = 0.253 kg/day.

           It will be assumed that the pH of the combined chromium- stream
will be at a pH of 2.5-3.0 at which the reduction of Cr+6 will be carried
out by the addition of sulfur dioxide.  For the above calculated totals,

           39.34 Ib/day x 2.1 ^-~2  =82.6 Ib/day = 39.42. kg/day
                              J.D Or
of sulfur dioxide are required.
Acid-Alkali Stream
           The quantity of the various materials going to the waste treatment
plant from the combined acid-alkali and nickel rinse streams and the dumps
from Lines 1 to 9 together with the Al-anodizing and Zn-phosphating line
processing solution rinses and dumps are summarized in Table B-4.  The total
quantity of individual materials present in the combined lines is given at
the right of Table B-4.

                                    B-25

-------
          Acid-Alkali Stream Neutralization.  The determination of the
quantity of caustic soda or lime that will be required to react with the
excess acid present in the stream was carried out as follows:

          (1)  The various acids and alkalis were reacted together
               until all the alkali was used up.

          (2)  The excess acid present was then neutralized using
               either caustic soda or lime.

The sequence of reacting the various acid and alkaline materials present in
the overall acid-alkali stream (Table B-4) and the attendant calculations
are shown below:

          (la)  Neutralization of HNCL with Na CO.,:
                   HNO
            3 present = 34«28 Ib/day = 15.54 kg/day

         Na-CCL  present = 40.76 Ib/day = 18.57 kg/day

      The amount of Na CO., used up is then 34o28 -r— x 0.84 =

      28.80 Ib/day = 13.04 kg/day, where 0.84 is the molecular
      weight ratio of the acid-alkali neutralization reaction.
      The amount of Na_CO., left unreacted is then 40.76 Ib/day
      - 28.80 Ib/day =11.96 Ib/day = 5.42 kg/day.

(Ib)   Neutralization of HC1 with Na CO  and NaOH:

         NaOH present = 81.60 Ib/day = 36.91 kg/day

         Na2C03  left from (la) = 11.96 Ib/day = 5.42 kg/day

         11.96 Ib Na2C03 will neutralize 8.26 Ib HC1

         HC1 left = 65.99 - 8.26 = 57.73 Ib/day = 26.15 kg/day.

      The amount of NaOH required to neutralize this amount of
      HC1 is

         57.73 Ib/day x 1.10 = 63.50 Ib/day or 28,77 kg/day

      and the amount of NaOH left unreacted is

         81.60 - 63.50 = 18.10 Ib/day = 8.20 kg/day.

(Ic)   Neutralization of H3B03 with NaOH:
        H B03 present =7.29 Ib/day = 3.30 kg/day
        NaOH left from (Ib) = 18.10 Ib/day = 8.20 kg/day
      NaOH required to react with 7.29 H.-.BO- is

        7.29 Ib/day x 0.65 = 4.74 Ib/day = 2.15 kg/day

                          B-26

-------







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                and the amount of NaOH left unreacted is

                  18.10 - 4.74 = 13.36 Ib/day = 6.05 kg/day,

          (Id)  Neutralization of t^K^ with NaOH:
                  H3PO, present = 32.46 Ib/day = 15.50 kg/day

                The amount of NaOH required to react with this amount
                of H3PO, is

                  32.46 Ib/day x 1.22 - 39.60 Ib/day = 17.94 kg/day.

          (2a)  Since only 13.36 Ib NaOH are available in the waste stream,
                the addition of 39.60 - 13.36 • 26.24 Ib/day - 11.89 kg/day
                of NaOH is required.

          (2b)  Neutralization of H SO, with NaOH:

                  H2SO, present = 238.4 Ib/day = 107.99 kg/day

                The amount of NaOH required to react with this amount of
                acid is

                  238.4 Ib/day x 0.82 = 195.5 Ib/day = 88.56 kg/day.

                Allowing for a NaOH feed rate 10 percent in excess of the
                theoretical amount

                  1.10 x 195.5 Ib/day = 215.1 Ib/day =  97.42 kg/day are

                required.

Combining (2a) and (2b), 241.3 Ib/day (109.3 kg/day) of additional NaOH is
needed for the overall neutralization of the acid-alkali stream.  The equi-
valent amounts of Ca(OH)_ that would be required in lieu of NaOH would be

          241.3 Ib/day x 0.926 = 223.4 Ib/day = 101,2 kg/day.

The final pH of the acid-alkali stream, excluding precipitation of any
metal hydroxides, is assumed to be 6.0.
          Caustic or Lime Requirements for Raising pH of Solutions.  It will
be assumed that when the treated cyanide stream (8380 gal/day or 31,720
I/day, pH 9 to 10) is joined with .the treated chromium stream (7780 gal/day
or 29,450 I/day, pH 2.5 to 3.0) that the resultant pH of the stream will
be at 5.0.  It will also be assumed that the pH of all the streams making
up the overall acid/alkali stream (62,680 gal/day = 237,240 I/day) after
neutralization of the free acid contents with either NaOH or lime will be
6.0.

          To raise the pH of the combined CN and Cr streams from 5.0 to 8C5
requires 10"5'5 moles/liter of NaOH  (M wt = 40)

           rlO~5'5 M/l x 40 g/M * 4 x 10"4 - 0.0004 g/1 of NaOH

and the total amount of NaOH needed is

          4 x 10"4 g/1 x (31,720 + 29,450) I/day « 24.47 g/day.

Feeding NaOH to 10 percent in excess of the calculated amount would then
require 24.47 x 1.10 « 26.92 g/day.
                                    B-29

-------
          To raise the pH of the acid-alkali stream from 6.0 to 8.5 also
requires 10~ °  moles/liter of NaOH.  For a total flow rate of 237,240 I/day
and allowing a NaOH feed 10 percent in excess of the theoretical amount,
the required amount of NaOH is
          4 x 10"4 g/1 x 237,240 I/day x 1.10 = 104.4 g/day.
The total amount NaOH is then 24.47 + 104.4 = 129 g/day or 0.28 Ib/day.
The equivalent amount of Ca(OH)  is 129 x 0.926 = 120 g/day or 0.26 Ib/day.


          Combined Flow Stream Calculations.  The following are the flows
for the main streams in the overall waste-treatment (WT) plant:

          Combined cyanide streams               8380 gal/day or 31,720 I/day
          Combined chromium streams              7780 gal/day or 29,450 I/day
          Combined A-A streams (including Ni   62,680 gal/day or 237,240 I/day
            rinses and dumps, anodizers, and
            phosphating rinses and dumps, etc.)

          Electroless Ni rinses (to clarifier)    230 gal/day or 870 I/day _

                               Total Volume    79,070 gal/day or 299,280 I/day.

By including an additional 5 percent volume of water used in water treat-
ment, processing chemicals, wash down, etc., the total plant effluent flow
becomes 83,100 gal/day or 314,500 I/day.


          Quantity of NaOH Required to Precipitate Metal Ions as Hydroxides.
The use of the metal contents calculated for the various waste streams
(Table B-6) when multiplied by the equivalent quantity of NaOH gives the
quantity of metal hydroxides precipitated as dry weight of sludge.  For
example, the chromium waste stream carries 39.34 Ib/day or 17.82 kg/day
of hexavalent chromium, Cr^+, which has been reduced to trivalent chromium,
Cr3+, which is then precipitated according to the equation

                        Cr3+ + 30H~-» Cr(OH)3
                                             3+
requiring 3 moles rf NaOH for each mole of Cr  , or 52*01 g Cr react with
120.00 g NaOH to form 103.01 g Cr(OH>3.

          Consequently,
of NaOr* is required, forming

                            X 17>820 8/day = 35,294 g/day
                     Z.oi g

of Cr(OH) .  Expressed as Ib/hr, the respective amounts are 90.76 and 77.91.
                                   B-30

-------
                                                        2+
          Similarly, the 1.17 Ib/day (0.53 kg/day) of Zn   require 1.40
Ib/day (0.64 kg/day) of NaOH to produce 1.69 Ib/day (0.76 kg/day) of
Zn(OH) , and 56 Ib/day (0.25 kg/day) of Cd2+ require 0.40 Ib/day (0.18 kg/
day) of NaOH to produce 0.72 Ib/day (0.33 kg/day) of Cd(OH)2>

          The quantities of all the metal hydroxides from the cyanide and
acid-alkali stream were calculated in likewise fashion.
          Quantity of Ca(OH)? Required to Precipitate Metal Ions as Hydrox-
ides .   The theoretical ratio of lime to caustic soda is 0.926 (p. B-24;.
The quantity of metal-ion concentrations in the waste streams and the quan-
tity of precipitated metal hydroxides are unchanged from those calculated
with the use of NaOH.  From the preceding paragraph, 41,115 g/day (90.76
Ib/day) of NaOH is required to precipitate all chromium in the waste.  Using
Ca(OH) , instead, would then require 41,115 g/day x 0.926 = 38,073 g/day =
84.05 Ib/day.

          Total quantities of metal hydroxides formed for each metal ion
in solution are summarized in Table B-5.
          Determination of Solubility of CaSO, Formed During the Precipi-
tation of the Metal Hydroxides with Ca(OH) .  The solubility of CaSO  in
water at 20 C (68 F) is 2.980 g/1.  Therefore, the maximum amount of
dissolved CaSO,  that could leave the plant in the treated effluent is
          314,500 I/day x 2.980 g/1           .              .
          - 100J g/kg - *— =  937 kg/day = 2069 Ib/day.
The quantity of CaSO, formed by the neutralization of 107.99 kg/day  (238.4
Ib/day) of H SO, in the waste stream, requiring 74.1 g Ca(OH)  for each
98 g of H2S04 to produce 136.2 g of CaSOA> is

          107.99 kg/day x 1.39 = 150.1 kg/day = 331.4 Ib/day

using

          107.99 kg/day x 0.75 = 81.0 kg/day = 178.8 Ib/day

plus 10 percent excess for a total of 89.1 kg/hr = 196.7 Ib/day of Ca(OH)  .

          Making the assumption that the. incoming plant water contains 100
mg/1 of Ca in the form of CaSO, the additional quantity of Ca is

          314,500 I/day x 0.100 g/1   Q1 ._ .   ,_     ,. .,
          	7:	— = 31.45 kg/day = 69.43
                        g/kg
or, the quantity of CaSO, added is

          31.45 kg/day x 3.40 = 106.9 kg/day = 236.0 Ib/day.

The total quantity of CaSO  in the stream is then 150.1 + 106.9 = 257.0 kg/
day = 567.3 Ib/day, which amounts to 60 percent of the calculated solubility,
Therefore, no solid waste is generated.
                                   B-31

-------
TABLE B-5.  METAL HYDROXIDES LEAVING AS WASTES
Total Quantity Correction for Metal
in Combined Values Leaving
Streams in Effluent
Hydroxide
A1(OH)3
Cu(OH)2
Cd(OH)2
Cr(OH)3
Fe(OH)2
Ni(OH)2
Zn(OH)2
Mn(OH)2
Total
kg /day
24.77
4.62
1.17
35.29
15.38
11.47
13.84
0.32
—
Ib/day
54.68
10.20
2.58
77.91
33.95
25.32
30.55
0.71
—
kg/day
0.92
0.24
0.21
0.31
0.60
0.25
0.24
0.25
—
Ib/day
2.01
0.53
0.45
0.69
1.33
0.55
0.53
0.56
—
Corrected Value of
Hydroxides Leaving
with Wastes
kg/day
23.85
4.38
0.96
34.98
14.78
11.22
13.60
0.07
103.84
Ib/day
52.67
9.67
2.13
77.22
32.62
24.77
30.02
0.15
229.25
                     B-32

-------
          Determination of Solubility of Ca_PO, and CaSiCt, Formed During
The Precipitation of the Metal Hydroxides with Ca(OH)  .  With the lime
precipitation option employed at the final neutralization/precipitation
step, calculations were made to determine whether the  quantity of sodium
silicate and sodium phosphate originally leaving as soluble sodium salts
(with complete NaOH neutralization/precipitation) might be converted to
relatively insoluble calcium silicate and calcium phosphate salts, respec-
tively, which would leave in the solid waste sludge.   The quantity of Na9SiOo
and Na PO-12H90 going to the waste treatment system from the cleaners is
as follows (Table B-4) :

          Na2Si03:        18.62 kg/day = 40.95 Ib/day

          Na3P04'12H20:   7.24 kg/day = 15.99 Ib/day.

          The quantity of calcium salts used with lime instead of
caustic soda are

          CaSiO  = Na SiO  x 0.95 = 18.62 x 0.95 = 17.69 kg/day

                                                 = 39.05 Ib/day

          Ca3(P04)2 = Na3P04'12H20 x 0.41 = 7.24 x 0.41 = 2.97 kg/day

                                                        =6.55 Ib/day.

The solubilities of the calcium salts are

          CaSi03 = 0.095 g/1 at 17 C

          Ca3(PO )  = 0.020 g/1 in cold water.

The quantity of dissolved salts that could be discharged with the plant
effluent are

          casio3:

and

          r,  ^PH \    314,500 I/day x 0.02 g/1
          Ca3(P04)2:      	1000 g/kg	    = 6'29

                                               = 13.87 Ib/day.

Since the quantity formed is less than the soluble amounts that could be
carried out in the liquid effluent stream, there will be essentially no
Ca_(PO,>2 and CaSiO  leaving with the solid wastes.

          Table B-6 gives the metal concentrations present in each waste
treatment stream and the quantity of the respective metal hydroxides formed
as well as the quantity of the reagents required.   In the case of the
cyanide stream, the quantity of NaOH or Ca(OH)  that is required is that
which was calculated earlier as needed for the destruction of the cyanide
stream and the simultaneous precipitation of the metal hydroxides.


                                  B-33

-------
     TABLE B-6.   METAL ION CONCENTRATIONS IN WASTE STREAMS,  QUANTITY OF
                 METAL HYDROXIDE SLUDGE FORMED AND REAGENTS  USED FOR
                 PRECIPITATION
Concentration
Me Ion kg/day Ib/day
A. Cyanide Stream
Cu2+ 2.34 5.18
Zn2+ 7.80 17.22
Cd2+ 0.65 1.43
Subtotal 10.79 23.83
B. Chromium Stream
Cr3+ 17.82 39.34
Zn2+ 0.53 1.17
Cd2+ 0.25 0.56
Subtotal 18.60 41.07
C. Acid- Alkali Stream
Cu2+ 0.67 1.48
Zn2+ 0.80 1.49
Fe3+ 8.04 17.76
Ni2+ 7.13 15.95
Mn2+ 0.20 0.43
A13+ 8.57 18.53
Subtotal 25.41 55.64
D. Electroless Ni-Stream
Ni"1"* 0.13 0.27
Quantity of
Mex(OH)y Formed
kg/day

3.59
11.86
0.84
16.29

35.29
0.76
0.33
36.38

1.03
1.22
15.38
11.26
0.32
24.77
53.98

0.21
Ib/day

7.93
26.17
1.87
35.97

77.91
1.69
0.72
80.32

2.27
2.68
33.95
24.86
0.71
54.68
119.51

0.45
Quantity of Reagents Required*
NaOH
kg/day

2.95
9.55
0.46
12.96

41.12
0.64
0.18
41.94

0.84
0.98
17.27
9.72
0.29
38.12
67.22

0.37
Ib/day

6.50
21.08
1.02
28.60

90.76
1.40
0.40
92.56

1.86
2.16
38.13
21.45
0.64
84.14
148.38

0.81
Ca(OH)2
kg/day

2.73
8.84
0.43
12.00

38.08
0.59
0.17
38.84

0.78
0.91
15.99
9.00
0.27
35.30
62.25

0.34
Ib/day

6.03
19.52
0.94
26.49

84.06
1.31
0.37
85.73

1.71
2.00
35.30
19.87
0.59
77.92
137.39

0.76
*Includes 10 percent in excess of theoretical amounts.
                                   B-34

-------
          The quantity of metal hydroxides formed from the various streams
was calculated on the basis of a complete conversion of the metal to the
hydroxide.  To determine the quantity of hydroxides that would wind up with
the solid waste sludge, it is necessary to make an allowance for the metal
values leaving in the effluent stream either as the dissolved metal or in
the suspended solids.  To make this correction, the following concentrations
of metals (either dissolved or in the suspended solids) in the effluent
were assumed.


              Metal                    Concentration, mg/1

              Copper                           0.5
              Nickel                           0.5
              Chromium                         0»5
              Zinc                             Oo5
              Aluminum                         1.0
              Cadmium                          0.5
              Iron                             1.0
              Manganese                        0.5

          Multiplying the volume of effluent by the above concentration
gives the total amount of metal ions leaving in the plant effluent either
as dissolved solids or suspended metal hydroxides„  For a concentration of
metal in the effluent of 0»5 tng/1 the total metal is

          0.5 x 10"6 kg/1 x 314,500 I/day = 0.1573 kg/day = 0.347 Ib/day

and twice as much for the concentration of 1.0 mg/lc  Converting the metal
concentrations to their respective hydroxides and subtracting this amount
from the total hydroxides precipitated gives the quantity of metal hydroxides
discharged from the waste treatment plant for land disposal.
Clarifier Calculations
          The following calculations were carried out to determine the
flocculent dosage,  sludge volume,  etc.;

          (1)  The  total quantity  of metallic hydroxides (excluding
               Ca(OH)2 present is  103.8  kg/day or 229.3 Ib/day.
               The  quantity of insoluble sludges occurring from the
               cleaners is 23.6 kg/day or 52.1 Ib/day.   The quantity
               of unreacted Ca(OH)   (based on 70 percent of the
               10 percent excess lime used for neutralization/
               precipitation operations) is 33.92 x 0.7 = 23.74 kg/day
               or 52.42 Ib/day.

          (2)  A flocculent will be  employed in the clarifier,  so
               that the effluent from the top of the clarifier
               would be suitable for discharge to a stream (or
               sewer)  [e.g., 10-20 ppm suspended solids].   The
               flocculent is generally fed as a dispersion (about
               5 percent)  to the neutralized waste at a dosage  of

                                  B-35

-------
               10 to 100 mg/1.  For the model plant a value of
               40 mg/1 will be employed.  The quantity of floccu-
               lent required is as follows :

                   314,500 I/day x 40 x 10"6 kg/1 = 12.58 kg/day

                   or 27.77 Ib/day.

          The total amount of solids is then 103.8 + 23.64 + 12.58 =
139.98 kg /day = 309.0 Ib/day when NaOH is used, and with the use of lime,
is 139.98 + 23.74 = 163.72 kg/day = 360.9 Ib/day.

          It will be assumed that the clarifier will produce an underflow
containing 2 percent solids.  It will also be assumed that the density of
the 2 percent sludge mixture will be similar to that of water.  The volume
of underflow is calculated to be
using NaOH for the process, and similarly 8186 I/day or 2163 gal/day using
Ca(OH)2.

          The alternate use of a sludge thickener (centrifuge) will be
assumed to concentrate the sludge from 2 to 20 percent solids producing
a sludge cake of 801 I/day (185 gal/day) or 819 I/day (217 gal/day) when
NaOH or Ca(OH),, is used in the treatment process.  The higher volume of
sludge with the lime neutralization/precipitation system results from the
fact that some of the unreacted Ca(OH)  leaves with the sludge destined
for waste disposal.
Summarized Data on Chemicals Consumption
in Waste Treatment Plant
          The caustic or lime consumption in the waste treatment plant
 (based on 10 percent in excess of theoretical requirement) is summarized
 in Table B-7.  The consumption of chlorine, sulfuric dioxide, and floccu-
 lent in the waste treatment plant were as follows:
                                  kg/day      Ib/day

          Chlorine:               108.6       239.7
          Sulfur dioxide:         30.42       82.6
          Flocculent:             12.58       27.8
                                  B-36

-------












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-------
                     Materials Consumption in Model Plant


Anode Consumption
          The quantity of soluble anodes used for each electroplating oper-
ation will closely approximate the quantity of metals plated out.  Making
assumptions for plate thickness and using the numbers of processed area for
each operation, the anode use is calculated from a modified form of Faraday's
Law commonly used by platers and given in most plating handbooks:

TTj_ ,  ,,   ,    .*_ •,   area plated x plate thickness x unit wt/unit thickness
Wt in Ibs deposited = 	e	c	—	-rrr-	'	
            ^                             16 oz/lb                          .

For example, the quantity of copper deposited when 7,747 sq ft (720 m ) are
plated per day to a thickness of 0.000075 inch (0.075 mil) or 0.19 urn is

Wt of Cu = 7,747 sq ft/day x 0.075jil x 0.74 OZ/sq ft mil = ^ ^^

                                                           = 12.17 kg/day.

The following is the summarized data on the anode consumption for the model
plant.  Anode wastes are discussed in Section B of this phase of the report.

                                     Deposit           Anode
                      Factor        Thickness       Consumption
    Anode Metal    oz/sq ft mil     mil     pm    kg/day    Ib/day

      Copper
      Nickel
      Zinc
      Cadmium
Bright Dip Consumption (Line 7)
          Using the assumption that 85 percent of the bright dip solution
is recovered by use of three stagnant rinses following the bright dip
operation, the spent bright dip solution is periodically withdrawn from
the first tank as a solution containing about 35 percent H«PO, acid and
sold to a fertilizer manufacturer.

          This drag out would account for the consumption of 15 percent of
the bright dip solution (which initially has a concentration of 67 percent
HLPO, - 3 percent HNO~.)  From earlier calculations

          the quantity of H PO  carried off in the drag out = 14.44 kg/day

                                                            = 31.87 Ib/day

          the quantity of HNO., carried off in the drag out = 0.65 kg/day

                                                           =1.43 Ib/day.


                                   B-38
0.74
0.742
0.59
0.72
0.075
0.6
0.32
0.35
0.19
15.2
8.13
8.89
12.17
97.20
73.36
12.32
26.87
214.57
161.94
27.20

-------
Since these values represent 15 percent of the consumption of the original
bright dip solution, the amount of bright dip ingredients needed is as
follows :

          HP0:        = 96'25 k§/day = 212 o 23 Ib/day
          HN03:        = 4.31 kg/day = 9.50 Ib/day.


The 85 percent of the spent bright dip solution (35 percent H3P04) hauled
away per day is equal to 81.81 kg or 180.4 Ib I^PO^.  The volume hauled
away based on 35 percent H^PO^ which has a density of 1.436 g/cm^ is
                              ki 56'97 1/day - 15'05

The quantity of HNO  hauled away with the bright dip is 3.64 kg/day or 8.02
Ib/day.
Summary of Materials Consumption
          The materials consumed in the model plant in electroplating and
metal finishing operations are summarized in Table B-8.
                          Sludge-Handling Operations
          To provide data and information on the different sludge-handling and
disposal procedures, calculations of costs for two disposal methods  (desig-
nated Options 1 and 2 in Figure B-2) were carried out.  Option 1 involves
the use of a centrifuge on the underflow from the clarifier to concentrate
the sludge from a 2 percent to a 20 percent solids content.  Option 2
employs a lagoon to settle out and concentrate the sludge to a 6 percent
solids content.  The calculations for each option follow.


Option 1 - Centrifuged Sludge Disposal Calculations
Centrifuge Size and Cost Calculations
          The earlier calculations had shown that the underflows from the
clarifier (assuming a 2 percent solids content) were as follows:

          (1)  7,000 I/day or 1,849 gal/day (caustic system)

          (2)  8,186  I/day or 2,163 gal/day (lime system).

Conversion of the 2 percent solids underflow in a centrifuge to a sludge
containing 20 percent solids resulted in the following volumes of sludge:

                                   B-39

-------
      TABLE B-8.  MATERIALS CONSUMPTION FOR MODEL  PLANT ELECTROPLATING
                  OPERATIONS
Consumption
Material
(a)*
Sodium hydroxide, NaOHv '
(a)
Sodium carbonate, Na0C00
23 , ^
Sodium metasilicate, Na?SiO ^
Trisodium phosphate, Na~PO. '12H 0^
( \
Surfactant
Sodium cyanide, NaCN
Sodium dichromate, Na0Cr_0 '2H00
' 227 2
Nickel sulfate, NiSO,-6H20
Nickel sulfate, NiSO,-7H 0
Nickel chloride, NiCl2'6H 0
Nickel acetate, NiC HO
Phosphating salt, H PO -Zn«(PO,)
Sodium acetate, NaC H 0
Sodium hypophosphate, NaH_PO?-H 0
Chromic acid, CrO
Cadmium oxide, CdO
Zinc oxide, ZnO
Boric acid, H BO
Hydrochloric acid, HC1
Nitric acid, HNO_
' 3
Phosphoric acid, H PO,
Sulfuric acid, H SO
kg/ day
66.16
28.88
24.72
9.76
4.08
25.28
3.54

26.72
0.56
3.92
0.72
6.08
0.24
0.24
37.92
0.80
4.80
3.20
27.68
25.04

95.68
149.4
Ib/day
145.92
63.68
54.48
21.44
8.96
55.68
7.52

58.88
1.28
8.56
1.60
13.44
0.48
0.48
83.60
1.68
10.64
7.12
61.04
55.28
-------
                             FOOTNOTES FOR TABLE B-8
(a)   The bulk of these materials are contained in the soak and electrolytic
     cleaners used in the plant.  The total quantity of cleaners used is
     94.6 kg/day = 208.9 Ib/day.  The breakdown of the quantity of each
     compound used in the cleaners is given below:

                                            Consumption
                   Material                kg/day  Ib/day

                 NaOH
                 Surfactant

                   Total
(b)   Part of the consumption shown for these two acids is employed for the
     bright dip operation on the Al anodizing line and is recovered and
     sold to a fertilizer manufacturer.   The quantity of phosphoric and
     nitric acids recovered are 81.81  kg/day (180.4 Ib/day)  and 3.65 kg/day
     (8.02 Ib/day),  respectively.
                                   B-41

-------
     OPTION 1
Treated
Streams
              Clarifier
                   2% Solids
                                    Effluent
                                    Centrifuge
             _^.  20% Solids
     OPTION 2
   Treated
   Streams
                    Clarifier
                          I
                      2%  Solids
Effluent
                    Supernatant
                                         Lagoon
                                              1
                                           6%  Solids
                     FIGURE B-2.  SLUDGE-HANDLING OPTIONS


                                   B-42

-------
          (1)  700 I/day or 185 gal/day  (caustic system)



          (2)  819 I/day or 217 gal/day  (lime system).



The ratings of the centrifuges required were



          (1)     7,000 I/day x 0.02         n. ,_ iy  .     _ Q,    .. ,  .
               .   *	0  '  .I	r-f.	:—-rr— = 14.60 1/min or 3.86 gal/mm
               0.06 x 8 hr/day x 60 min/hr         .        .     6
                                             caustic system)



          (2)  17.01 1 min or 4.51 gal/min (lime system).





Option 2 - Lagoon Sludge Disposal
          For Option 2, it was assumed that the underflow from the clari-

fier was sent directly to a lagoon for further clarification and settling.

It was also assumed that at the time the settled sludge was hauled away,

the solids content had increased from 2 to 6 percent.  The volume of 6

percent sludge to be hauled away was


          ,,,  7,000 1/hr x 0.02   . «„, , , ,       ,,-,   1 /,   ,
          (1)  — - n •_, - = 2,333 I/day or  617 gal/day (caustic
                     U • Uo                                            \
                                                               system)
          (2)  8'186 y^ X °'°2 = 2,729 I/day or 721 gal/day  (lime system).
                     U. Ob



          Lagoon Size,  Since the lagoon size will not differ  significantly

for the two precipitation systems, the lagoon size calculations were based

on the lime system.  Assuming a holding capacity for 30 days (no discharge

of supernatant liquid from the lagoon was assumed for these calculations)

the size of the lagoon required was determined as follows:



          Volume of underflow to lagoon:  8,186 I/day x 30 days =


          245,580 1 (245.6m3) or 64,883 gal (8,675 cu ft).



                                                               3
Allowing a 20 percent oversize, the volume required is 270.4 m or 9,550

cu ft.  Assuming a working depth of 2 m  (6 ft), a length  of 20 m  (60  ft),

and a width of 10 m (30 ft) and a 3 m (10 ft) wide border around  the

lagoon, therefore, requires a land area of 26 m x 16 m =  416 m  (80 ft x

50 ft = 4000 sq ft) or 0.092 acres.
                                  B-43

-------
        (B)  DETERMINATION OF THE QUANTITY OF WASTE GENERATED IN AN
     ELECTROPLATING AND METAL FINISHING PLANT FROM MECHANICAL PRE- AND
      POST-PLATING OPERATIONS. SOLUTION AND EQUIPMENT MAINTENANCE AND
                           FROM ORGANIC SOLVENTS
                                  Summary
          In the section of this report entitled "Waste Characterization"
numerous types of wastes were enumerated.  The preceding discussion of the
model plant deals strictly with the wastes generated from rinse waters and
solution dumps which are disposed of principally as metal hydroxide sludges.
The following section is an attempt to quantify all additional wastes which
might occur, such as wastes from solution and equipment maintenance, as
well as a number of add-on operations such as surface finishing both before
and after plating.

          The assumptions made for the model plant are incorporated in the
following discussion.  The operating conditions for the plant were further
developed and are summarized in Table B-9.  This exercise was necessary in
order to arrive at reasonable quantities of waste.  For example, filter cake
volume, anode area and weight are dependent on the solution volume and the
processing rate which, in turn, is dependent on the cathode current density
and efficiency.  The operational conditions used are those which are common
in the industry and are given in metal finishing handbooks.

          Some wastes were believed not to be significant.  Failure of
equipment and replacement of parts are such items.  For instance, pumps
require replacement of seals; piping, valves, spray nozzles, etc., need to
be replaced occasionally; heat exchangers, heating or cooling coils, and
tank linings have limited life, which is much greater than 1 year, however.
Loss of hydraulic fluid from automated equipment, corroded duct work, and
maintenance of heat and power supplies also are excluded, as well as re-
placement parts for the waste treatment system itself.

          One can postulate many ways of how solutions and equipment can
be maintained in terms of frequency and the type of equipment used, and
what basis metal requires what specific kind of preplating preparation.
Nevertheless, whatever operations are employed in a given plant, some
wastes will result from it.  While the model plant additions discussed
here may not be typical, as there are many possible variations, the criteria
set up are such that a plant could perform these operations, and, conse-
quently, produce these types and quantities of waste which are summarized
in Tables B-10 and B-ll.
                   Wastes From Basis Metal Preparation
          Some additional finishing of the basis metal was assumed to take
place in the model plant.  One half of the brass parts obtaining a decorative

                                    B-44

-------
chromium finish (lines 1 and 2) require a high-luster finish.  Cutting and
polishing operations of 216 m2/day (2,328 sq ft/day) were estimated to re-
move 3,040 kg/yr (6,710 Ib/yr) of brass by abrasive action of polishing
and buffing compounds and wheels on the parts, making the assumption that
6.35 urn (0.00025 inch) of metal was removed in the process.  Similarly, if
the compound was applied to a thickness of 0.0025 cm (0.001 inch), then
1.486 m2 (16 sq ft) of area would use up 0.45 kg (1 Ib) of compound
assuming its density would be nearly equal to that of water.  At such a
rate, 12,607 kg (27,830 Ib) of compound are consumed annually.  Further
waste is obtained from the wear of buffing and polishing wheels, taking it
equal to the amount of brass removed, or 3,040 kg/yr (6,710 Ib/yr).  The
combined wastes of 23,220 kg/yr (51,250 Ib/yr) are precipitated in dry
dust collectors and disposed of with regular trash to a landfill.  The
abrasive action causes the wheels and buffs to be worn down.  At one-half
of their original weight equal to 3,040 kg/yr (6,710 Ib/yr) the unused
portions are returned to the suppliers as waste for recycling.  In order
to perform these operations 12 men were added to the plant, assuming that
all operations were performed manually.  Alternatively, if the parts were
the same, the operation could have been automated, reducing the required
manpower and possibly the quantity of waste from control of conroound and
buff use.

          As is the case with brass, it has been assumed that 50 percent of
the steel parts processed in the automatic rack zinc line  (line 3) required
some form of basis metal preparation.  Half of this quantity was assumed
to go through a deburring operation and the remaining half through a bur-
nishing operation.  Assuming a basis metal thickness of 0.191 cm  (0.075
inch), a total of 2,925 kg/day (6,456 Ib/day) of steel parts must be
deburred.  For a deburring time of 2 hours, the load is distributed in
8 barrels containing 98 kg (200 Ib) of parts.  For a removal rate of 1/10
of 1 percent of the load, 1,510 kg/yr (3,330 Ib/yr) of steel is removed
using up an equal amount of aluminum oxide media, and 7,550 kg/yr (16,640
Ib/yr) of proprietary compound, containing soaps, chelating and rust-
preventative agents when the charge is 1 pound per load.

          The burnishing operation is carried out with steel balls and
shapes in the same number of barrels containing the same amount of pro-
prietary compound, 7,550 kg/yr (16,440 Ib/yr).  No metal removal takes
place; however, a replacement of 2 oz/load of steel media for wear and loss
can be assumed, amounting to 2,080 Ibs of steel per year.  Whereas, most
of the latter ends up with the general trash, the unloading of the charge
by simply washing the parts with tap water occurs through the sewer, as is
the case with the burnishing operation.

          The preparation for hard chromium plating is accomplished by
grinding the basis metal (steel).  In this operation, 0.00125 cm (0.0005
inch) of steel is removed amounting to 7.95 kg/day (1.52 Ib/day) or 2,060
kg/yr (4,550 Ib/yr).  It is also assumed that the parts are overplated
with chromium by 0.00025 cm (0.001 inch) which must be removed by grinding.
The quantity of chromium generated is 380 kg/yr (840 Ib/yr), which can be
collected and returned to a scrap dealer.
                                    B-45

-------
                     IABLE B-9.   OPERATING CONDITIONS
Line
No.
1


2


3
4
5
6
7
8
9
Bach Volume
Bath
Cu
Ni
Cr
Cr
Ni
Cr
Zn
Zn
Cd
Cr
Anodic Ing
Fhosphatlng
Electroless
Ni
1
3,800
7,000
3,800
1,900
5,700
1,900
18,900
11,400
3,800
1,900
15,200
2,300
1,900
gal
1,000
4,500
1,000
500
1,500
500
5,000
3,000
1,000
500
4,000
600
500
Number
of
Stations
1
9
2
1
3
1
10
6
2
1
8
3
1
Coating Thickness
Urn
2.0
15
1.3
2.0
15
1.3
7.5
7.5
9.0
50
10
10 mg/dm2
12.5
0.001 inch
0.075
0.6
0.05
0.075
0.6
0.05
0.3
0.3
0.35
2
0.4
0.003 o«/£t2
0.5
Cathode
	 -C.P.
A/dm A/ft
2.5
5.0
10
2.5
5.0
10
4.0
4.0
2.0
15
1.2
—
25
50
100
25
50
100
40
40
20
150
12
—
Cathode Cathode
Efficiency, Area. ;
percent dm ft
50
100
15
50
100
15
60
60
90
15
•
—
372
1616
372
104
455
104
1719
1031
372
1003
1486
5017
1997
40
174
40
11.2
49
11.2
185
111
40
108
160
540
215
B-46

-------
FOR MODEL PLANT  RATING LINES
Anode
	 -Area „
dm ft
557
1616
557
156
455
156
2573
1551
557
1505
1486
60
174
60
16.8
49
16.8
277
167
60
162
160
Avg. Anode Anode
Wt. in Bath Anode Replacement Bath Purification
kg
739
2090
Ib
1630
4610
Insoluble
209
585
460
1290
Insoluble
1560
921
408
3440
2060
900
Insoluble
Insoluble
Material Cycle, days Filtering Co. Removal
Rolled
Rolled
Pb-Sb
Rolled
Bar
depol.

bar
Rolled depol.
& electrolytic
Fb-Sb
Forged
Forged
Forged
Pb-Sb
Pb-Sb

balls
balls
balls


66
28
-
66
28
-
36
36
33
-
-
Continuous X
Continuous
-
Continuous X
Continuous
-
Batch X
Batch X
Batch X
-
.
Electrolytic

X


X

X
X
X


                                                 Batch
(X)
                                         B-47

-------















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                               Process Wastes
          Plating solutions must be kept free of solids, particles, precipi-
tates, and impurities, which when left in solution could cause rough deposits,
Solids are removed by passing the solution through a filter medium of a
porous material which is normally precoated with a filter aid, such as
diatomaceous earth.  In addition, activated carbon is used to remove
organic materials by absorption.  As the filter openings clog, the high
rate of solution flow is constantly decreased, requiring frequent cleaning
of the filter.  The copper, nickel, and cadmium baths are continuously
filtered.  The zinc baths are batch filtered twice a year, while the
chromium baths, anodizing, and phosphating solutions are not filtered.  In
order to properly size the filters, the bath volume must be calculated.
For a copper strike having a cathodic current efficiency of 50 percent
and depositing 2 g,m (0.000075 inch) at a current density of 2.5 amp/dm2
(25 amp/ft2), the plating time required is 3.2 minutes.  For Line 1, the
process rate is 560 m2/day (6,024 sq ft/day) or 4 m2 (40 sq ft) per load.
Assuming that each rack can carry 2 m2 (20 sq ft) of parts to be plated,
a bath volume of 1,000 gal is required if tank width and depth are 1.5 m
(5 ft) each and tank length is 1.65 m (5-1/2 ft), allowing for a rack size
of 0.75 x 1.2 m (2-1/2 x 4 ft).  For a filtering rate of 1,350 l/m2/hr
(33-1/3 gal/sq ft/hr) the required filter area is 2.8 m2 (30 sq ft) if the
3,785 1  (1,000 gal) of solution are passed through the filter once each
hour.  Using a precoat of diatomaceous earth and activated carbon at a
ratio of 5:1 and a loading of 667 g/m2 (2 oz/sq ft) of filtering aid
every 2 weeks, the filter cake disposal is 88 kg/yr (195 Ib/yr), composed
of 37 kg (81-1/2 Ib) diatomaceous earth, 7.4 kg (16-1/2 Ib) activated
carbon, and 43.6 kg (97-1/2 Ib) of hazardous plating bath chemicals,
assuming that the filter coat absorbs its equal weight in plating bath plus
dust and dirt.

          Copper bar anodes of 1.2 m (4 ft) length and a cross section of
35 cm2 (5.5 sq in) used in the bath weigh 39 kg (86 Ib) each, when new.
Assuming that half of the anodes are used up on the average, 38 anodes are
required in the bath when the anode-to-cathode ratio is 1.5 to 1, weighing
737 kg (1,626 Ib).  The anodes are not totally consumed; they are replaced
in the bath after 85 percent consumption, resulting in a total anode re-
placement of 627 kg (1,382 Ib) every 66 days at a copper deposition rate
of 9.44 kg/day (20.88 Ib/day).  The unusable anode scrap of 44 kg (980
Ib/yr) is sold as pure copper metal.

          The anode bags are reused once so that 78 bags are disposed of
once a year.  Each bag has an area of 0.4 m2  (0.5 sq yd) weighing 60 g
(2 oz) for a total of 6 kg/yr  (13 Ib/yr).  Together with the anode bags
6 kg  (13 Ib) of bath chemicals are disposed of with the regular trash,
composed of 2.0 kg/yr (4.5 Ib/yr) CuCN, 2.9 kg/yr (6.3 Ib/yr) NaCN, 0.2
kg/yr  (0.5 Ib/yr) of NaOH, and 0.9 kg/yr (1.7 Ib/yr) of Na2CC>3.

          Anodes corrode with formation of a sludge which collects in the
anode bags.  With the assumption that 1 percent of the anodes becomes
insoluble sludge, 25 kg (54 Ib) are destined for disposal in a year's time.


                                      B-50

-------
           The copper plating bath of Line 2 is equipped with a solution
submersible filter.  Twenty-six cartridges are used annually weighing
11.4 kg (25 Ib) plus 12.3 kg (27 Ib) of filter cake and 12.3 kg (27 Ib)
of absorbed bath chemicals.

           The two zinc plating baths of Lines 3 and 4 use bagged, forged
zinc ball-anodes and are batch filtered twice a year.  The chromium baths
are not filtered, but an anode sludge consisting of lead antimony chromate
is scrubbed from the anodes once a week, amounting to 11 kg/yr (25 Ib/yr)
for Line 1, 3 kg/yr  (6 Ib/yr) for Line 2, and 1 kg/yr (2 Ib/yr) for the
hard chromium plating operations.  With the anodes being scrubbed in a
rinse tank, this waste may go to the treatment plant or the sewer.

           The scrap nickel anodes of 15 percent of the total load of
Line 1, or 2964 kg  (6536 Ib) of nickel are used in anode baskets in the
nickel bath of Line  2.  Consequently, no scrap nickel results from the
plant operations.

           The total plant operation requires the passage of 1368 racks per
day, or 355,650 racks processed per year.  Assuming that 1/2 of 1 percent
of the racks are recoated and that the coating material, vinyl plastisol,
weighs 1 kg (2 Ib) per rack, then 1615 kg (3560 Ib) of rack coating is
disposed of annually.  If each rack lasts through 1000 process cycles,
then 1610 kg/yr  (3550 Ib/yr) of brass for a rack weight of 4.5 kg (10 Ib)
each are hauled from the plant to a scrap dealer.  With each recoating of
the racks, titanium  contact tips weighing 0.45 kg (1 Ib) per rack, or
810 kg (1780 Ib) of  titanium are also sold to a scrap dealer.  With each
plating cycle, metal is deposited on all exposed and submerged metal-
conductors of the  racks.  Assuming that this amount is equal to 5 percent
of all metals deposited on workpieces, 2600 kg (5740 Ib) of metal per
year, namely 160 kg/yr  (350 Ib/yr) Cu, 1270 kg/yr (2800 Ib/yr) Ni, 950 kg/yr
(2100 Ib/yr) Zn, 160 kg/yr  (355 Ib/yr) Cd, and 60 kg/yr (135 Ib/yr) Cr are
sold for recycling.

           Plating solutions are sensitive to metallic impurities which,
when codeposited with the metal, have a deleterious effect on the proper-
ties of the deposit.  Low current density purification, called dummying, is
therefore applied  to most plating baths.  It could be carried out on a
batch basis or continuously by cycling the plating solution through an
auxiliary tank.  For example, the nickel bath of Line 1 is purified by
electrolysis of 0.5  amp/dm^ (5 amp/sq ft), using 420 dm^ (45 sq ft) of
cathode area (equivalent to an electrolysis current of 0.013 amp/1 [0.05
amp/gal] cf solution) and depositing 1.8 kg/day (4.0 Ib/day) of metal alloy
consisting of nickel  (the highest fraction), copper, zinc, and iron, the
basis metals processed on the line.

           The two zinc baths are treated twice each year by a chemical
treatment of zinc  dust, which displaces the more noble metals in the
solution plus an addition of polysulfide.  With a charge of 2 g/1 (0.25
oz/gal) of each, 135 kg (300 Ib) of metal, mostly copper, and 135 kg (300 Ib)
of metal sulfides  are precipitated and removed by filtering.  Alkaline
cyanide baths build  up carbonate concentration during the operation.  When
that concentration exceeds a certain value, it is common practice to remove

                                    B-51

-------
the  carbonate by freezing.  Depending on geographic location of the plant,
this may be accomplished by pumping the bath to an outside storage tank
in the winter time or artificially cooling the bath.  If such a procedure
is carried out once a year and the removal rate is 45 g/1 (6 oz/gal) of
Na2C03, then for the zinc bath of Line 3, 766 kg  (1690 Ib) of Na CO  are
generated and must be disposed of to the waste treatment plant ifi form of
a sludge containing all the constituents of the bath.  Alternatively, the
sludge may be drummed and taken to a landfill.

          The electroless nickel plating bath of Line 9 has a waste disposal
problem all its own.  An increase of the phosphite level to above 1.2 moles/
liter through oxidation of the (H?P07)  ion generally requires that the bath
would be discarded by returning it to the manufacturer.  Because of the high
volume of production (160 m /day) in a large volume of solution (1900 1 or
500 gal) depositing 16 kg (35.2 Ib) of nickel per day for a thickness of
0.00125 cm (0.0005 inch), it was decided to regenerate the bath in-house by
addition of Ni(OH)_, hypophosphorous acid, calcium sulfate and hydrated
lime, the latter two being the first two steps in the regeneration process.
The precipitated calcium orthophosphite, 40.3 kg/day (88.8 Ib/day) for the
amount of nickel deposited, is pressure filtered and removed, amounting to
10430 kg (23,000 Ib) annually.  In addition, NaS04 has to be removed by
freezing.  The quantity of waste disposed of is 4550 kg/yr (10,040 Ib/yr).
Other procedures, such as phosphite removal by ion exchange, would be more
economical, producing much less waste.

          Metal finishing plants normally are not 100 percent efficient.
A certain number of parts are rejected on quality inspection because of
defects in the coatings.  With the assumption that 0,5 percent of the
finished parts are rejected, for a proposed material thickness of 0.2 cm
(0.075 inch) and from the production rate, 37640 kg (83,000 Ib) of steel
parts and 2330 kg (5130 Ib) of brass parts containing Cu-Ni-Cr and/or Zn
are collected and sold to a scrap dealer periodically.  The cadmium and
hard-chromium plating parts are assumed to be stripped and replated.
                                Organic Wastes
          Some of the organic wastes, for example rack coatings, have been
dealt with earlier in this section of the report.  A degreasing operation
using trichlor (CHC1:CC1_) is needed to remove the bulk of the polishing
and buffing compounds from the parts prior to plating,  Assuming that the
compounds are disposed of in a sludge containing equal amounts of the sol-
vent, 10,700 1 (2830 gal) of CHC1:CC12 are lost annually. The remaining
solvent is assumed to be purified continuously in the plant by a distilling
apparatus attached to the degreaser.
                                  Conclusion
          The preceding calculations are examples of the wastes generated
by the model plant other than the chemical sludges from waste treatment
operations.  The assumptions made in the examples are the same for corres-
ponding type processes and solutions and the total wastes which are disposed
of are tabulated in the preceding Tables B-9 to B-ll.  In order to perform
these functions, 15 employees were added to the total plant force.

                                B-52

-------
            PART II.   CALCULATIONS  OF  CHEMICALS  IN WASTE  STREAMS
              FOR ELECTROPLATING AND METAL  FINISHING  OPERATIONS
                      LINES  2  THROUGH  9  FOR MODEL PLANT
Line 2.  Manual Racks Cu(CN)-Ni-Cr
Plating Calculations
          Hot Alkali Soak Clean

              Make-up concentration:
              Drag out rate:
              Dump cycle:
              Tank volume:
              Dump rate:
                            8 oz/gal
                            5.16 gal/day
                            25 days
                            600 gal
                            24 gal/day
          Daily Amounts in Drag Out & Dump Stream
              NaOH
              NaSiO
              Na^PO. -12H-0  =
                24    2
                     (24)(2olO) = 50.4 oz/day = 3.15 Ib/day
                     (24)(lo32) = 31.7 oz/day = 1,98 Ib/day
                     (24)(1,50) = 36.0 oz/day = 2.25 Ib/day
                     (24)(0.72) = 17,3 oz/day - 1.08 Ib/day
          Electrolytic Anodic Clean ~ Steel and Nonferrous Metals
              Make-up concentration:
              Drag out rate:
              Dump cycle:
              Tank volume:
              Dump rate:
                            8 oz/gal
                            5ol6 gal/day
                            20 days
                            300 gal
                            15 gal/day
          Daily Amounts in Drag Out & Dump Stream
              NaOH
              Na-CO
                 =  (15) (2.10) = 31o5 oz/day = 1.97 Ib/day
                 =  (15)(0.78) = 11.7 oz/day = 0.73 Ib/day
                 =  (15)(2.40) = 36.0 oz/day = 2.25 Ib/day
                 =  (15)(0.60) = 9.0 oz/day = 0.55 Ib/day
Sulfuric Acid Dip

    Make-up concentration:
    Drag out rate:
    Dump cycle:
    Tank volume:
    Dump rate:
    Workpieces:
                                      45 g/1
                                      5ol6 gal/day
                                      10 days
                                      200 gal
                                      20 gal/day
                                      70 percent steel; 30 percent: brass
                                    B-53

-------
It was assumed that 15 percent of the acid was used up in
pickling the workpieces.  The acid concentration is maintained
by the periodic addition of fresh acid to replace the drag out
acid.  The quantity of unreacted H^SO, tnat leaves in the rinse
waters and is dumped is as follows :

    (5.16 + 20) (38. 25) (3. 78) = 3,643 g/day or 8.04 Ib/day.

The amount of metal in the rinse and dump streams is as follows:

    (25. 16) (6. 75) (3. 78) = 642 g H2SO,/day reacted with metals.

    70 percent reacted with iron and 30 percent with brass.

    (642)(0.70) e 255 g/day = Q<564 lb/day of iron.
    (642) (0.30) = 126 g/da      88<1 S/day = 0.194 lb/day of copper

       1>53                     37.9 g/day - 0.084 lb/day of zinc.

Sulfuric Acid Dip (After Cu(CN) Plating)

    As on Line 1, this dip was assumed to dissolve a negligible
    quantity of copper plate; no additions of fresh acid are made
    to this tank.

    Drag out rate:           5.16 gal/day
    Dump cycle:              10 days
    Tank volume:             200 gal
    Dump rate:               20 gal/day

    Quantity of acid leaving in the drag out and dump streams is:

         (20) (107) (3. 78) = 8100 g/day = 17.88 lb/day of sulfuric
                                                        acid.
                         B-54

-------
Line 3.  Zinc Automatic Rack Plating
(+ Chromating) Calculations

          Electrolytic Anodic Clean (Steel)

              Make-up concentration:  8 oz/gal
              Drag out rate:          25.8 gal/day
              Dump cycle:             15 days
              Tank volume :            500 gal
              Dump rate:              33.33 gal/day

          Daily Amounts in Drag Out and Dump Stream

              NaOH         =  (33. 33) (3.0) = 100.0 oz/day = 6.25 Ib/day
              Na CO,       =  (33o33)(2.4) = 80.00 oz/day = 5.00 Ib/day
              NapiO       =  (33. 33) (0.24) = 8.00 oz/day = 0.50 Ib/day
              Na3P04'12H20 -  (33o33)(0.30) = 10.0 oz/day = 0.63 Ib/day

          Concentrated Hydrochloric Acid Dip

              Make-up concentration:  111 g/1
              Drag out rate:          25.8 gal/day
              Dump cycle:             25 days
              Tank volume:             250 gal
              Dump rate:              10 gal/day

              It will be assumed that the original acid will be used up by
              reacting 20 percent of it with Fe and disposing of the remaining
              80 percent as unreacted acid in the dump and drag out streams.

              Total acid at start = (111) (250) (3 .785) = 104,895 g/day

                                                      = 231.6 Ib/day
              Acid reacted  with Fe = 20,979 g = 46.3 Ib    .  Q_ ....
                                                7T7 — j -  = I.OD Ib/day
                                                25 days              J
              Acid unreacted = 83,916  g = 185.2 Ib     ,
                                           25 days = 7°41
              The quantity of Fe dissolved = —ay = 1.42 Ib/day
              Where 10306 is the ratio of HCl to Fe according to the equation

                   Fe° + 2H+ -  Fe2+ + H2T

          Caustic Dip

              Make-up concentration:   1.0 oz/gal
              Drag out rate:          25 „ 8 gal/day
              Dump cycle:              5 days
              Tank volume:             250 gal
              Dump rate:               50 gal/day

              Quantity of NaOH leaving in the drag out  and  dump:

              (1.0) (7. 5) (50) (3. 78)  =  1,418 g  NaOH/day = 3.12  Ib/day 0

                                   B-55

-------
Chrpmate Dip

    Make-up concentration:  15 g/1 Na Cr_0 *2H 0 (2 oz/gal)
                            7.5 g/1 HN03 (1 oz/gal).

    It was assumed that 1/2 of the original Cr   content winds
    up on the workpieces.  It was also assumed that the total
    zinc dissolved during the chromating operation is equivalent
    to 1/2 the nitric acid originally present.
            +6
Amount of Cr   Leaving in Drag Out and Dump

    M.W. of Na2Cr20?'2H20 = 298.05
    7oCr+6 =     *    X 10° = 34*9 Percent
    Drag out rate:          25.8 gal/day
    Dump cycle :             5 days
    Tank volume:            250 gal
    Dump rate:              50 gal/day

    Quantity of dichromate leaving = (50)(3.78)(7.5) = 1,416 g/day

                                                     =3.12 Ib/day.
                  +6
    Quantity of Cr  leaving = 3.12(0.349) = 1.088 Ib/day.

    Quantity of unreacted nitric acid leaving in the drag out and dump:

    (3.75)(50)(3.78) = 709 g HN03/day = 1.56 Ib HN03/day.

    Quantity of dissolved zinc metal leaving in the drag out and dump:

    4Zn° + N0~ + 10H+ -» 4Zn + + NH* + 3KJD

    1 gram Zn  requires 2.41 g HNO,,, then

    '3 7S\
      -£r)(50)(3.78) = 294 g/day = 0.648 Ib/day.

    Zinc dissolves  in the nitric acid mainly by hydrogen ion dis-
    placement.
    Zn  + 2HN00 - 1  + 2NO,, + Zn
                          B-56

-------
Line 4.  Automatic Barrel Zlnc(CN) Calculations
          Hot Alkali Soak Clean

              Make-up concentration:  8.0 oz/gal
              Drag out rate:          25.8 gal/day
              Dump cycle :             10 days
              Tank volume:            600 gal
              Dump rate:              60 gal/day

          Daily Amounts in Drag Out and Dump Stream

              NaOH         =  (60) (2. 10) = 126 oz/day = 7.88 Ib/day
              Na CO        =  (60) (1.32) = 79.2 oz/day = 4.95 Ib/day
                           =  (60) (1.50) = 90.0 oz/day = 5.63 Ib/day
                           -  (60) (0.78) = 46.8 oz/day = 2.93 Ib/day

          Concentrated Hydrochloric Acid Dip

              Make-up concentration:  111 g/1
              Drag out rate:          25.8 gal/day
              Dump cycle:             15 days
              Tank volume:            200 gal
              Dump rate:              13.33 gal/day

              It will be assumed that the original acid will be used up by
              reacting 20 percent of it with Fe and disposing of the remaining
              80 percent as unreacted acid in the dump and drag out stream.

              Total acid at start = (111) (200) (3.78) = 83,916 g = 185.3 Ib

              Acid reacted with Fe = 16,783 g = 31'®j lb = 2.47 Ib/day
              Acid unreacted = 67,133 =  ,'  lb = 9.88 Ib/day
              The quantity of Fe dissolved =  '     p     = 1.89 Ib/day.

          Caustic Dip

              Make-up concentration:   1.0 oz/gal NaOH
              Drag out rate:           25.8 gal/day
              Dump cycle:              5 days
              Tank volume:             200 gal
              Dump rate:               40 gal/day

              Quantity of NaOH leaving in the drag out  and  dump  stream:

              (1) (7. 5) (40) (3. 78)  » 1,134 g NaOH/day = 2.50  lb NaOH/day.
                                   3-57

-------
Nitric Acid Dip

    Make-up concentration:  51 g/1
    Drag out rate:          25.8 gal/day
    Dump cycle:             5 days
    Tank volume:            200 gal
    Dump rate:              40 gal/day

    Quantity of acid leaving in the drag out and dump stream:

    (51.0) (40)(3.78) = 7,711 g/day = 17.02 Ib/day.

Chromate Dip

    Make-up concentration:  15 g/1 Na Cr207'2H 0

                            7.5 g/1 HN03.

    It was assumed  that 1/2 of the original Cr   in  the  bath winds
    up on the workpiece surfaces.  It was also assumed that the
    total zinc dissolved  during the chromating operation is equi-
    valent to 1/2 the nitric acid present in the original bath.
          I/-
Amount Cr   Leaving in Drag Out and Dump

    Drag out rate:          25.8 gal/day
    Dump cycle:             5 days
    Tank volume:            200 gal
    Dump rate:              40 gal/day

    Quantity of dichromate leaving:

    (40)(3.78)(7.5) = 1,136 g/day = 2.496 Ib/day.

    Quantity of Cr+6 leaving =  (2.496)(0.349) = 0.872 Ib/day.

    Quantity of dissolved zinc leaving in the dragout and dump:

    1 gram Zn requires 2.41 g HNO,


   ff~j= (40) (3.78)  = 235 g/day = 0,52 Ib/day.


    Quantity of unreacted HNO« leaving in the di ag out ai.-d di.irp

    (3.75)(40) (3.78) = 567 g/day = 1.25 Ib/day.
                          B-58

-------
Line 5.  Manual Barrel Cadmium(CN)
Calculations
          Cathodic Alkaline Clean (Steel)

              Make-up concentration:  8.0 oz/gal
              Drag out rate:          8.6 gal/day
              Dump cycle:             10 days
              Tank volume:            400 gal
              Dump rate:              40 gal/day

          Daily Amounts in Drag Out and Dump Stream

              NaOH         =  (40) (3.0) = 120 oz/day = 7.5 Ib/day
              Na-CO-       =  (40) (24) = 96.0 oz/day » 6.0 Ib/day
                           =  (40) (0.24) =9.60 oz/day =0.60 Ib/day
                         0 =  (40) (0.30) = 12.0 oz/day = 0.75 Ib/day

          Concentrated Hydrochloric Acid Dip

              Make-up concentration:  111 g/1
              Drag out rate:          8.6 gal/day
              Dump cycle :             10 days
              Tank volume:            200 gal
              Dump rate:              20 gal /day

              It was assumed that the original acid is used up by reacting
              20 percent of it with Fe and disposing of the remaining 80
              percent as unreacted acid in the dump and drag out stream.

              Total acid at start = (111) (200) (3 .78) = 83,916 g = 185.3 Ib

              Acid reacted with Fe = 16,783 g = "01  = 3.705 Ib/day
              Acid unreacted = 67,133 =    ',  lb = 14.82 Ib/day
                                         10 days              J
              The quantity of Fe dissolved =  ^_X = 2 . 84 Ib/dav.
                                                 1 . JUD
          Caustic Dip

              Make-up concentration:   2 oz/gal
              Drag out rate:           8.6 gal/day
              Dump cycle:              5 days
              Tank volume:            200 gal
              Dump rate:               40 gal/day

              Quantity of  NaOH leaving in the drag out and dump dtream:

              (2) (7. 5) (40) (3. 73) = 2,268 g/day * 5.01  lb/Joy.
                                   B-59

-------
Chrotnate Dip

    Make-up concentration:  15 g/1 Na Cr-O '2H?0

                            7.5 g/1 HN03.

    It was assumed that 1/2 of the original Cr   winds up on
    the Cd-plated workpieces.  It was also assumed that the total
    cadmium dissolved during the chromating operation is equi-
    valent to 1/2 the nitric acid present in the original bath.
            • /•
Amount of Cr   Leaving in Drag Out and Dump

    Drag out rate:          8.6 gal/day
    Dump cycle:             10 days
    Tank volume:            200 gal
    Dump rate:              20 gal/day

    Quantity of dichromate leaving:  (20)(3.78)(7.5) = 567 g/day

                                                     = 1.252 Ib/day.

    Quantity of Cr+6 leaving = (1.252)(0.349)  = 0.437 Ib/day.

    Quantity of dissolved cadmium metal leaving in the drag out
    and dump:
    1 gram Cd requires 1.12 g of HNO,

   (i7if)(20)(3'78) " 253 8/day = °*56 lb/dav-
    Quantity of unreacted nitric acid leaving in the drag out and
    dump:

    (3.75)(20)(3.78) = 284 g/day = 0.626 Ib/day.
                         B-60

-------
Line 6.  Manual Rack Hard Chromium
Calculations
          Cathodic Alkaline Clean (Steel)

              Make-up concentration:  8 oz/gal
              Drag out rate:          2.60 gal/day
              Dump cycle :             20 days
              Tank volume:            200 gal
              Dump rate:              10 gal/day

          Daily Amounts in Drag Out and Dump Stream
              NaOH         «  (10) (3.0) - 30.0 oz/day - 1.875 Ib/day
              Na2COo       "  (10) (2. 4) - 24.0 oz/day =1.50 Ib/day
              Na^SiO       =  (10) (0.24) =2.40 oz/day = 0.150 Ib/day
                           »  (10) (0.30) = 3.00 oz/day = 0.188 Ib/day.
          Anodic Sulfuric Acid Treatment

              Make-up concentration:  960 g/1
              Drag out rate:          2.60 gal/day
              Dump cycle:             60 days
              Tank volume:            200 gal
              Dump rate:              3.33 gal/day

              It was assumed that 20 percent of the original sulfuric acid
              present is used to convert steel (Fe) to ferrous sulfates

              1 g steel reacts with 1.76 g of H SO,

              Quantity of Fe in the drag out and dump:

              (0.20)fp2_)(3.33)(3.78)  = 1,373 g/day = 3.03 Ib/day.


              Quantity of unreacted sulfuric acid in the  drag out and dump:

              (0.8) (960) (3. 33) (3. 78) = 9,667 g/day = 21.34 Ib/day.
                                   B-61

-------
Line 7.  Manual Rack Anodizing Calculations
          Hot Alkali Soak Clean (Aluminum)

              Make-up concentration:  8 oz/gal
              Drag out rate:          19.37 gal/day
              Dump cycle:             15 days
              Tank volume:            800 gal
              Dump rate:              53.33 gal/day
Item
Na2Si03
Na2C03
Na3P04-12H20
Surfactant
Wt. %
40
45
10
5
Orig. Comp.
oz/gal
3.2
3.6
0.8
0.4
75% Residual
Comp., oz/gal
2.7
2.7
0.6
0.3
          Daily Amounts in Drag. Out and Dump Stream
              Na CO-       =  (53. 33) (2. 4) = 128 oz/day « 8.0 Ib/day
              Na^SiO       =  (53. 33) (2. 7) = 144 oz/day = 9.0 Ib/day
                           =  (53. 33) (0.6) = 32 oz/day = 2.0 Ib/day.
          Caustic Etch

              Make-up concentration:   53 g/1 NaOH
              Drag out rate:          19.37 gal/day
              Dump cycle:             7.5 days
              Tank volume :             400 gal
              Dump rate:              53.33 gal/day

              It will be assumed that 20 percent of the NaOH is used up
              in etching the aluminum workpieces.  Quantity  of NaOH leaving
              in the drag out and dump :

              (53K0.8)(53.33)(3.78)  = 8,547 g/day = 18.87 Ib/day.

              Quantity of Al leaving  in the drag out and dump:

              2 Al + 20H~ + 2 H20  -  2 A10~ + 3H2?

              1 g Al requires 1.48 g  NaOH for dissolution.

              (53)(0.2)(53.33)(3.78)   _ 1444 g/day _          ,
                      (1.48)          ~  453 g/lb  " J>1B7 lb/dav'
                                   B-62

-------
Nitric Acid Desmut

    Make-up concentration:  100 g/1 HNO.,
    Drag out rate:          19»37 gal/day
    Dump cycle:             20 days
    Tank volume :             400 gal
    Dump rate :               20 gal/day

    The desmut serves to remove small quantities of materials
    such as copper, manganese, and other elements from the
    aluminum surface.  It will be assumed that at the time o'l
    dumping, 5 percent of the original acid present was used
    up in dissolving small amounts of copper and manganese with
    60 percent used for copper and 40 percent for Mn«

    3 Cu° + 2 NCC + 8H+ -  3 Cu2+ + 2 NOT  +4 t^O
                       I        f\ |^
    3 Mn° + 2 N0~ + 8H  -*  3 Mn   -f 2 NOT  +4 H20

    1 g Cu requires:  0.66 g HNO.,

    1 g Mn requires:  0.77 g HNO~ „

    Quantity of unreacted HNO ^ leaving in the drag out and dump:

    (95) (20) (3. 78) = 7,182 g/day = 15.85 Ib/day.

    Quantity of Cu and Mn leaving in the drag out and dump:


                    = 344 s/day = °°759 lb/day of copper
    (20) (2^0) (3. 78} = ig6 g/day = Qo433 lb/day of raanganese>

Bright Dip

    The bright dip solution employs save rinses with most of the
    acids recovered and sold to a fertilizer manufacturer as
    indicated in Table A-2, Line 7.

Anodize

    The aluminum anodizing solution is discarded when the alum-
    inum concentration reaches 12 g/1.

    Make-up concentration:  165 g/1 H SO,
    Drag out rate:          19.37 gal/day
    Dump cycle:             20 days
    Tank volume:            3000 gal
    Dump rate:               150 gal /day

    Quantity of sulfuric acid reacting with aluminum in the
    anodizing operation:

                         B-63

-------
    2 Al° + 6 H+ -  2 A13+ + 3 ly

    1 g Al requires 5.45 g H SO  for reaction, and 12 g

    require (12) (5. 45) = 65.4 g H SO./l.

    Quantity of unreacted sulfuric acid in the drag out and dump:

    (99. 6) (150) (3. 78) = 56,473 g/day = 124.7 Ib/day.

    Quantity of aluminum leaving in the drag out and dump:

    (12.0) (150) (3. 78) = 6,804 g/day = 15.02 Ib/day.

Nickel Acetate Seal

    Make-up concentration:  10 g/1 Ni(C H-^O-) -4H 0
    Drag out rate:          19.37 gal/day        ^
    Dump cycle:             5 days
    Tank volume:            400 gal
    Dump rate:              80 gal/day

    It will be assumed that 1/2 of the nickel acetate is used
    up on sealing the anodized aluminum surfaces.  Quantity of
    nickel leaving in the drag out and dump:

           Ni           58.69   „„ ,
                                             Nl
    Ni(C2H302)2.4H20   2484     '

    (50) (0.236) (80) (3. 78) = 357 g/day = 0.788 Ib/day.
                         B-64

-------
Line 8.  Automatic Barrel Zinc
Phosphating Calculations

          Hot Alkaline Soak Clean (Steel)

              Make-up concentration:  8.0 oz/gal
              Drag out rate:          21.52 gal/day
              Dump cycle :             20 days
              Tank volume:            250 gal
              Dump rate:              12.5 gal/day

          Daily Amounts  in Drag Out and Dump Stream

              NaOH         -   (12.5)(2.10) = 26.25 oz/day = 1.64  Ib/day
              Na CO,       =   (12.5)(1.32) = 16.50 oz/day = 1.03  Ib/day
              Na^SiO       =   (12.5)(1.50) = 18.75 oz/day = 1.17  Ib/day
              Na P04-12H20 =   (12.5)(12.5) = 9.00 oz/day = 0.56 Ib/day.

          Hydrochloric Acid Pickle

              Make-up concentration:  75 g/1
              Drag out rate:          21.52 gal/day
              Dump cycle:             10 days
              Tank volume:            250 gal
              Dump rate:              25 gal/day

              It will be assumed  that the original acid will  be used  up
              by reacting 20 percent of it with Fe and disposing  of the
              remaining  80 percent  as unreacted acid  in the dump  and
              drag out stream.

              Quantity of unreacted HC1 in the drag out and dump  stream:

              (75)(0.8)(25)(3.78) = 5,670 g/day = 12.52 Ib/day.

              Quantity of Fe leaving in the drag out  and dump stream:


                      ^-  (25) (3.78)  = 1,085 g/day = 2.40 Ib/day.
         Zinc Phosphate

              It will be assumed that 1/2 of the phosphating solution  is
              used up and retained in the coating on  the steel workpieces:

              Make-up coricentratin:   42 g/1 H PO • Zn (PO  )
              Drag out rate:          21.52 gal/day
              Dump cycle:             15 days
              Tank volume:            250 gal
              Dump rate:              16.67 gal/day

              Quantity of unreacted H PO  leaving in  the drag out and  dump
              stream:


                   H3P°4          98 0
              	J  H	  _  "° •" _ (-) OQO
              H3P04-Zn3(P04)2    484.1

                                    B-65

-------
    (21) (0.202) (16. 67) (3. 78) = 267.3 g/day = 0.59 Ib/day.

    Quantity of Zn (P0,)~ leaving in the drag out and dump
    stream:

    (21) (0.798) (16. 67) (3. 78) = 1,056 g/day = 2.33 Ib/day.

    Quantity of Zn leaving in the drag out and dump stream:
                       =0.508  (2. 33)(0. 508) = 1.18 Ib/day.

Hot Dip Seal

    Make-up concentration:  0.25 g/1 CrO_
    Drag out rate:          21.52 gal/day
    Dump cycle :             5 days
    Tank volume:            250 gal
    Dump rate:              50 gal/day

    It will be assumed that 1/2 of the chromic acid solution
    winds up on the sealed coating.

    Quantity of CrO  solution leaving in the dump stream:

    (0.125)(50)(3.78) = 23.6 g/day = 0.052 Ib/day.

    Quantity of Cr   leaving in the dump stream:

    (0.052) (0.52) =0.027 Ib/day.
                         B-66

-------
Line 9.  Manual Electroless Rack
Nickel Calculations
          Hot Alkali Soak Clean (Steel)

              Make-up concentration:  8.0 oz/gal
              Drag out rate:          5.16 gal/day
              Dump cycle :             10 days
              Tank volume:            200 gal
              Dump rate:              20 gal/day

          Daily Amounts in Drag out and Dump Stream
              NaOH         =  (20) (2. 10) = 42.0 oz/day = 2.63 Ib/day
              Na CO        =  (20) (1.32) = 26.4 oz/day =1.65 Ib/day
              Na SiO.,      =  (20) (1.50) = 30.0 oz/day = 1.88 Ib/day
                           =  (20) (0.72) = 14.4 oz/day = 0.90 Ib/day.
          Hydrochloric Acid Dip

              Make-up concentration:  240 g/1
              Drag out rate:          5.16 gal/hr
              Dump cycle:             15 days
              Tank volume:            200 gal
              Dump rate:               13.33 gal/day

              It will be  assumed that the original acid is used up by
              reacting 20 percent of it with Fe and disposing of the
              remaining 80 percent as unreacted acid in the dump and
              drag out stream.

              Quantity of unreacted acid leaving in the drag out and
              dump :

              (240)(0.80)(13.33)(3.78)  = 9,674 g/dny = 21.36 Ib/day.

              Quantity of Fe leaving in the drag out and dump:


                       )' (13. 33) (3. 78) = 1,852 g/day = 4.09 Ib/day.
                                  B-67

-------
           PART III.  CALCULATIONS OF CHEMICALS IN WASTE STREAMS
          ORIGINATING FROM PLATING AND/OR PROCESS BATHS THAT ARE
             NOT DUMPED FOR LINES 2 THROUGH 9 FOR MODEL PLANT
Line 2 - Calculations
           The quantity of chemicals dragged out from the three plating
baths on Line 2 and carried away in the rinse waters are given below:


     Copper Cyanide

          Cu(CN):  (5.0) (7. 5) (19, 53) = 732 g/day = 1.618 Ib/day
          NaCN:    (7.0) (7.5) (19.53) = 1,025 g/day = 2,263 Ib/day
          NaOH:    (0.5) (7.5) (19.53) = 73,2 g/day = 0.162 Ib/day
          Na2C03:  (2.0) (7.5) (19,53) » 293 g/day = 0.647 Ib/day

     Nickel Bath

          NiSO ,'6H 0:   (40.0) (7.5) (19.53) = 5,856 g/day = 12.93 Ib/day
               '6KO:   (6.0)(7.5)(19.53) = 879 g/day = 1.940 Ib/day
                       (5.0) (7. 5) (19. 53) = 732 g/day = 1.618 Ib/day

     Chromium Bath

          CrO :   (45)(7.5)(19.53) = 6,591 g/day = 14.55 Ib/day
          H2S04:  (0.45) (7. 5) (19.53) = 65.9 g/day = 0.146 Ib/day

          Taking into account the quantity of CrC^ used up providing the
          chromium metal plated out, the total CrO 3 consumption is:

          (14.55)(1.15) = 16.73 Ib/day,

Line 3 - Calculations

          The quantity of chemicals dragged out from the zinc plating bath
and carried away in the rinse water are as follows:

          Zn:    (40) (25. 8) (3. 78) = 3,901 g/day = 8.61 Ib/day
          ZriO:   3,901/0.803 = 4,858 g/day = 10.72 Ib/day
          NaOH:  (90) (25. 8) (3.78) = 8,777 g/day = 19.38 Ib/day
          NaCN:  (90) (25. 8) (3. 78) = 8,777 g/day = 19.38 Ib/day.

Line 4 - Calculations

          The same values shown above for Line 3 apply to Line 4 operations.
                                    B-68

-------
Line 5 - Calculations

          The quantity of chemicals dragged out from the cadmium plating
bath and carried away in the rinse water are as follows:

          Cd:      (2.66)(7.5X32.55) = 649 g/day =  1.433 Ib/day
          CdO:    649/0.875 = 742 g day = 1.637 Ib/day
          NaCN:    (13.3) (7.5)(32.55) = 3247 g/day = 7.17 Ib/day
          NaOH:    (1.9)(7.5)(32.55) = 464 g/day = 1.024 Ib/day
          Na2C03:  (7.0) (7.5) (32.55) = 1709 g/day =  3.772 Ib/day.


          The values shown below represent the quantity of  chemicals  that
are required for chromating the cadmium plated parts:

          Na Cr 0  • 2H 0:  (2.0)(7.5)(32.55) * 488 g/day = 1.078  Ib/day
          HNO-:            (1.0)(7.5)(32.55) = 244 g/day = 0.539  Ib/day.
 Line 6  - Calculations
          The  quantity  of  chemicals  dragged  out  from the  chromium plating
bath and carried away in the rinse waters are as  follows:

          CrO  :    (45.0)(7.5)(9.84)  =  3321 g/day  =  7.33 Ib/day
          H2SD4:   (0.5)(7.5)(9.84) = 36.9 g/day = 0.081 Ib/day.

          It will  be assumed that 30 percent of the  CrO,,  is  used
          up to provide the chromium metal to be  plated out.  Therefore,
          the  total requirement of CrO.,  is:

                   (7.33)(1.30) = 9.53  Ib/day.
Line  7  - Calculations

           The  quantity  of  chemicals  dragged  out  from the  bright  dip  and
carried away in  the rinse waters are as  follows:

           Combined acids:  206  g/1 =  1.717  Ib/gal
           H PO :    (206)(67/70)(19.37)(3.78)  =  14,437 g/day » 31.87  lb/day
           HN03:     (206)(3/70)(19.37X3.78)  = 646  g/day = 1.427  Ib/day.

           It will be assumed that 2  g/1  of aluminum are present  in the
           last bright dip  save tank.   The  quantity of aluminum leaving
           in the rinses  is:

                    (2.0)(19.37)(3.78)  =  146  g/day  = 0.323 lb/day.
                                   B-69

-------
Line 9 - Calculations

          The quantity of chemicals dragged out from the electroless  nickel
plating bath and carried away in the rinse waters is as follows:

          NiSO, • 7H20:    (30)(5.16) (3.78) = 585 g/day = 1.292  Ib/day
          NaELPCL ' ZH 0:  (10) (5.16) (3.78) = 195 g/day = 0.431  Ib/day
          NaC2H362-3H26:   (10)(5.16)(3.78) = 195 g/day = 0.431  Ib/day.

          The spent electroless nickel solution is regenerated at  the
plant.
                                  B-70

-------
                APPENDIX C - MODEL PLANT B (16 EMPLOYEES)
               SOLID WASTES FROM A MODEL ELECTROPLATING AND
                          METAL FINISHING PLANT
                       Small-Size Job Shop, Model B
                      Employing from 5 to 25 Persons
                         Chemical Waste Treatment
          The following calculations of wastes produced and materials con-
sumed are the same as those employed for the plating shop with 38 employees
representing the medium-size job shop.  The electrodeposition of copper,
nickel, chromium, and zinc represents about two-thirds of the plant capa-
city.  The other operations are cadmium, aluminum anodizing, and phosphating.
The total employment is 16.
                          Model Plant "B" (Small)
            To Represent Job Shops with from 5 to 25 Employees
Assumptions
          Dragout rate
            Rack lines = 12.22 1/100 m  p.O gal/1000 ft )
            Barrel lines = 20.37 1/100 m  (5.0 gal/1000 ft )

          Rinsing efficiency = 70 percent

          Allowable dissolved solids in rinse:  750 mg/1 from cleaners,
                                                    dips, etc.
                                                 37 mg/1 from metal deposi-
                                                    tion solution
                                                 15 mg/1 from chromium
                                                    plating solution.
                                   01

-------
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                                         C-2

-------
Sulfuric Acid Pickel:
Cu(CN) Plate:
Line 1 - Automatic rack Cu(CN)-Ni-Cr, 320 m /day (3444 ft2/day)
         Plating 70 percent steel and 30 percent brass.
         Dragout = 39.06 I/day (10.32 gal/day).
Hot Alkali Soak Clean:     8 oz/gal     Single rinse = 150 gal/hr
                           Tank volume - 1200 gal
                           Dump frequency = 25 days
Electrolytic Anodic Clean: 8 oz/gal     Single rinse = 150 ,gal/hr
                           Tank volume = 600 gal
                           Dump frequency =15 days
                           6 oz/gal     Single rinse = 120 gal/hr
                           Tank volume = 300 gal
                           Dump frequency = 10 days
                           Cu(CN)   5 pz/gal
                           NaCN     7 oz/gal
                           NaOH     0.5 oz/gal
                           Na2C03   2.0 oz/gal
                           2-tank counter current rinse = 100 gal/hr
                           10 percent (107 g/1)
                           Tank volume = 300 gal
                           Dump frequency = 10 days
                                        40 oz/gal
                                         6 oz/gal
                               L.   £~
                           H.BO.,         5 oz/gal
                           2-tank counter current rinse = 150 gal/hr
                           CrO     45 oz/gal
                           H2SO    0.45 oz/gal
                           2-tank counter current rinse = 280 gal/hr
                             = 36,800 I/day (9720 gal/day)
          Acid-alkali stream = 25,290 I/day (6680 gal/day)(1200 gal/day
                               containing Ni)
          Cyanide stream     = 3,030 I/day (800 gal/day)
          Chromium stream    = 8,480 I/day (2,240 gal/day)
Sulfuric Acid Dip:
Nickel plate:
Chromium Plate:
          Total flow
NiSO,-6H00
    4   2
                                    C-3

-------
Line 2 - Manual rack Cu(CN)-Ni-Cr,  120 m2/day (1288 ft2/day)
         Plating 70 percent steel,  30 percent brass
         Dragout =14.53  I/day (3.84  gal/day)
Hot Alkali Soak Clean:     8 oz/gal     Single rinse = 60 gal/hr
                           Total volume = 450 gal
                           Dump frequency =  25  days
Electrolytic Anodic Clean: 8 oz/gal     Single rinse = 60 gal/hr
                           Tank volume = 225 gal
                           Dump frequency = 20 days
Sulfuric Acid Pickle:      6 oz/gal     Single rinse = 45 gal/hr
                           Tank volume = 115 gal
                           Dump frequency = 10 days
Cu(CN) Plate:              Composition as Line 1
                           2-tank counter current rinse = 40 gal/hr
Sulfuric Acid Dip:         10 percent  (107 g/1)     Single rinse = 100 gal/hr
                           Tank volume = 115 gal
                           Dump frequency = 10 days
                           Composition as Line 1
                           2-tank counter current rinse = 60 gal/hr
                           Composition as Line 1
                           2-tank counter current rinse = 105 gal/hr
                      Total flow         = 14,230 I/day (3760 gal/day)
                      Acid-alkali stream =  9,840 I/day (2600 gal/day)
                      Cyanide stream      =  1,210 I/day ( 320 gal/day)
                      Chromium stream    =  3,180 I/day ( 840 gal/day)
Nickel Plate:
Chromium Plate:
                                    C-4

-------
                                                        Single rinse = 400 sal/hr
                                                    2             2
Line 3 - Automatic barrel Zn(CN) + chromating, 280 m /day (3016 ft /day)
         Plating steel
         Dragout = 57.32 I/day (15.12 gal/day)
                           8 oz/gal     Single rinse = 220 gal/hr
                           Tank volume = 350 gal
                           Dump frequency = 10 days
                           30 vol %  (20°Be) 111 g/1
                           Tank volume = 120 gal
                           Dump frequency =15 days
                           NaOH   1 oz/gal     No rinse
                           Tank volume = 120 gal
                           Dump frequency = 5 days
                           Zn     40 g/1
                           NaOH   90 g/1
                           NaCN   90 g/1
                           2-tank counter current rinse = 210 gal/hr
Hot Alkali Soak Clean:
Hydrochloric Acid Dip:
Caustic Dip:
Zinc (CN) Plate
Nitric Acid Dip
Chromate Conversion:
                           15 vol % HN03, 51 g/1     No rinse
                           Tank volume = 120 gal
                           Dump frequency =  5 days
                           Na0Cr00  -2H00   2.0 oz/gal
                           HNO
                                           1.0 oz/gal
                           Tank volume = 120 gal
                           Dump frequency = 5 days
                           2-tank counter current rinse = 65 gal/hr
                       Total  flow         =  27,100 I/day (7160 gal/day)
                       Acid- alkali stream =  18,770 I/day (4960 gal/day)
                       Cyanide stream     =   6,360 I/day (1680 gal/day)
                       Chromium stream    =   1,970 I/day ( 520 gal/day)
                                   C-5

-------
Line 4 - Manual barrel Cd(CN) + chromating, 160 m2/day (1720 ft2/day)
         Plating steel
         Dragout = 32.70 I/day (8.64 gal/day)
Electrolytic Clean:
Hydrochloric Acid Dip:
Caustic Dip:
Cadmium (CN) Plate:
Chromate Conversion:
Single rinse = 235 gal/hr
    8 oz/gal     Single rinse = 130 gal/hr
    Tank volume = 400 gal
    Dump frequency = 10 days
    30 vol % (20°Be) 111 g/1
    Tank volume = 200 gal
    Dump frequency = 10 days
    NaOH = 2 oz/gal     Single rinse = 35 gal/hr
    Tank volume = 200 gal
    Dump frequency = 5 days
    Cd     =  2.66 oz/gal
    NaCN   = 13.3  oz/gal
    NaOH   =  1.9  oz/gal
    Na CO  =  7.0  oz/gal
    2-tank counter current rinse = 115 gal/hr
    Composition as Line 3
    2-tank counter current rinse = 40 gal/hr
    Tank volume = 200 gal
    Dump frequency = 10 days
Total flow         = 16,805 I/day (4440 gal/day)
Acid-alkali stream = 12,110 I/day (3200 gal/day)
Cyanide stream     =  3,485 I/day (920 gal/day)
Chromium stream    =  1,210 I/day (320 gal/day)
                                   C-6

-------
Line _5 - Manual rack Al-anodizing, 160 m2/day (1720 ft2/day)
         Dragout = 19.68 I/day (5.20 gal/day)
Alkali Soak Cleaner:       8 oz/gal     Single rinse = 75 gal/hr
                           Tank volume = 200 gal
                           Dump frequency = 15 days
Caustic Etch:              5% NaOH (53 g/1)     Single rinse = 65 gal/hr
                           Tank volume = 100 gal
                           Dump frequency =7.5 days
Desmut:                    HNC>3 = 100 g/1   Single rinse = 125 gal/hr
                           Tank volume = 100 gal
                           Dump frequency = 20 days
Bright Dip:                67%
                            3% ™«   f (206 g/1 total)
                           2-tank counter current rinse = 70 gal/hr
Anodizing:                 15% H2SO,
                           2-tank counter current rinse = 65 gal/hr
                           Tank volume = 800 gal
                           Dump frequency =12.5 days
Nickel Acetate Seal:       10 g/1      Single rinse = 250 gal/hr
                           Tank volume = 200 gal
                           Dump frequency = 5 days
                Total flow to acid-alkali stream = 19,680 I/day (5200 gal/day)
                                   C-7

-------
                                                 2             2
  .ie 6 - Automatic barrel zinc-phosphating, 400 m /day (4304 ft /day)
         Basic metal - steel
         Dragout = 81.76 I/day (2106 gal/day)
Alkaline Soak Cleaner:     8 oz/gal     Single rinse = 310 gal/hr
                           Tank volume = 250 gal
                           Dump frequency - 20 days
Acid Pickle:               20% HCl (20°Be = 75 g/1)     Single rinse = 390 gal/hr
                           Tank volume = 250 gal
                           Dump frequency = 10 days
Zinc Phosphate:            I^PO^Zn^PO^ = 42 g/1
                           2-tank counter current rinse = 130 gal/hr
                           Tank volume = 250 gal
                           Dump frequency = 5 days
Hot Dip Seal:              ~l/4  g/1  Cr03,  no  rinse
                           Tank volume = 250 gal
                           Dump frequency = 5 days
                Total flow to acid-alkali  stream =  25,130 I/day (6640 gal/day).
The generalization, comments, and assumptions used for the 38-employee model
plant also apply for the smaller 16-employee plating shop.

            Calculations Related to Cleaning, Acid-Dips, and Other
                 Processing Baths that are Periodically Dumped

          The alkaline cleaner compositions are the same as those given for
the 38-employee plant.

Calculations for Line 1

Alkali soak cleaner in dragout and dump stream:
                                       kg/day             Ib/day
              NaOH                      2.86               6.32
              Na2CO,                    1.81               4.00
              Na.SiO,                   2.03               4.48
              Na^PO -12H20              1.05               2.32
                                    C-8

-------
Electrolytic cleaner:

                                       kg/day           Ib/day

              NaOH                      2.3.9             5.28
              Na CO                     0.87             1.92
              Na'SiO,                   2.72             6.00
              Na^PO. «12H 0              0.69             1.52


Sulfuric acid pickle:

          Unreacted  H?SO  in the dragout and dump stream =  7.01 kg/day
                                                         =  15.44  Ib/day

          The quantity of metals in the dragout and dump stream are

             Fe = 410.4 g/day = 0.904 Ib/day

             Brass = 202.4 g/day = 141.6 g/day = 0.312  Ib/day of  copper

                                 = 60.7 g/day = 0.136 Ib/day of zinc.


Sulfuric acid dip:

          Quantity of fLSO,  in  the  dragout  and  dump  stream =  12.16 kg/day
                                                            =  26.80 Ib/day.

Chemicals lost in the dragout from plating  baths:

          (a)  Cu(CN)-plating

                 Cu(CN)           1.464 kg/day = 3.224  Ib/day
                 NaCN             2.040 kg/day = 4.512  Ib/day
                 NaOH             1.464 kg/day = 0.320  Ib/day
                 Na  C03           0.534 kg/day = 1.288  Ib/day

          (b)  Ni-plating

                 NiSO,'61^0       11.680 kg/day = 25.76 Ib/day
                                   1.680 kg/day -  3,712 Ib/day
                                   1.400 kg/day =  3.096 Ib/day
           (c)  Cr-plating
                                  12.600 kg/day =  27.84  Ib/day
                                   0.126 kg/day =  0.280  Ib/day
                  (Total quantity of CrO^ needed [15% on workpiece]
                  = 14.50 kg/day = 32  Ib/day)
                                   C-9

-------
TABLE C-2.   ALKALIS IN DRAGOUTS AND DUMP STREAMS
            FROM CLEANERS
Lines
1

2

3

4

5

6
Total

NaOH
kg/day Ib/day kg/
2.86 6.32 1.
2.39 5.28 0.
1.05 2.32 0.
0.65 1.44 C.
2.07 4.56 1.
0.69 1.52
2.39 5.28 1.
0.29 5.04
0.80 1.76 0.
0.76 1.68
0.72 1.60 0.
16.67 36.80 7.
TABLE C-3. ACIDS
Na CO. Na«
day' IB" /day
81 4
87 1
69 1
25 0
30 2

52 3

51 1

47 1
42 16
.00
.92
.52
.56
.88
-
.36
-
.12
-
.04
.40
kg /day
2.03
2.72
0.76
0.76
1.49
-
1.70
-
0.58
-
0.54
10.58
SiO,
IB/day
4.48
6.00
1.68
1.68
3.28
-
3.76
-
1.28
-
1.20
23.36
Na.PO
kg/day
1.05
0.69
0.40
0.18
0.76
-
0.91
-
0.29
-
0.29
4.57
4lI2H2£
Ib/day
2.32
1.52
0.88
0.40
1.68
-
2.00
-
0.64
-
0.64
10.08












AND DISSOLVED METALS IN ACID-ALKALI
STREAM FROM

V°4
H3B03
HC1
HN03
H2S04
Fe
Cu
Zn
Al
Ni
Mn
Line
1
6.99+12.14
1.41
-
-
-
0.410
0.141
0.062
-
3.19
"•
Line
2
2.21+4.
0.54
-
-
-
0.145
0.054
0.022
-
1.20
—
DUMPS
Line
3
67 -
-
2.65
4.53
-
0.517
-
-
-
-
™
AND DRAGOUTS, kg/day
Line
4
_
-
6.70
-
-
-
-
-
-
-
•"
Line
5
15.22
-
-
1.96
3.84
-
0.33
-
0.20
0.011
0.065
Line
6
_
-
5.65
-
0.25
1.09
-
0.54
-
-
^
Total
1-6
41.23
1.95
15.00
6.49
4.09
2.15
0.52
0.62
0.20
4.40
0.06






5
5
4

1
5
                    C-10

-------
     TABLE C-4.  ACIDS AND DISSOLVED METALS IN ACID-ALKALI STREAM
                 FROM DUMPS AND DRAGOUTS, Ib/day
                                                                 Total,
          Line  1       Line 2     Line 3  Line 4  Line 5  Line 6   1-6
H SO  15.44+26.804.88+10.32   --      --    33.60-    __    91.04
H3B02     3.12          1.20       	     4.32
HC          —            _.        5.84    14.80    —     12.48  33.12
HNO         --            --       10.00     —     4.32     —    14.72
H SO        —            —         —      —     8.48     0.56   9.04
Fe        9.04          0.32      1.12     --      —      2.40   4.744
Cu        0.312         0.12       --      --     0.72     —     1.152
Zn        0.136         0.048      —      --      —      1.20   1.384
Al          —            --         --      —     0.44     —     0.44
Ni        7.04          2.64       --      --     0.024    —     9.70.
                                                                      4
Mn          —            —         —      --     0.144    _-     0.14.
                                  C-ll

-------
Cyanide Destruction

         Line 1:  Cu(CN)-plating
                     CN = 425.1 + 1085.9 = 1511 g/day = 3.336 Ib/day
         Line 2:  Cu(CN)-plating
                     CN = 158.2 + 404.4 = 562.6 g/day = 1.240 Ib/day
         Line 3:  Zn(CN)-plating
                     CN = 2728 g/day = 6.00 Ib/day
         Line 4:  Cd(CN)-plating
                     CN = 1760 g/day =3.92 Ib/day
         Total CN, 1-4 = 6.562 kg/day = 14.48 Ib/day
         Total rinse flow, 1-4 = (800 + 320) + 1680 + 920 = 5320 gal/day
                                     Cu      +  Zn  + Cd  - 20,135 I/day
The quantity of metals in the  CN-streams are:
                  Cu = 1037 + 387 = 1424 g/day = 3.12 Ib/day
                  Zn = 2285 g/day = 5.04 Ib/day
                  Cd =  830 g/day = 1.44 Ib/day
Quantity of C12 required = 49.35 kg/day = 108.8 Ib/day
Quantity of caustic soda required = 67.04 kg/day = 148 Ib/day =  25.20 gal/day
                                    of 50% NaOH or
Quantity of lime required = 61.97 kg/day = 136.8 Ib/day.

Reduction of Hexavalent Chromium
Chromium plating:
         Line 1:  Cr = 6840 g/day = 15.12 Ib/day
         Line 2:  Cr = 2552 g/day = 5.60 Ib/day
         Total Cr, lines 1 and 2 = 9392 g/day = 20.72 Ib/day
         Total rinse flow, lines 1 and 2 = 2240 + 840 = 3080 gal/day
                                                      = 11,660 I/day

Chromating lines:
         Line 3:  Cr = 233.0 g/day = 0.512 Ib/day in the dragout and dump
                  520 gal/day  rinse + 24 gal/day dump = 544 gal/day
                  = 2060 I/day containing 174.0 g/day = 0.384 Ib/day of zinc
                                   C-12

-------
          Line 4:  Cr = 196 g/day = 0.432 Ib/day in  the dragout  and  dump
                        320 gal/day rinse + 20 gal/day dump = 340  gal/day
                        = 1290 I/day containing 254  g/day =0.56 Ib/day of
                        cadmium
          Line 6:  Cr = 12.32 g/day = 0.0272 Ib/day
          Total chromium, lines 3, 4, and 6 = 441.0  g/day = 0.976  Ib/day
          Total rinse flow, lines 3, 4, and 6 = 926  gal/day = 3545 I/day
          Total chromium, lines 1-6 = 9832 g/day = 21.68 Ib/day
          Total rinse flow, lines 1-6 = 4016 gal/day = 15,200 I/day
Quantity of S02 required = 20.68 kg/day =45.6 Ib/day
Quantity of Zn present = 0.18 kg/day = 0.40 Ib/day
Quantity of Cd present =0.25 kg/day = 0.56 Ib/day.

Acid-Alkali Stream

Neutralization:
           (a)  HNO_ neutralized with 5.58 kg (12.32  Ib) Na CO
                  J                                       Z  3
                    Na CO- remaining = 1.85 kg  (4.08 Ib)
           (b)  HC1 neutralized with 1.85 kg  (4.08  Ib) Na2C03 and
                12.33 kg  (27.2 Ib) NaOH
                    NaOH remaining = 4.35 kg (9.60 Ib)
           (c)  H2B03 neutralized with 1.27 kg (2.80  Ib) NaOH
                    NaOH remaining = 3.08 kg (6.80 Ib)
           (d)  Neutralization of H3PC>4 with 3.08 kg  (6.80 Ib) NaOH
                and 1.92 kg (4.24 Ib) of NaOH added  to the stream
           (e)  Neutralization of H^SO, requires an additional 33.8 kg
                (74.6 Ib) of NaOH
          Total NaOH to be added to neutralize the acid-alkali stream
excluding metal hydroxide precipitation is 35.73 kg/day  (78.9 Ib/day).
The equivalent quantity of lime required would be  35.63 kg/day  (78.6 Ib/day)

Rinse Water Flow and pH Adjustmerits

          Acid-alkali stream = 29,280 gal/day              )
          Combined CN-streams = 3720 gal/day >,/n     .    V  361'?2?^|aH^ay
                                     6     } \ 7640 gal/dayi  = U,975 I/day.
          Combined Cr-streams = 3920 gal/day j
                                   C-13

-------
          Allowing 5 percent water added in the treatment chemicals, total
            flow = 38,760 gal/day = 146,710 I/day.
          To raise the pH from 5.0 to 8.5 for the combined CN and Cr streams
            requires 0.013 kg/day (0.028 Ib/day) of NaOH.
          To raise the pH from 6.0 to 8.5 for the acid-alkali stream
            requires 0.048 kg/day (0.106 Ib/day) of NaOH.
The Use of Lime Instead of
Caustic Soda in the Treatment Plant
          Neutralization of residual H^PO, requires 1.56 kg/day  (3.44 Ib/day)
            of Ca(OH)
          Neutralization of H SO, requires 34.07 kg/day (75.12 Ib/day)
            Ca(OH)2
            CaS04 formed = 57.40 kg/day (126.6 Ib/day).

Contributions of Various Streams
to Metal Hydroxide Sludges
CN stream:
                                       kg/day         Ib/day
                        Cu(OH)2         2.18           4.80
                        Zn(OH)2         3.48           7.68
                        Cd(OH)2         0.87           1.92
Cr stream:
          Cr(OH)3  19.34 kg/day (42.64 Ib/day) requiring
                   26.34 kg/day (58.08 Ib/day) NaOH
          Zn(OH)2  0.29 kg/day (0.64 Ib/day) requiring
                   0.22 kg/day (0.48 Ib/day) NaOH
          Cd(OH)2  0.33 kg/day (0.72 Ib/day) requiring
                   0.18 kg/day  (0.40 Ib/day) NaOH
Acid-alkali stream:
          Fe(OH)2  3.48 kg/day (7.68 Ib/day) requiring
                   3.08 kg/day (6.80 Ib/day) NaOH
                                    C-14

-------
         Cu(OH)2

         Zn(OH)2

         Ni(OH)2

         A1(OH)3

         Mn(OH)3


          Totals

Combined streams:
          Fe(OH)0
                  0.80 kg/da.y (1.76 lb/day% ;  requiring
                  0.65 kg/day (1.44 Ib/day )  NaOH
                  0.94 kg/day (2.08 Ib/da y)  requiring
                  0.76 kg/day (1.68 Ib/d ay)  NaOH
                  6.93 kg/day (15.28  lb/ 'day) requiring
                  5.99 kg/day (13.20  lb /day) NaOH
                  4.61 kg/day (10.16  To/day) requiring
                  3.74 kg/day (8.24  IVj/day) NaOH
                  0.11 kg/day  (0.24  1 b/day) requiring
                  0.11 kg/day  (0.24   Ib/day) NaOH	
                  16.87 kg/day (37. 20 Ib/day) requiring
                  14.33 kg/day (31 .60 Ib/day) NaOH
                  3.48  kg/day  (7.'38 Ib/day) requiring
                  3.08  kg/day  (6. 80 Ib/day) NaOH
          Cu(OH)2  2.98  kg/day  (6,,56 Ib/day) requiring
                  0.65  kg/day  (1,,44 Ib/day) NaOH
          Zn(OH)?  4.72  kg/day  (l'J.40  Ib/day)  requiring
                  0.98  kg/day  (2 .16 Ib/day) NaOH
          Ni(OH)   6.93  kg/day  (1.5.28  Ib/day)  requiiring
                  5.99  kg/day  ('13.20  Ib/day)  NaOH
          A1(OH)3  4.61  kg/day  (.10.16  Ib/day)  requiring
                  3.74  kg/day   (8.24 Ib/day) NaOH
          Mn(OH)   0.11  kg/day   (0.24 Ib/day) requiring
                  0.11  kg/day   (0.24 Ib/day) NaOH
          Cr(OH)3   19.34 kg/day  (42.64 Ib/day)  requiring
                   26.34 kg/d,ay  (58.08 Ib/day)  Nf.OH
          Cd(OH)2   1.20  kg/da.y  (2.64 Ib/day) requiring
                   0.18  kg/day  (0.40 Ib/day) NaOH	
          Totals    43.36 kg/day  (95.60 Ib/day)  requiring
                   41.07' kg,/day  (90.56 Ib/day)  NaOH
          Allowing a 10  percent  excess of  NaOT.i, the total quantity required is
45.17 kg/day (99.60 Ib/day,  or  15.68 gal/day of 50 percent NaOH)  solution.
The equivalent quantity o^  lime  required is -41.83 kg/day  (92.24 Ib/day).
                                     C-15

-------
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                                   C-16

-------
Flocculant Consumption
          146,710 1 x 0.040 g/1 = 5868 g/day = 12.96 Ib/day.

Quantity of Sludge Produced

          41.98 + 13.10 + 5.88 = 60.95 kg/day
          (92.56 + 28.88 + 12.96 = 134.4 Ib/day) (using NaOH)
          60.95 + 5.88 = 66.83 kg/day (155.92 Ib/day) using Ca(OH)2
          Clarifier underflow containing 2 percent solids produces
            3046 I/day = 805 gal/day of sludge (NaOH) or
            3534 I/day = 934 gal/day of sludge (Ca(OH) )
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            354.3 I/day = 93.6 gal/day of sludge cake (Ca(OH)2).
Anode Consumption
          Lines 1 and 2:  (a)  Copper plating = 7.432 kg/day = 16.40 Ib/day
                          (b)  Nickel plating = 59.44 kg/day = 131.2 Ib/day
          Line 3:  Zinc plating = 17.632 kg/day = 38.96 Ib/day
          Line 4:  Cadmium plating = 12.288 kg/day = 27.12 Ib/day

Bright Dip Consumption
          HoPO, = 25.65 kg/day = 56.56 Ib/day   Quantity of acid needed
          HN03  = 1.16 kg/day = 2.56 Ib/day      for bright diP

          The quantity of spent bright dip hauled away consists of
            21.77 kg/day = 48.00 Ib/day H3P04
            and                                 = 51.17 I/day = 13.52 gal/day.
            0.98 kg/day =2.16 Ib/day HN03
                                   C-17

-------
















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C-18

-------
TABLE C-7.  MATERIALS CONSUMPTION IN
            ELECTROPLATING OPERATIONS
Material
Alkaline cleaners
NaOH
Na2C03
Na2Si03
Na3P04'12H 0
Surfactant
NaOH
Na2C03
NaCN
Na2Cr20?'2H20
NiSO. -6H00
4 2
NiCl2-6H20
NiC2H302
Cr03
CdO
Na2Sn03-3H20
HC1
HN03
H3P°4
Consumption,
kg /day
40.96
16.64
7.44
10.56
4.56
1.76
9.20
2.56
11.20
1.36
16.08
2.32
0.16
7.92
19.92
0.72
5.52
1.92
15.04
6.64
2.64
41.28

Ib/day
90.48
36.80
16.40
23.36
10.08
3.84
20.24
5.60
24.80
2.96
35.52
5.12
0.40
17.52
44.40
1.68
12.16
4.32
33.12
14.72
9.04
91.04
              C-19

-------
Option 1;
Centrifuged sludge disposal (20 percent solids content)
  Centrifuge size - 6.43 1/min =1.7 gal/rain (NaOH)
                  =7.57 I/rain =2.0 ga1/min (CaOH)

Cost for a unit having a capacity of 2.5 gal/min is
  $7,000
           Hauling costs:
                $20.24/day (NaOH)
                $23.44/day (CaOH)
Option 2:  Lagoon sludge disposal (6 percent solids content)

           Volume of sludge = 1015 I/day (268 gal/day)(NaOH)
                            =1180 I/day (311 gal/day)(Ca(OH)2)
           Lagoon size:
              Holding capacity  30 days

              Volume of underflow to lagoon =

              106,000 1 = 28,000 gal (3,745 cu ft)

              20 percent oversize * 4,500 cu ft

              Lagoon size = 30 ft x 25 ft x 6 ft, plus

              10-ft-wide border = 50 ft x 45 ft x 6 ft
                                           2
              requiring an area of 2,250 ft  (0.05 acre)

              Land cost:  Rural $  415
                          Urban $2,065

              Excavation and site preparation:  $350
              Plastic liner installation:       $450
           Total lagoon costs:  Rural $1,215
                                Urban $2,865

           Hauling costs:  $32.16/day (NaOH)
                           $37.36/day (Ca(OH)2)
                         C-20

-------
                                APPENDIX D
                       MODEL PLANT C (87 EMPLOYEES)
          The data presented in this section were calculated following
the criteria set up in Appendix B for the medium-size, 38-employee, model
plant.  Only the plant operations and the area processed for each line
have been changed (Table D-3.) .   The operations described on pages D-5
through D-8 are in addition to  or different from the operations of the
38-employee plant.
                                   D-l

-------



























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-------
Assumptions

          Dragout rate;                                   „
            rack lines =  12 .22 1/100 m  £3.0 gal/1000 ft )„
            barrel l:'oies  = :20.37 1/100 m  (5.0 gal/1000 ft )

          Rinsing efficiency = 70 percent

          Allowable dissolved solids in rinse = 750 mg/1 from cleaners,
                                                     acids, etc.
                                               =  37 mg/1 from metal deposi-
                                                     tion solution
                                               =  15 mg/1 from chromium
                                                     plating solution

Line  1 - Automatic  rack  Cu(CN)-M-Cr
         Thr.-ee identical  plating machines,  each producing  560 m^/day
         Th.e  plating  sequence is identical  to that  of  the  shop  with
         33 employees:    1 line plating  steel, 1 line plating brass,
         1.  line plating   zinc die castings  (p. C-5) .

Line  2 - Manual rack  Cv .(CN)-Ni-Cr with  the  same applications as Line  1.

Line  3 - Automatic  rac k  Zn(CN) + chromating same as 38-employee plant.

Line  4 - Automatic  ba rrel Zn(CN) + chromating 2 identical  plating  machines,
         each  produci .ng  480 m2/day, with a  plating  sequence identical to
         the one use-  1 in the 38-employee plant.

Line  5 - Manual bar? ;el Cd(Cr) + chromating  and Sn-Cd(CN).   The  line is
         similar to   the  one used in the 38-employee plant,  except  a
         Sn-Cd-allc >y bath is added which uses the  same cleaners and
         rinses.

Line  6 - Manual r. ack hard Cr.  Same as  the  one used in the 38-employee
         plant, b ut vith two chromium plating tanks of identical size
         producir ig twice the amount.

Line  7 - Manual rack, Al-anodizing.   Changes identical to  those in Line  6.

Line  8 - Automatic barrel Zn-phosphating.   Same as  Line 8  of the 38-
         emplo  yee plan.t.

Line  9 - Manu .al electroless Ni.   Same as Line 9 of  the 38-employee plant.

Line  10 - Automatic rack.   Pb-Sn-alloy  fluoborate  bath.
                                     D-4

-------
Processing Sequence for Plating Cu(CN)-Ni-Cr
on Zinc Die Castings. 560 m2/day (6024 £tz/day)
Dragout 69.64 I/day = 184 gal/day
Vibratory finishing
Electrolytic anodic clean
Sulfuric acid dip
Cu(CN) - strike
  (0.05 mil thick)
Sulfuric acid dip
Cu-Plate
Ni-Plate

Cr-Plate
Wastes from vibratory finishing are included in
the wastes from the plant operations other than
electroplating.

8 oz/gal, single rinse 2120 gal/day
Tank volume 1000 gal
Dump frequency 15 days

1/2% H2S04 = 5 g/1 (0.042 Ib/gal) •
2-tank counter current rinse - 480 gal/day
Tank volume  500 gal
Dump frequency  5 days

Cu(CN)         3.5 oz/gal  (Cu = 2.5 oz/gal)
NaCN           4.6 oz/gal  (CN =2.44 oz/gal)
Na2C03         4.0 oz/gal
Rochelle salt  6.0 oz/gal
2-tank counter current rinse  1600 gal/day

1% H2S04 - 10 g/1 (0.084  Ib/gal)  single rinse
  770 gal/day
Tank volume  500 gal
Dump frequency  5 days

Cu2 P207-3H20  46 oz/gal  (345 g/1)  (Cu-3.0 ozl
  gal)
KOH    2.4 oz/gal
NH4OH (29%)  1 oz/gal  (8 g/1)
2-tank countercurrent rinse   2560 gal/day
as before
as before
            Total flow
            Acid-alkali-stream  =
            CN-stream           =
            Cr-stream           =
         I/day
        51,480
        30,430
         6,060
        15,000
gal/day
13,600
 8,040
 1,600
 3,960
           2160 gal/day

           3960 gal/day
                                    D-5

-------
Processing Sequence for Line 2, Plating
on Zinc Die Castings =160 mz/day = 1720 ft2/day
Drag out = 19.68 I/day = 5.20 gal/day

Vibratory finishing

Electrolytic anodic clean  8 oz/gal, single rinse 600 gal/day
                           Tank volume = 300 gal
                           Dump frequency = 20 days
Sulfuric acid dip



Cu(CN)-strike


Sulfuric acid dip



Cu-Plate


Ni-Plate

Cr-Plate
1/2% H SO, , 2-tank counter current rinse 480 gal/day
Tank volume = 200 gal
Dump frequency = 5 days

Composition same as Line 1, (zinc die castings)
2-tank counter current rinse  480 gal/day

1% H SO,, single rinse  720 gal/day
Tank volume = 200 gal
Dump frequency = 5 days

As Line 1
2-tank counter current rinse  520 gal/day

As before  640 gal/day

As before  1,120 gal/day
              Total flow
              Acid-alkali-stream =
              CN-stream          =
              Cr-stream          =
            I/day    gal/day
            17,260    4,560
            11,200    2,960
             1,820      480
             4,240    1,120
Line  5
              Total water  flow   =
              Acid-alkali  stream =
              CN-stream          =
              Cr-stream          =
             31,500
             24,230
              6,060*
              1,210
     gal/day

      8,320
      6,400
      1,600
        320
    3480  I/day  = 970  gal/day  for  cadmium plating  losing  the  same bath  con-
    stituents as before,  and  5600 I/day  = 1480  gal/day for Sn-Cu-plating.
 Sn-Cu-Plata
 CuCN
 K SnO °3H 0
 KCN      /
 KOH
 KNaC.H.O °4H00
     446   2
28.5 g/1 (3.8 oz/gal)
35.25 g/1 (4,7 oz/gal)
62,3 g/1 (8.3 oz/gal)
9.8 g/1 (1.3 oz/gal)
4.5 g/1 (6.0 oz/gal)
               Total  dissolved  solids  = 110,300  ppm

                                   D-6

-------
                          1 1 O ^ftO   ft ft
              Water use « —'    x pprr = 680 gal/day = 2,580 I/day
                            J 7      U. /

              where 8.8 is the drag out in gal/day and 0.7 is the rinse
              factor.

Line 6


                                             I/day      gal/day

              Drag out            =          20.29       5.36
              Total water flow    =          21,500      5,680
              Acid-alkali         =          16,960      4,400
              Cr-stream          =          4,540      1,200
Line  7
              Drag  out            =             147     38,72
              Total water  flow    -         109,920     29,040
              Acid-alkali  stream =         109,920     29,040
 Line  10
              Automatic  rack  Pb-Sn,  800 m /day  (8,608 ft  /day)
              Plating  steel,  drag  out  96.9 I/day  = 25.6 gal/day

Electrolytic  clean          8  oz/gal, single rinse = 11,200  I/day (2,960 gal/day)
                            Tank  volume =  500 gal
                            Dump  frequency =15  days

Hydrochloric  acid dip       20 volo%  (83%)  single  rinse =  15,140 I/day
                                                       =  4,000  gal/day
                            Tank  volume =  250 gal
                            Dump  frequency = 20  days

Ni-strike  (0.001 mil)       NiCl  '6H  0  - 240 g/1 (32 oz/gal)
                            HC1 = 55  g/1
                            Total dissolved solids = 185,900  ppm
                            2-tank  counter flow  rinse = 9,690 I/day
                                                      = 2,560 gal/day

Pb-Sn-plate (93-7)          Sn         6  g/1
                            Pb         88  g/1
                            HBF,      150  g/1
                            H3B03      40  g/1
                            2-tank  counter flow  rinse = 12,110 I/day
                                                      = 3,200 gal/day
                            Total flow  = 48,150  I/day = 12,720 gal/day

Alkaline Soak Cleaner  Consumption

                            257» in  sludge  - 79.44  kg/day  (255.4  Ib/day)
                            75% to  react with acids = 59.64  kg/day
                                                      (131.5  Ib/day)

                                   D-7

-------
Electrolytic Cleaner Consumption  60.96 kg/day (134.6 Ib/day)

                           25% in sludge =  15.27 kg/day (33.68 Ib/day)
                           75% to react with acids = 45.75 kg/day
                                                     (101.9 Ib/day)

NaOH Consumption           25.04 kg/day (55.28 Ib/day)

                           to react with acids

Chemicals from Cleaners Available for Reaction

                           37.06 kg/day + 25.07 kg/day = 62.13 kg/day

                           NaOH         =  81.72 Ib/day + 55.28 Ib/day =
                                                          = 137.0 Ib/day
                           Na CO        =  19.10 kg/day (42.12 Ib/day)
                           Na.Sld,      =  33.23 kg/day (73.26 Ib/day)
                           Na3K>4"l2H20 =  11.78 kg/day (25.98 Ib/day)
                           Surfactant   =  emulsified
                                   D-8

-------
Drag  Outs From Plating Tanks
(a)  Cu-Ni-Cr-Plating
61^0
6H20
     Hid,
     CuCN
     Cu
     NaCN
     NaOH
     Na2C03
     Rochelle Salt
     Cr°3
     Cr
      Cu
      KOH
      NH OH
      CN
 (b)  Zn-Plating
      Zn
      NaOH
      NaCN
      CN
      Na2Cr20
      HNO~
    2H2°
      Zn (dissolved)
      Cr
Line
kg/day
62.47
8.99

7.49
25.21

9.69
0.52
4.18
3.14
51.74

0.44
24.05

1.26
0.56

3.88
8.73
8.73
4.64
1.45
0.73
0.29
0.51
1
Ib/day
137.8
19.82

16.51
55.60

21.37
1.15
9.22
6.92
114.1

0.96
53.04

2.77
1.23

8.55
19.25
19.25
10.22
3.21
1.60
0.65
1.12
Line
kg/day
17.85
2.57

2.14
2.01

2.770
0.15
1.20
0.90
14.29

0.12
6.88

0.36
0.160

7.76
17.46
17.46
4.64
2.90
1.46
0.58
1.02
2
Ib/day
39.36
5.67

4.72
4.44

6.11
0.33
2.64
1.98
32.62

0.27
15.17

0.79
0.35

17.11
38.50
38.50
10.22
6.42
3.20
1.30
2.24
Total
kg/day
80.32
11.56
25.28
9.63
9.05
6.42
12.46
0.67
5.38
4.03
66.53
34.60
0.56
30.93
11.07
1.61
0.72
9.25
11.64
26.19
26,19
9.27
4.36
2.18
0.88
1.52
Ib/day
177.14
25.50
55.74
21.23
19.96
14.15
27.48
1.48
11.86
8.90
146.7
76.29
1.23
68.21
24.42
3.56
1.58
20.40
25.66
57.74
57.74
20.44
9.62
4.80
1.94
3.36

-------
Cd- Plat ing
Cd
NaCN
NaOH
Na2C°3
CN
Na2Cr20? • 2H2C
Cr
HN03
Cd(dissolved)

0.664
3.349
0.475
1.752
1.78
I 0.501
0.174
0.087
0.25

1.464
7.384
1.048
3.864
3.92
1.104
0.384
0.192
0.56

Sn-Cu-Plating
kg /day
CuCN 0.951
Cu 0.689
K2SN03 • 31^0 1-175
Sn 0.468
KCN 2.075
KOH 0.327
Rochelle Salt 1.502
CN 1 . 923
Sn (dissolved)O. 11
Al (dissolved)0.15
lb/day
2.096
1.520
2.592
1.032
4.576
0.720
3.312
4.240
0.24
0.32
(d)   Hard-chromium



(e)


Cr03
Cr
V°4
Anodizing
Ni-acetate
Ni
6.75
3.51
0.08

1.45
0.34
14.89
7.74
0.17

3.21
0.76
(f)   Einc-phosphating - all in dump streams




(g)   Electroless Ni
NiSO • 7H20
Ni
NalLPO • HO
NaC^
(h) Pb-Sn-plating
N1C12 ' 6^0
Ni
HC1
Sn
Pb
HBF4
1L BO,
0.59
0.12
0.20
0.20

23.29
5.75
5.33
0.58
8.54
14.55
3.88
1.30
0.27
0.44
0.44

51.36
12.68
11.76
1.28
18.82
32.08
8.56
                                     D-10

-------
TABLE D-2M.  ALKALINE SOAK CLEANERS IN DRAGOUT AND DUMP STREAMS,  kg/day
Line 1
NaC.'l 9 . 53
Na?CO, 5.99
Na. SiO.. 6.82
Na,PO -1211 0 3.27
Surfactant 1,63
Total 27.24
2
2.86
1.81
2.03
0.98
0.49
7.97
3 4
(2.29)
(1.42) 7.15
4.50
5.12
2.47
1.31
20.55
567
(21.37)
(0.36) - 6.35
3.99
4.54
2.1.8
1.09
- 18.15
8
0.76
0.47
0.54
0.25
0.15
2.17
9
1.20
0.76
0.83
0.40
0.22
3.41
10 Total
(25.07)
•• 27.86
- 17.52
- 19.70
- 9.54
4.90
- 79.52
TABLE D-3M.  ELECTROLYTIC CLEANERS IN DRAGOUT AND DUMP  STREAMS,  kg/day
Line 1
NaOH
Ha2C03
Na SiO,
Jto3P04 • 12F
Surf act ant
Total
11
4
13
LO 3
0
33
.90
.43
.61
.37
.22
.53
2
2.68
0.98
3.08
0.76
0.15
7.66

2
0
2
0
0
5
3 4
.00
.73 -
.25
.58
.11
.67
5
2.39
0.87
2.72
0.69
0.15
6.82

2
0
0
0
0
1
678
.39
.22 - -
.69
.18 -
.04
.72
9 10
2
0.
2.
0.
0.
5.
00
73
25
58
11
67
Total
23.36
7.96
24.60
6.16
0.78
61.07
                                 D-ll

-------
TABLE D-2EU.   ALKALINE SOAK CLEANERS  IN  DRAGOUT AND DUMP STREAMS, kg/day

NaOH
Ka CO
Na SiO
Na3PO -12H20
Surfactant
Total
Line 1
21.04
13.20
15.04
7.20
3.60
60.08
2
6.32
4.00
4.48
2.16
1.08
17.60
3 4
(5.04)
(3.12) 15.76
9.92
11.28
5.44
2.88
45.28
5 6 7
(47.12)
(0.80) - 14.00
8.80
- 10.00
4.80
2.40
- 40.00
8
1.68
1.04
1.20
0.56
0.32
4.80
9
2.64
1.68 '
1.84
0.88
0.48
7.52
10 Total
(55.28)
- 61.44
- 38.64
- 43.44
- 21.04
- 10.80
- 175.36
TABLE D-3EU.   ELECTROLYTIC CLEANERS  IN  DRAGOUT AND DUMP  STREAMS, kg/day
Line 1
NaOH
Na2C°3
Na2Si04
Na3PO • 12 H^
Surfactant
Total
26
9
30
) 7
0
73
.24
.76
.00
.44
.48
.92
2
5.92
2.16
6.80
1.68
0.32
16.88

4
1
4
1
0
12
3
.40
.60
.96
.28
.24
.48
4
5
1
6
1
0
- 15
5
.28
.92
.00
.52
.32
.04

5
0
1
0
0
3
6 789
.28 -
.48 ...
.52 - - -
.40 -
.08 -
.76 - - -
10
4.40
1.60
4.96
1.28
0.24
12.48
Total
47.58
7.52
54.24
13.60
1.68
134.56
                               D-12

-------

















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-------
         TABLE D-8.  QUANTITY OF METALS LOST WITH EFFLUENT AS METAL
                     HYDROXIDE AND QUANTITY OF HYDROXIDE USED FOR
                     METAL PRECIPITATION
         Amount of Metal
          in Effluent.
Hydroxide Equivalent
Leaving in Effluent,
 Amount of
NaOH required,

Cu
Ni
Cr
Zn
Sn
Cd
Pb
Fe
Al

kfi/day
0.330
0.330
Oo330
0.330
Oo330
0.330
0.330
0.668
0.668

lb/dav
0.728
0.728
0.728
0.728
0.728
0.728
0.728
1.472
1.472

kg/day
0.508
0.522
0.653
0.497
0.468*
0.428
0.385
1.074
1.926

Ib/day
1.120
1.152
1.440
1.096
1.032*
0.944
0.848
2.368
4.248

kg/day
25.94
42.38
105.79
16.00
-
0.40
3.16
25.00
37.66
256.32
Ib/day
57.20
93.44
233.28
35.28
-
0.88
6.96
55.12
83.04
565.20
10% excess NaOH = 281.97 kg/day = 621.76 Ib/day

* Precipitated as SnO 'H-0


Deductions for NaOH used in CN-destruction (p 18) = 23.47 kg/day
                                                  = 51.76 Ib/day

NaOH required = 281.97 - 23,47 = 258,50 kg/day (570.0 Ib/day)

Ca(OH)2 equivalent = 239.36 kg/day = 528.5 Ib/day
                                   D-21

-------
Cyanide Destruction
        Lines 1  & 2     Lines 3 & 4       Line 5          Total      NaOH Required
       kg/day  Ib/day  kg/day  Ib/day   kg/day  Ib/day   kg/day  Ib/day  kg/day  Ib/day
CuCN
NaCN
CN
KCN
Cu
Zn
Cd
Sn
9.05
12.46
9.25
-
6.42
-
-
-
19
27
20

14



.96
.48 26.19 57.74
.40 9.27 20.44
-
.15
11.64 25.66
-
_
0

2
2
0

0
0
.95
-
.87
.08
.71
-
.66
.47
2.10
-
6.33
4.58
1.56
-
1.46
1.03
9
38
21
2
7
11
0
0
.82
.65
.39
.08
.13
.64
.66
.45
21
85
47
4
15
25
1
1
.66
.22
.17
.58
.71
.66
.46
.00
-
-
-
-
8.92 19.68
14.08 31.04
0.47 1.04
.
                                                                        51.76
          6.82 kg  Cl   are required for each kg of CN
          10% excess  = 7.50 kg/kg of CN
          18.49 x  7.50 - 138.68 kg/day of Cl
          40.27 x  7.50 = 353.6 Ib/day of C12


          9.23 kg  NaOH are required for each kg of CN
          10% excess  = 10.15 kg
          21.39 x  10.15 = 217.1 kg/day of NaOH
          47.17 x  10.15 = 478.8 Ib/day of NaOH

          The Ca(OH)  equivalent = 201.1 kg/day = 443.4 Ib/day


Hexavalent Chromium Reduction
                                                   t i
          1.86 kg  of  SO,, are required per kg of Cr
          10% excess  = 2.04 kg

          Total Cr   in stream = 41.13 kg/day = 90.70 Ib/day
          Quantity of S02 required = 41.13 x 2.04 = 83.9 kg/day
                                    = 90.70 x 2.04 = 185.0 Ib/day


Acid-Alkali-Stream Neutralization
(a)  Neutralization  of  HNO-  with Na^CO-

          25.18 kg  (55.52  Ib)  of Na CO., available
          22.06 kg  (48.64  Ib)  of HNO  present
               (22.06)(0.84)  =  18.54 Kg Na CO  used up
               Quantity  of  Na C03 left =6.64 kg/day = 14.64 Ib/day
                                    D-22

-------
(b)   Neutralization of HCl with Na2C03,  NaOH,  KOH, and NH^OH

           Quantity of NaOH present = 62.15 kg/day = 137.04 Ib/day
           Quantity of Na2CO  available  =6.64 kg/day = 14,64 Ib/day
           Quantity of HCl present = 80.25 kg/day = 176.96 Ib/day

           1.83 kg Na2C03 will neutralize 1.26 kg HCl

           Quantity of HCl still present = 75.68 kg/day = 166.8 Ib/day

           62.15 kg of NaOH will neutralize 56.49 kg HCl

           Quantity of HCl still present = 19.19 kg/day = 42.32 Ib/day
           KOH present =1.96 kg/day =4.32 Ib/day
             which will neutralize 1.23  kg (2.72 Ib HCl)
           Quantity of HCl still present = 17.96 kg/day =39.6 Ib/day
           NH.OH present =0.69 kg/day =1.52 Ib/day

           0.69 kg/day of NH.OH will neutralize 0.62 kg of HCl

           HCl left = 17.34 kg/day'= 38.24 Ib/day

(c)         NaOH required to neutralize 17.34 kg of HCl = 19.08 kg/day
                                                       = 42.08 Ib/day
           NaOH required to neutralize 13.50 kg/day (29.76 Ib/day) of H BO
             =8.78 kg/day = 19.36 Ib/day
           NaOH required to neutralize 29.89 kg/day (65.92 Ib/day) of H PO
             36.46 kg/day = 80.40 Ib/day
                                                                       34
           NaOH required to neutralize 320.7 kg/day (707.1 Ib/day) of H SO,
             = 263.0 kg/day = 579.8 Ib/day

           Total NaOH required = 592 kg/day = 1305 Ib/day
           10% excess = 651 kg/day = 1436 Ib/day
           Ca(OH)2 equivalent = 603 kg/day = 1329 Ib/day

           The quantity of NaOH or Ca(OH)  required to raise the pH to 8.5
           is negligible.

           All CaSO, , Ca-(PO,),), and CaSiO_ formed when lime is used for
           precipitation and neutralization will leave with the effluent
           as dissolved solids.

           Quantity of unreacted Ca(OH),. (70 percent of 10% excess) is
             51.19 kg/day = 112.9 Ib/day


Flocculent Dosage
           40 ppm of flocculent will be used for clarification

           (0.04 g/l)(666,010) = 26.64 kg/day = 58.80 Ib/day


                                     D-23

-------
Total Quantity of Solids (Dry Weight)
              Source of Sludge
                                            Amount
              kg/day   Ib/day
              Cleaner
              Metal Hydroxides
              Flocculent
               35.12
              261.8
               26.64
 77.52
578.48
 58.80
              Total Sludge
              323.56   714.80
          When Ca(OH)9 is used the total quantity of sludge = 323.6 + 51.2 =
              374.8 kg/day = 826.5 Ib/day
Clarifier Under Flow
          2% solids = 16,200 I/day = 4,280 gal/day (NaOH)
                    = 18,775 I/day = 4,960 gal/day (Ca(OH)2)
Centrifuged Sludge
          20% solids = 1,620 I/day = 428 gal/day (NaOH)

                     = 1,880 I/day = 496 gal/day (Ca(OH)2)
Chemicals Required for Waste Treatment
          NaOH
            or Ca(OH).

          C12
          S°2
          Flocculent
=  259 + 217 + 651 =  1,127 kg/day = 2,484 Ib/day
=  239 + 201 + 603 = 1,043 kg/day = 2,302 Ib/day
=  138.7 kg/day = 160.2 Ib/day
=  83.9 kg/day = 185 Ib/day
•  26.64 kg/day = 58.80 Ib/day
                                   D-24

-------
                         APPENDIX E
        TABLES OF WASTE QUANTITIES OF VARIOUS TYPES
GENERATED BY THE ELECTROPLATING AND METAL FINISHING INDUSTRY

-------
                                APPENDIX E
                 TABLES OF WASTE QUANTITIES OF VARIOUS TYPES
        GENERATED BY THE ELECTROPLATING AND METAL FINISHING INDUSTRY
          The information on waste quantities developed through model-plant
calculation has been tabulated and is included in this Appendix.  The tables
contained herein include those concerned with total potentially hazardous
waste quantities, quantities for each of the four general categories of
wastes, and quantities of the hydroxides of specific metals.  In all cases,
quantities are given by state and by region.
                                  E-l

-------
        TABLE E-l.  QUANTITY  OF TOTAL INDUSTRY AND POTENTIALLY  HAZARDOUS
                   WASTES  DESTINED TOR LAXD DISPOSAL FROM THE  ELECTROPLATING
                   AND METAL FINISHING INDUSTRY  (JOB SHOPS); METRIC TONS;
                   DRY WEIGHT; 1975
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
Wect Virginia
Reg Jon III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

1,090.88
1,129.84
0.00
58.44
38.96
38.96
2,35.7.08

1,655.80
1,909.04
3,564.84

19.48
214.28
1,344.12
0.00
155.84
1,733.72

272.72
506.48
116.88
77.92
136.36
214.28
155.84
155.84
1,636.32

2,142.80
915.56
2,396.04
350.64
2,805.12
389.60
8,999.76
Size (Employees) '
38

1,729.03
1,394.38
3,960.03
0.00
0.00
55.78
7,139.22

1,171.28
2,509.88
3,681.16

0.00
111.55
1,282.83
111.55
223.10
1,729.03

334.65
167.33
111.55
278.88
0.00
446.20
55.78
557.75
1,952.14

2,007.90
725.07
5,633.28
501.98
2,565.65
446.20
11,880.08
87

634.59
1,163.42
634.59
0.00
105.77
0.00
2,538.37

634.59
2,221.07
2,855.66

0.00
0.00
1,163.42
105.77
211.53
1,480.72

105.77
105.77
317.30
211.53
105.77
211.53
211.53
105.77
1,374.97

2,538.36
951.88
3,490.25
423.06
2,326.83
634.59
10,364.97
Total

3,454.50
3,687.64
4,594.62
58.44
144.73
94.74
12,034.67

3,461.67
6,639.99
10,101.66

19.48
325.83
3,790.37
217.32
590.47
4,943.47

713.14
779.58
545.73
568.33
242.13
872.01
423.15
819.36
4,963.43

6,689.06
2,592.52
11,519.56
1,275.68
7,697.60
1,470.39
31,244.81
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                      E-2

-------
                            TABLE  E-l.   (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Plant
16
^38.96
19.48
97.40
136.36
896.08
1,188.28
292.20
272.72
584.40
58.44
1,207.76
272.72
19.48
0.00
19.48
116.88
0.00
428.56
214.28
1,558.40
19.48
77.92
1,870.08
0.00
58.44
194.80
389.60
642.84
Size (Employees)
38
111.55
55.78
55.78
55.78
780.85
1,059.74
167.33
0.00
334.65
111.55
613.53
167.33
0.00
0.00
0.00
55.78
0.00
223.11
223.10
1,896.35
0.00
0.00
2,119.45
0.00
0.00
55.78
223.10
278.88
87
105.77
0.00
0.00
211.53
846.12
1,163.42
423.06
740.36
951.88
0.00
2,115.30
528.83
0.00
0.00
0.00
0.00
0.00
528.83
105.77
1,586.48
0.00
0.00
1,692.25
0.00
0.00
317.30
0.00
317.30
Total
256.28
75.26
153.18
403.67
2,523.05
3,411.44
882.58
1,013.08
1,870.94
169.99
3,936.59
968.88
19.48
0.00
19.48
172.66
0.00
1,180.50
543.15
5,041.23
19.48
77.92
5,681.78
0.00
58.44
567.88
612.70
1,239.02
Total U. S.
23,629.24   30,676.34   24,431.79
78,737.37
                                   E-3

-------
              TABLE E-2.   QUANTITY OF TOTAL  INDUSTRY AND  POTENTIALLY  HAZARDOUS
                          WATER  POLLUTION  CONTROL  SLUDGES GENERATED FROM  THE
                          ELECTROPLATING AND METAL FINISHING  INDUSTRY;  (JOB
                          SHOPS); METRIC TONS; DRY WEIGHT*; 1975
Plant Size (Employees)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

297.92
308.56
0.00
15.96
10.64
10.64
643.72

452.20
521.36
973.56

5.32
58.52
367.08
0.00
42.56
473,48

74.48
138.32
31.92
21.28
37.24
58.52
42.56
42.56
446.88

585.20
250.04
654.36
95.76
766.08
106.40
2,457.84
38

379.75
306.25
869.75
0.00
0.00
12.25
1,568.00

257.25
551.25
808.50

0.00
24.50
281.75
24.50
49.00
379.75

73.50
36.75
24.50
61.25
0.00
98.00
12.25
122.50
428.75

441.00
159.25
1,237.25
110.25
563.50
98.00
2,609.25
87

170.10
311.85
170.10
0.00
28.35
0.00
680.40

170.10
595.35
765.45

0.00
0.00
311.85
28.35
56.70
396.90

28.35
28.35
85.05
56.70
28.35
56.70
56.70
28.35
368.55

680.40
255.15
935.55
113.40
623.70
170.10
2,778.30
Total

847.77
926.66
1,039.85
15.96
38.99
22.89
2,892.12

879.55
1,667.96
2,547.51

5.32
83.02
960.68
52.85
148.26
1,250.13

176.33
203.42
141.47
139.23
65.59
213.22
111.51
193.41
1,244.18

1,706.60
664.44
2,827.16
319.41
1,953.28
374.50
7,845.39
*  These dry weights can be converted to wet weights by applying a factor
   of 20 for a sludge containing 5 percent solids.
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                   E-4

-------
TABLE E-2.   (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Plant
16

io.64
5.32
26.60
37.24
244.72
324.52

79.80
74.48
159.60
15.96
329.84

74.48
5.32
0.00
5.32
31.92
0.00
117.04

58.52
425.60
5.32
21.28
510.72

0.00
15.96
53.20
106.40
175.56
6,453.16
Size (Employees)
38

24.50
12.25
12.25
12.25
171.50
232.75

36.75
0.00
73.50
24.50
134.75

36.75
0.00
0.00
0.00
12.25
0.00
49.00

49.00
416.50
0.00
0.00
465.50

0.00
0.00
12.25
49.00
61.25
6,737.50
87

28.35
0.00
0.00
56.70
226.80
311.85

113.40
198.45
255.15
0.00
567.00

141.75
0.00
0.00
0.00
0.00
0.00
141.75

28.35
425.25
0.00
0.00
453.60

0.00
0.00
85.05
0.00
85.05
6,548.85
Total

63.49
17.57
38.85
106.19
643.02
869.12

229.95
272.93
488.25
40.46
1,031.59

252.98
5.32
0.00
5.32
44,17
0.00
307.79

135.87
1,267.35
5.32
21.28
1,429.82

0.00
15.96
150.50
155.40
321.86
19,739.51
        E-5

-------
   TABLE E-3.   QUANTITY OF TOTAL INDUSTRY  AvID POTENTIALLY HAZARDOUS PROCESS
               WASTES  GENERATED FROM THE ELECTROPLATING AND METAL FINISHING
               INDUSTRY;  (JOB SHOPS),  METRIC TOMS;  DRY WEIGHT*;  1975
Plant Size (Employees)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode- Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

678.16
702.38
0.00
36.33
24.22
24.22
1,465.31

1,029.35
1,186.78
2,216.13

12.11
133.21
835.59
0.00
96.88
1,077.79

169.54
314.86
72.66
48.44
84.77
133.21
96.88
96.88
1,017.24

1,332.10
569.17
1,489.53
217.98
1,743.84
242.20
5,594.82
38

784.61
632.75
1,797.01
0.00
0.00
25.31
3,239.68

531.51
1,138.95
1,670.46

0.00
50.62
582.13
50.62
101.24
784.61

151.86
75.93
50.62
126.55
0.00
202.48
25.31
253.10
885.85

911.16
329.03
2,556.31
227.79
1,164.26
202.48
5,391.03
87

351.48
644 . 38
351.48
0.00
58.58
0.00
1,405.92

351.48
1,230.18
1,581.66

0.00
0.00
644.38
58.58
117.16
820.12

58.58
58.58
175.74
117.16
58.58
117.16
117.16
58.58
761.54

1,405.92
527.22
1,933.14
234.32
1,288.76
351.48
5,740.84
Total

1,814.25
1,979.51
2,148.49
36.33
82.80
49.53
6,110.91

1,912.34
3,555.91
5,468.25

12.11
183.83
2,062.10
109.20
315.28
2,682.52

379.98
449.37
299.02
292.15
143.35
452.85
239.35
408.56
2,664.63

3,649.18
1,425.42
5,978.98
680.09
4,196.86
796.16
16,726.69
* Dry Wei ;hr = Wet Weight

Note:  Total Industry Wastes = Potentially Hazardous Wastes
                                      E-6

-------
                             TABLE  E-3.  (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
16

24.22
12.11
uO.55
84.77
557.06
738.71

181.65
169.54
363.30
36.33
750.82

169.54
12.11
0.00
12.11
72.66
0.00
266.42

133.21
968.80
12.11
48.44
1,162.56

0.00
36.33
121.10
242.20
399.63
38

50.62
25,31
25.31
25.31
354.34
480.89

75.93
0.00
151.86
50.62
278.41

75.93
0.00
0.00
0.00
25.31
0.00
101.24

101.24
860.54
0.00
0.00
961.78

0.00
0.00
25.31
101.24
126.55
87

58.58
0.00
0.00
117.16
468.64
644.38

234.32
410.06
527.22
0.00
1,171.60

292.90
0.00
0.00
0.00
0.00
0.00
292.90

58.58
878.70
0.00
0.00
937.28

0.00
0.00
175.74
0.00
175.74
Total

133.42
37.42
85.86
227.24
1,380.04
1,863.98

491.90
579.60
1,042.38
86.95
2,200.83

538,37
12.11
0.00
12.11
97.97
0.00
660.56

293.03
2,708.04
12.11
48.44
3,061.62

0.00
36.33
322.15
343.44
701.92
Total U. S.
14,689.43    13,920.50    13,531.98
42,141.91
                                     E-7

-------
   TABLE E-4.   QUANTITY  OF  TOTAL INDUSTRY  AND  POTENTIALLY HAZARDOUS
               DEGREASER SLUDGES  GENERATED  FROM THE  ELECTROPLATING
               AXD METAL FINISHING INDUSTRY (JOB SHOPS);  METRIC TONS;
               DRY WEIGHT*;  1975
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

114.80
118.90
0.00
6.15
4.10
4.10
248.05

174.25
200.90
375.15

2.05
22.55
141.45
0.00
16.40
182.45

28.70
53.30
12.30
8.20
14.35
22.55
16.40
16.40
172.20

225.50
96.35
252.15
36.90
295.20
41.00
947.10
Size (Employees)
38

111.29
89.75
254.89
0.00
0.00
3.59
459.52

75.39
161.55
236.94

0.00
7.18
82.57
7.18
14.36
111.29

21.54
10.77
7.18
17.95
0.00
28.72
3.59
35.90
125.65

129.24
46.67
362.59
32.31
165.14
28.72
764.67
87

25.26
46.31
25.26
0.00
4.21
0.00
101.04

25.26
88.41
113.67

0.00
0.00
46.31
4.21
•8.42
58.94

4.21
4.21
12.63
8.42
4.21
8.42
8.42
4.21
54.73

101.04
37.89
138.93
16.84
92.62
25.26
412.58
Total

251.35
254.96
280.15
6.15
8.31
7.69
808.61

274.90
450.86
725.76

2.05
29.73
270.33
11.39
39.18
352.68

54.45
68.28
32.11
34.57
18.56
59.69
28.41
56.51
352.58

455.78
180.91
753.67
86.05
552.96
94.98
2,124.35
* Dry Weight = Wet Weight.
Mote:  Total Tndustry Wastes = Potentially Hazardous Wastes.

-------
                            TABLE E-4. (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
16

4.10
2.05
10.25
14.35
94.30
125.05

30.75
28.70
61.50
6.15
127.10

28.70
2.05
0.00
2.05
12.30
0.00
45.10

22.55
164.00
2.05
8.20
196.80

0.00
6.15
20.50
41.00
67.65
38

7.18
3.59
3.59
3.59
50.26
68.21

10.77
0.00
21.54
7.18
39.49

10.77
0.00
0.00
0.00
3.59
0.00
14.36

14.36
122.06
0.00
0.00
136.42

0.00
0.00
3.59
14.36
17.95
87

4.21
0.00
0.00
8.42
33.68
46.31

16.84
29.47
37.89
0.00
84.20

21.05
0.00
0.00
0.00
0.00
0.00
21.05

4.21
63.15
0.00
0.00
67.36

0.00
0.00
12.63
0.00
12.63
Total

15.49
5.64
13.84
26.36
178.24
239.57

58.36
58.17
120.93
13.33
250.79

60.52
2.05
0.00
2.05
15.89
0.00
80.51

41.12
349.21
2.05
8.20
400.58

0.00
6.15
36.72
55.36
98.23
Total U. S.
2,486.65    1,974.50
972.51
5,433.66
                                   E-9

-------
          TABLE E-5.   QUANTITY OF TOTAL INDUSTRY  AND POTENTIALLY HAZARDOUS
                      ELECTROLKSS NICKEL PLATING  WASTES  GENERATED FROM THE
                      ELECTROPLATING AND METAL FINISHING INDUSTRY (JOB SHOPS);
                      METRIC TONS; DRY WEIGHT*;  1975
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
Size (Employees)
38

453.38
365.63
1,038.38
0.00
0.00
14.63
1,872.02

307.13
658.13
965.26

0.00
29.25
336.38
29.25
58.50
453.38

87.75
43.88
29.25
73.13
0.00
117.00
14.63
146.25
511.89

526.50
190.13
1,477.13
131.63
672.75
117.00
3,115.14
87

87.75
160.88
87.75
0.00
14.63
0.00
351.01

87.75
307.13
394.88

0.00
0.00
160.88
14.63
29.25
204.76

14.63
14.63
43.88
29.25
14.63
29.25
29.25
14.63
190.15

351.00
131.63
482.63
58.50
321.75
87.75
1,433.26
Total

541.13
526.50
1,126.13
0.00
14.63
14.63
2,223.03

394.88
965.25
1,360.13

0.00
29.25
497.25
43.88
87.75
658.13

102.38
58.50
73.13
102.38
14.63
146.25
43.88
160.88
702.03

877.50
321.75
1,959.75
190.13
994.50
204.75
4,548.38
* These dry weights can be converted to wet weights by applying a factor
  of two for a sludge containing 50 percent solids after filtration.
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                     E-10

-------
                            TABLE E-5.   (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
16

'0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
38

29.25
14.63
14.63
14.63
204.75
277.89

43.88
0.00
87.75
29.25
160.88

43.88
0.00
0.00
0.00
14.63
0.00
58.51

58.50
497.25
0.00
0.00
555.75

0.00
0.00
14.63
58.50
73.13
87

14.63
0.00
0.00
29.25
117.00
160.88

58.50
102.38
131.63
0.00
292.51

73.13
0.00
0.00
0.00
0.00
0.00
73.13

14.63
219.38
0.00
0.00
234.01

0.00
0.00
43.88
0.00
43.88
Total

43.88
14.63
14.63
43.88
321.75
438.77

102.38
102.38
219.38
29.25
453.39

117.00
0.00
0.00
0.00
14.63
0.00
131.63

73.13
716.63
0.00
0.00
789.76

0.00
0.00
58.50
58.50
117.00
Total U. S.
0.00
                                      8,043.60     3,378.47
11,422.25
                                    E-ll

-------













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Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
rH O CM rH 3 r- O SO O so rH O ON
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Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Tota
CM co o o m
O rH O O rH
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-------
           TABLE E-7.  TOTAL  QUANTITY  OF  CHROMIUM HYDROXIDE WASTES GENERATED
                       IN THE WATER POLLUTION CONTROL  SLUDGES FROM THE  ELECTRO-
                       PLATING AND METAL  FINISHING  INDUSTRY  (JOB  SHOPS); METRIC
                       TONS;  DRY  WEIGHT;  1975
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

47.49
49.18
0.00
2.54
1.70
1.70
102.61

72.08
83.10
155.18

.85
9.33
58.51
0.00
6.78
75.47

11.87
22.05
5.09
3.39
5.94
9.33
6.78
6.78
71.23

93.28
39.86
104.30
15.26
122.11
16.96
391.77
Si?p (Employees)
38

47.89
38.62
109.69
0.00
0.00
1.54
197.74

32.44
69.52
101.96

0.00
3.09
35.53
3.09
6.18
47.89

9.27
4.63
3.09
7.72
0.00
12.36
1.54
15.45
54.06

55.62
20.08
156.04
13.90
71.07
12.36
329.07
87

20.70
37.95
20.70
0.00
3.45
0.00
82.80

20.70
72.45
93.15

0.00
0.00
37.95
3.45
6.90
48.30

3.45
3.45
10.35
6.90
3.45
6.90
6.90
3.45
44.85

82.80
31.05
113.84
13.80
75.90
20.70
338.09
Total

116.08
125.76
130.39
2.54
5.15
3.24
383.16

125.22
225.07
350.29

.85
12.42
131.99
6.54
19.86
171.66

24.59
30.13
18.53
18.02
9.39
28.59
15.23
25.68
170.16

231.69
90.99
374.19
42.97
269.08
50.02
1,058.94
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                      E-14

-------
                            TABLE E-7.  (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
16

1.70
.85
4.24
5.94
39.01
51.74

12.72
11.87
25.44
2.54
52.57

11.87
.85
0.00
.85
5.09
0.00
18.66

9.33
67.84
.85
3.39
81.41

0.00
2.54
8.48
16.96
27.98
38

3.09
1.54
1.54
1.54
21.63
29.34

4.63
0.00
9.27
3.09
16.99

4.63
0.00
0.00
0.00
1.54
0.00
6.17

6.18
52.53
0.00
0.00
58.71

0.00
0.00
1.54
6.18
7.72
87

3.45
0.00
0.00
6.90
27.60
37.95

13.80
24.15
31.05
0.00
69.00

17.25
0.00
0.00
0.00
0.00
0.00
17.25

3.45
51.75
0.00
0.00
55.20

0.00
0.00
10.35
0.00
10.35
Total

8.24
2.39
5.78
14.38
88.24
119.03

31.15
36.02
65.76
5.63
138.56

33.76
.85
0.00
.85
6.63
0.00
42.09

18.96
172.12
.85
3.39
195.32

0.00
2.54
20.37
23.14
46.05
Total U. S.
1,028.62
849.65
                                                   796.94
2,675.26
                                    E-15

-------
            TABLE E-8.  TOTAL QUANTITY OF NICKEL HYDROXIDE WASTES GENERATED
                        IN THE WATER POLLUTION CONTROL SLUDGES FROM THE
                        ELECTROPLATING AND METAL FINISHING INDUSTRY (JOB SHOPS);
                        METRIC TONS; DRY WEIGHT; 1975
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

21.35
22.11
0.00
1.14
.76
.76
46.12

32.40
37.36
69.76

.38
4.19
26.31
0.00
3.05
33.93

5.34
9.91
2.29
1.52
2.67
4.19
3.05
3.05
32.02

41.94
17.92
46.89
6.86
54.90
7.62
176.13
Size (Employees)
38

19.27
15.54
44.14
0.00
0.00
.62
79.57

13.06
27.98
41.04

0.00
1.24
14.30
1.24
2.49
19.27

3.73
1.87
1.24
3.11
0.00
4.97
.62
6.22
21.76

22.38
8.08
62.79
5.60
28.60
4.97
132.42
87

16.40
30.07
16.40
0.00
2.73
0.00
65.60

16.40
57.41
73.81

0.00
0.00
30.07
2.73
5.47
38.27

2.73
2.73
8.20
5.47
2.73
5.47
5.47
2.73
35.53

65.62
24.61
90.22
10.94
60.15
16.40
267.94
Total

57.03
67.73
60.55
1.14
3.50
1.38
191.33

61.87
122.75
184.62

.38
5.44
70.68
3.98
11.00
91.48

11.80
14.51
11.73
10.10
5.40
14.64
9.14
12.00
89.32

129.93
50.61
199.91
23.39
143.65
29.00
576.49
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                     E-16

-------
TABLE E-8.   (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
16

.76
.38
1.91
2.67
17.54
23.26

5.72
5.34
11.44
1.14
23.64

5.34
.38
0.00
.38
2.29
0.00
8.39

4.19
30.50
.38
1.52
36.59

0.00
1.14
3.81
7.62
12.57
462.41
38

1.24
.62
.62
.62
8.70
11.80

1.87
0.00
3.73
1.24
6.84

1.87
0.00
0.00
0.00
.62
0.00
2.49

2.49
21.14
0.00
0.00
23.63

0.00
0.00
.62
2.49
3.11
341.93
87

2.73
0.00
0.00
5.47
21.87
30.07

10.94
19.14
24.61
0.00
54.69

13.67
0.00
0.00
0.00
0.00
0.00
13.67

2.73
41.01
0.00
0.00
43.74

0.00
0.00
8.20
0.00
8.20
631.52
Total

4.74
1.00
2.53
8.76
48.11
65.14

18.52
24.48
39.77
2.39
85.16

20.87
.38
0.00
.38
2.91
0.00
24.54

9.41
92.65
.38
1.52
103.96

0.00
1.14
12.64
10.11
23.89
1,435.93
          E-17

-------
        TABLE E-9.  TOTAL QUANTITY OF ZINC HYDROXIDE WASTES GENERATED IN THE
                    WATER POLLUTION CONTROL SLUDGES FROM THE ELECTROPLATING
                    AND METAL FINISHING INDUSTRY (JOB SHOPS); METRIC TONS;
                    DRY WEIGHT; 1975.
Plant Size (Employees)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

14.95
15.49
0.00
.80
.53
.53
32.30

22.70
26.17
48.87

.27
2.94
18.43
0.00
2.14
23.78

3.74
6.94
1.60
1.07
1.87
2.94
2.14
2.14
22.44

20.38
12.55
32.85
4.81
38.46
5.34
114.39
38

24.26
19.57
55.57
0.00
0.00
.78
100.18

16.44
35.22
51.66

0.00
1.57
18.00
1.57
3.13
24.27

4.70
2.35
1.57
3.91
0.00
6.26
.78
7.83
27.40

28.18
10.18
79.06
7.04
36.01
6.26
166.73
87

6.89
12.63
6.89
0.00
1.15
0.00
27.56

6.89
24.11
31.00

0.00
0.00
12.63
1.15
2.30
16.08

1.15
1.15
3.44
2.30
1.15
2.30
2.30
1.15
14.94

27.56
10.33
37.89
4.59
25.26
6.89
112.52
Total

46.11
47.69
62.46
.80
1.68
1.32
160.06

46.03
85.51
131.54

.27
4.50
49.06
2.71
7.56
64.. 10

9.58
10.44
6.61
7.28
3.02
11.50
5.22
11.11
64.76

85.11
33.06
149.79
16.44
99.72
18.49
402.61
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                      E-18

-------
TABLE  E-9.  (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Kebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
Sox\th Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Plant
16

.53
.27
\.34
1.87
12.28
16.29

4.01
3.74
8.01
.80
16.56

3.74
.27
0.00
.27
1.60
0.00
5.88

2.94
21.36
.27
1.07
25.64

0.00
.80
2.67
5.34
8,81
314.96
Size (Employees)
38

1.57
.78
.78
.78
10.96
14.87

2.35
0.00
4.70
1.57
8.62

2.35
0.00
0.00
0.00
.78
0.00
3.13

3.13
26.61
0.00
0.00
29.74

0.00
0.00
.78
3.13
3.91
430.51
87

1.15
0.00
0.00
2.30
9.19
12.64

4.59
8.04
10.33
0.00
22.96

5.74
0.00
0.00
0.00
0.00
0.00
5.74

1.15
17.22
0.00
0.00
18.37

0.00
0.00
3.44
0.00
3.44
265.25
Total

3.25
1.05
2.12
4.95
32.43
43.80

10.95
11.78
23.04
2.37
48.14

11.83
.27
0.00
.27
2.39
0.00
14.76

7.22
65.20
.27
1.07
73.76

0.00
.80
6.90
8.47
16.17
1,019.70
        E-19

-------
       TABLE  E-10. TOTAL QUANTITY OF  IRON HYDROXIDE WASTES GENERATED IN
                   THE WATER POLLUTION CONTROL SLUDGES FROM THE ELECTRO-
                   PLATING AND METAL  FINISHING INDUSTRY  (JOB SHOPS);
                   METRIC TONS; DRY WEIGHT; 1975.
Plant Size (Employees)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

9.74
10.09
0.00
.52
.35
.35
21.05

14.79
17.05
31.84

.17
1.91
12.01
0.00
1.39
15.48

2.44
4.52
1.04
.70
1.22
1.91
1.39
1.39
14.61

19.14
8.18
21.40
3.13
25.06
3.48
80.39
38

24.91
20.09
57.06
0.00
0.00
.80
102.86

16.88
36.17
53.05

0.00
1.61
18.48
1.61
3.21
24.91

4.82
2.41
1.61
4.02
0.00
6.43
.80
8.04
28.13

28.93
10.45
81.17
7.23
36.97
6.43
171.18
87

9.18
16.84
9.18
0.00
1.53
0.00
36.73

9.18
32.14
41.32

0.00
0.00
16.84
1.53
3.06
21.43

1.53
1.53
4.59
3.06
1.53
3.06
3.06
1.53
18.89

36.74
13.78
50.51
6.12
33.68
9.18
149.74
Total

43.84
47.02
66.25
.52
1.88
1.15
160.66

40.85
85.36
126.21

.17
3.52
47.33
3.14
7.67
61.83

8.79
8.47
7.24
7.78
2.75
11.40
5.26
10.96
62.65

84.81
32.40
153.09
16.49
95.70
19.09
401.58
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                       E-2C

-------
TABLE E-10. (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
vJyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Plant
16

.35
.17
.87
1.22
8.00
10.61

2.61
2.44
5.22
.52
10.79

2.44
.17
0.00
.17
1.04
0.00
3.82

1.91
13.92
.17
.70
16.70

0.00
.52
1.74
3.48
5.74
211.03
Size (Employees)
38

1.61
.80
.80
.80
11.25
15.26

2.41
0.00
4.82
1.61
8.84

2.41
0.00
0.00
0.00
.80
0.00
3.21

3.21
27.33
0.00
0.00
30.54

0.00
0.00
.80
3.21
4.01
441.27
87

1.53
0.00
0.00
3.06
12.25
16.84

6.12
10.71
13.78
0.00
30.61

7.65
0.00
0.00
0.00
0.00
0.00
7.65

1.53
22.96
0.00
0.00
24.49

0.00
0.00
4.59
0.00
4.59
352.29
Total

3.49
.98
1.67
5.08
31.50
42.72

11.14
13.15
23.82
2.13
50.24

12.50
.17
0.00
.17
1.85
0.00
14.69

6.66
64.21
.17
.70
71.74

0.00
.52
7.14
6.69
14.35
1,006.67
         E-21

-------
            TABLE £-11. TOTAL QUANTITY OF ALUMINUM HYDROXIDE WASTES GENERATED
                        IN THE WATER POLLUTION CONTROL SLUDGES FROM THE ELECTRO-
                        PLATING AND METAL FINISHING INDUSTRY (JOB SHOPS);  I- ETRIC
                        TONS; DRY WEIGHT; 1975
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

7.05
7.30
0.00
.38
.25
.25
15.23

10.70
12.34
23.04

.13
1.38
8.69
0.00
1.01
11.21

1.76
3.27
.76
.50
.88
1.38
1,01
1.01
10.57

13.85
5.92
15.48
2.27
18.13
2.52
58.17
Size (Employees)
38

22.37
18.04
51.24
0.00
0.00
.72
92.37

15.16
32.48
47.64

0.00
1.44
16.60
1.44
2.89
22.37

4.33
2.17
1.44
3.61
0.00
5.77
.72
7.22
25.26

25.98
9.38
72.89
6.50
33.20
5.77
153.72
87

7.91
14.49
7.91
0.00
1.32
0.00
31.63

7.91
27.67
35.58

0.00
0.00
14.49
1.32
2.64
18.45

1.32
1.32
3.95
2.64
1.32
2.64
2.64
1.32
17.15

31.62
11.86
43.48
5.27
28.99
7.91
129.13
Total

37.33
39.83
59.15
.38
1.57
.97
139.23

33.77
72.49
106.26

.13
2.83
39.78
2.76
6.53 ,
52.03

7.41
6.76
6.15
6.75
2.20
9.79
4.36
9.54
52.96

71.45
27.16
131.86
14.03
80.31
16.20
341.01
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                     E-22

-------
TABLE E-ll.  (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
16

.25
.13
.63
.88
5.79
7.68

1.89
1.76
3.78
.38
7.81

1.76
.13
0,00
.13
.76
0.00
2.78

1.38
10.07
.13
.50
12.08

0.00
.38
1.26
2.52
4.16
152.73
38

1.44
.72
.72
.72
10.10
13.70

2.17
0.00
4.33
1.44
7.94

2.17
0.00
0.00
0.00
.72
0.00
2.89

2.89
24.54
0.00
0.00
27.43

0.00
0.00
.72
2.89
3.61
396.93
87

1.32
0.00
0.00
2.64
10.54
14.50

5.27
9.22
11.86
0.00
26.35

6.59
0.00
0.00
0.00
0.00
0.00
6.59

1.32
19.76
0.00
0.00
21.08

0.00
0.00
3.95
0.00
3.95
304.41
Total

3.01
.85
1.35
4.24
26.44
35.89

9.32
10.99
19.96
1.82
42.09

10.52
.13
0.00
.13
1.48
0.00
12.26

5.59
54.37
.13
.50
60.59

0.00
.38
5.93
5.40
11.71
854.03
         E-23

-------
           TABLE  E-12. TOTAL QUANTITY OF COPPER HYDilOXIDE WASTES
                       GENERATED IN THE WATER POLLUTION CONTROL
                       SLUDGES FROM THE ELECTROPLATING AND METAL
                       FINISHING INDUSTRY  (JOB SHOPS); METRIC TONS:
                       DRY WEIGHT: 1975
Plant Size (Employees)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

8.94
9.25
0.00
.48
.32
.32
19.31

13.56
15.64
29.20

.16
1.76
11.01
0.00
1.28
14.21

2.23
4.15
.96
.64
1.12
1.76
1.28
1.28
13.42

17.55
7.50
19.63
2.87
22.98
3.19
73,72
38

7.74
6.24
17.72
0.00
0.00
.25
31.95

5.24
11.23
16.47

0.00
.50
5.74
.50
1.00
7.74

1.50
.75
.50
1.25
0.00
2.00
.25
2.50
8.75

8.99
3.24
25.21
2.25
11.48
2.00
53.17
87

9.93
18.20
9.93
0.00
1.65
0.00
39.71

9.93
34.75
44.68

0.00
0.00
18.20
1.65
3.31
23.16

1.65
1.65
4.96
3.31
1.65
3.31
3.31
1.65
21.49

39.72
14.89
54.61
6.62
36.41
9.93
162.18
Total

26.61
33.69
27.65
.48
1.97
.57
90.97

28.73
61.62
90.35

.16
2.26
34.95
2. IS
5.59
45.11

5.38
6.55
6.42
5.20
2.77
7.07
4.84
5.43
43.66

66.26
25.63
99.45
11.74
70.87
15.12
289.06
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                    E-24

-------
                            TABLE E-12. (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
16

.32
.16
.80
1.12
7.34
9.74

2.39
2.23
4.79
.48
9.89

2.23
.16
0.00
.16
.96
0.00
3.51

1.76
12.77
.16
.64
15.33

0.00
.48
1.60
3.19
5.27
38

.50
.25
.25
.25
3.49
4.74

.75
0.00
1.50
.50
2.75

.75
0.00
0.00
0.00
.25
0.00
1.00

1.00
8.49
0.00
0.00
9.48

0.00
0.00
.25
1.00
1.25
87

1.65
0.00
0.00
3.31
13.24
18.20

6.62
11.58
14.89
0.00
33.09

8.27
0.00
0.00
0.00
0.00
0.00
8.27

1.65
24.82
0.00
0.00
26.47

0.00
0.00
4.96
0.00
4.96
Total

2.47
.41
1.05
4.68
24.07
32.68

9.76
13.82
21.18
.98
45.73

11.25
.16
0.00
.16
1.21
0.00
12.78

4.41
46.08
.16
.64
51.28

0.00
.48
6.81
4.19
11.48
Total U. S.
193.60
137.30
382.20
713.11
                                      E-25

-------
      TABLE E-13. TOTAL QUANTITY OF LEAD HYDROXIDE WASTES  GENERATED  IN  THE
                  WATER POLLUTION CONTROL  SLUDGES FROM THE ELECTROPLATING
                  AND METAL FINISHING  INDUSTRY  (JOB  SHOPS); METRIC TONS;
                  DRY WEIGHT; 1975
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant Size
16

o.oo
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
o.co

0.00
0.00
0.00
0.00
0.00
0.00
0.00
(Employe
38

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
OS)
87

4.14
7.59
4.14
0.00
.69
0.00
16.56

4.14
14.49
18.63

0.00
0.00
7.59
.69
1.38
9.66

.69
.69
2.07
1.38
.69
1.38
1.38
.69
8.97

16.56
6.21
22.77
2.76
15.18
4.14
67.62
Total

4.14
7.59
4.14
0.00
.69
0.00
16.56

4.14
14.49
18.63

0.00
0.00
7.59
.69
1.38
9.66

.69
.69
2.07
1.38
.69
1.38
1.38
.69
8.97

16.56
6.21
22.77
2.76
15.18
4.14
67.62
Note:  Total Industry Wastes = Potentially Hazardous V.'astes.
                                    E-26

-------
TABLE E-13.  (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
16

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
o.oc
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
38

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
o.oo

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
87

.69
0.00
0.00
1.38
5.52
7.59

2.76
4.83
6.21
0.00
13.80

3.45
0.00
0.00
0.00
0.00
0.00
3.45

..69
10.35
0.00
0.00
11.04

0.00
0.00
2.07
0.00
2.07
159.39
Total

.69
0.00
0.00
1.38
5.52
7.59

2.76
4.83
6.21
0.00
13.80

3.45
0.00
0.00
0.00
0.00
0.00
3.45

.69
10.35
0.00
0.00
11.04

0.00
0.00
2.07
0.00
2.07
159.39
       E-27

-------
            TABLE E-14.  TOTAL QUANTITY  OF  CADMIUM HYDROXIDE WASTES  GENERATED
                        IN THE WATER  POLLUTION  CONTROL  SLUDGES  FROM THE
                        ELECTROPLATING  ANT) METAL  FINISHING INDUSTRY (JOB  SHOPS);
                        METRIC TONS;  DRY WEIGHT;  1975
Plant Size (Employees)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

4.21
4.36
0.00
.23
.15
.15
9.10

6.39
7.37
13.76

.08
.83
5.19
0.00
.60
6.70

1.05
1.96
.45
.30
.53
.83
.60
.60
6.32

8.28
3.54
9.25
1.35
10.83
1.50
34.75
38

2.00
1.61
4.58
0.00
0.00
.06
8.25

1.35
2.90
4.25

0.00
.13
1.48
.13
.26
2.00

.39
.19
.13
.32
0.00
.52
.06
.64
2.25

2.32
.84
6.51
.58
2.97
.52
13.74
87

.31
.56
.31
0.00
.05
0.00
1.23

.31
1.07
1.38

0.00
0.00
.56
.05
-.10
.71

.05
.05
.15
.10
.05
.10
.10
.05
.65

1.23
.46
1.68
.20
1.12
.31
5.00
Total

6.52
6.54
4.88
.23
.20
.21
18.58

8.06
11.35
19.39

.08
.96
7.23
.18
.96
9.41

1.49
2.20
.73
.73
.58
1.45
.77
1.30
9.22

11.82
4.83
17.45
2.14
14.92
2.33
53.49
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                      E-28

-------
                            TABLE  E-14. (Continued)
Plant Si?,e (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
16

.15
.08
.38
.53
3.46
4.60

1.13
1.05
2.26
.23
4.67

1.05
.08
0.00
.08
.45
0.00
1.66

.83
6.02
.08
.30
7.23

0.00
.23
.75
1.50
2.48
38

.13
.06
.06
.06
.90
1.21

.19
0.00
.39
.13
.71

.19
0.00
0.00
0.00
.06
0.00
.25

.26
2.19
0.00
0.00
2.45

0.00
0.00
.06
.26
.32
87

.05
0.00
0.00
.10
.41
.56

.20
.36
.46
0.00
1.02

.26
0.00
0.00
0.00
0.00
0.00
.26

.05
.77
0.00
0.00
.82

0.00
0.00
.15
0.00
.15
Total

.33
.14
.44
.69
4.77
6.38

1.53
1.41
3,10
.35
6.40

1.50
.08
0.00
.08
.52
0.00
2.18

L.14
8.98
.08
.30
10.50

0.00
.23
.97
1.76
2.95
Total U. S.
                             91.26
35.60
11.84
138.50
                                      E-29

-------
         TABLE  E-15. TOTAL QUANTITY OF TIN HYDROXIDE WASTES GENERATED IN
                     THE WATER POLLUTION CONTROL SLUDGES FROM THE ELECTRO-
                     PLATING AND METAL FINISHING INDUSTRY (JOB SHOPS);
                     METRIC TONS; DRY WEIGHT; 1975
Plant Size (Employees)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

0.00
0.00
0.00
0.00
0.00
0.00
0,00

0.00
0.00
0.00

0.00
0.00
0.00
0,00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
38

o.co
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0,00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
87

.30
.55
.30
0.00
.05
0.00
1.20

.30
1.04
1.34

0.00
0.00
.55
.05
. .10
.70

.05
.05
.15
.10
.05
.10
.10
.05
.55

1.19
.45
1.64
.20
1.09
.30
4.87
Total

.30
.55
.30
0.00
.05
0.00
1.20

.30
1.04
1.34

0.00
0.00
.55
.05
.10
.70

.05
.05
.15
.10
.05
.10
.10
.05
.55

1.19
.45
1.64
.20
1.09
.30
4.87
Note:  Total Industry Waates = Potentially Hazardous Pastes.
                                  E-30

-------
TABLE E-15.  (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Vyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
16

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
38

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
87

.05
0.00
0.00
.10
.40
.55

.20
.35
.45
0.00
1.00

.25
0.00
0.00
0.00
0.00
0.00
.25

.05
.74
0.00
0.00
.79

0.00
0.00
.15
0.00
.15
11. 40
Total

.05
0.00
0.00
.10
.40
.55

.20
.35
.45
0.00
1.00

.25
0.00
0.00
0.00
0.00
0.00
.25

.05
.74
0.00
0.00
.79

0.00
0.00
.15
0.00
.15
11.40
      E-31

-------
            TABLE E-16. TOTAL QUANTITY OF MANGANESE HYDROXIDE WASTES GENERATED
                        IN THE WATER POLLUTION CONTROL SLUDGES FROM THE ELECTRO-
                        PLATING AND METAL FINISHING INDUSTRY (JOB SHOPS) METRIC
                        TONS; DRY WEIGHT; 1975
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0,00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
Size (Employees)
38

.12
.09
.27
0.00
0.00
0.00
.48

.08
.17
.25

0.00
.01
.09
.01
.02
.13

.02
.01
.01
.02
0.00
.03
0.00
.04
.14

.14
.05
.38
.03
.17
.03
.77

87

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
Total

.12
.09
.27
0.00
0.00
0.00
.48

.08
.17
.25

0.00
.01
.09
.01
.02
,13

.02
.01
.01
.02
0.00
.03
0.00
.04
.14

.14
.05
.38
.03
.17
.03
.77
Note:  Total Industry Wastes = Potentially Hazardous Wastes,
                                 E-32

-------
                            TABLE E-16.  (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
16

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
38

.01
0.00
0.00
0.00
.05
.07

.01
0.00
.02
.01
.04

.01
0.00
0.00
0.00
0.00
0.00
.02

.02
.13
0.00
0.00
.14

0.00
0.00
0.00
.02
.02
87

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
Total

.01
0.00
0.00
0.00
.05
.07

.01
0.00
.02
.01
.04

.01
0.00
0.00
0.00
0.00
0.00
.02

.02
.13
0.00
0.00
.14

0.00
0.00
0.00
.02
.02
Total U. S.
0.00
2.06
0.00
2.06
                                   E-33

-------
        TABLE E-17.  QUANTITY OF TOTAL INDUSTRY AND POTENTIALLY HAZARDOUS
                     WASTES DESTINED FOR LAND DISPOSAL FiJOM THE ELECTRO-
                     PLATING AND METAL FINISHING INDUSTRY  (JOB SHOPS);
                     METRIC TONS; DRY WEIGHT: 1977
EPA Region and State
Region I
Massachusetts
Connecticut
Fvhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16
,
1,644.16
',702.88
0.00
88.08
58.72
58.72
3,552.56

2,495.60
2,877.28
5,372.88

29.36
322.96
2,025.84
0.00
234.88
2,613.04

411.04
763.36
176.16
117.44
205.52
322.96
234.88
234.88
2,466.24

3,229.60
1,379.92
3,611.28
528.48
4,227.84
587.20
13,564.32
Si /i' (Employe
38

2,434.28
1,963.13
5,575.28
0.00
0.00
78.53
10,051.22

1,649.03
3,533.63
5,182.66

0.00
157.05
1,806.08
15/.05
314.10
2,434.28

471.15
235.58
157.05
392.63
0.00
628.20
78.53
785.25
2,748.39

2,826.90
1,020.83
7,931.03
706.72
3,612.15
628.20
cs)
87

950.49
1,742.57
950.49
0.00
158.42
0.00
3,801.97

950.49
3,326.72
4,277.21

0,00
0.00
1,742.57
158.42
316.83
2,217.82

158.42
158.42
475.25
316.83
158.42
316.83
316.83
158.42
2,059.42

3,801.96
1,425.74
5,227.70
633.66
3,485.13
950.49
16,725.83 15,524.68
Total

5,028.93
5,408.58
6,525.77
88.08
217.14
137.25
17,405.75

5,095.12
9,737.63
14,832.75

29.36
480.01
5,574.41
315.47
865.81
7,265.14

1,040.61
1,157.36
808.46
826.90
363.94
1,267.99
630.24
1,178.55
7,274.05

9,856.^6
3,826.49
16,770.01
1,868.;; 5
11,325.12
2,165.39
45,?!'. .33
Note:  Total Industry Wastes = Potentially Hazardous Wastes
                                 E-34

-------
                        TABLE E-17.  (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
16

58.72
29.36
146.80
205.52
1,350.56
1,790.96

440.40
411.04
880.80
88.08
1,820.32

411.04
29.36
0.00
29.36
176.16
0.00
645.92

322.96
2,348.80
29.36
117.44
2,818.56

0.00
88.08
293.60
587.20
968.88
38

157.05
78.53
78.53
78.53
1,099.35
1,491.99

235.58
0.00
471.15
157.05
863.78

235.58
0.00
O.CO
0.00
78.53
0.00
314.11

314.10
2,669.85
0.00
0.00
2,983.95

0.00
0.00
78.53
314.10
392.63
87

158.42
0.00
0.00
316.83
1,267.32
1,742.57

533.66
1,108.91
1,425.74
0.00
3,068.31

792,08
0.00
0,00
0.00
0.00
0.00
792.08

158.42
2,376.23
0.00
0.00
2,534.65

0.00
0.00
475.25
0.00
475.25
Total

374.19
107.89
225.33
600.88
3,717.23
5,025.52

1,209.64
1,519.95
2,777.69
245.13
5,752.41

1,438.70
29.36
0.00
29,36
254.69
0.00
1,732.11

795.48
7,394.88
29.36
117.44
8,337.16

0.00
88.08
S47.38
901.30
1,836.76
Total U. S.
35,613.63   43,188.84    36,493.96
115,296.48
                                   E-35

-------
      TAKLE E-18.    QUANTITY OK  TOTAL  INDUSTRY AND POTENTIALLY HAZARDOUS
                    WATER  POLLUTION CONTROL SLUDGES GENERATED FROM THE
                    ELECTROPLATING AM) METAL FINISHING  INDUSTRY  (JOB SHOPS);
                    METRIC TONS;  DRY WEIGHT*; 19V7
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region 11
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

851.20
881.60
0.00
45.60
30.40
30.40
1839.20

1292.00
1489.60
2781.60

15.20
167.20
1048.80
0.00
121.60
1352.80

212.80
395.20
91.20
60.80
106.40
167.20
121.60
121.60
1276.80

1672.00
714.40
1869.60
273.60
2188.80
304.00
7022.40
Size (Employees)
38

1,085.00
875.00
2,485.00
0.00
1 o.oo
35.00
4,480.00

735.00
1,575.00
2,310.00

0.00
70.00
805.00
70.00
140.00
1,085.00

210.00
105.00
70.00
175.00
0.00
280.00
35.00
350.00
1,225.00

1,260.00
455.00
3,535.00
315.00
1,610.00
280.00
7,455.00
87

486.00
891.00
486.00
0.00
81.00
0.00
1944.00

486.00
1701.00
2187.00

0.00
0.00
891.00
81.00
162.00
1134.00

81.00
81.00
243.00
162.00
81.00
162.00
162.00
81.00
1,053.00

1944.00
729.00
2673.00
324.00
1782.00
486.00
7938.00
Total

2,422.20
2,647.60
2, 97], 00
45.60
111.40
65.40
8,263.20

2,513.00
4,765.60
7,278.60

15.20
237.20
2,744.80
151.00
423.60
3,571.80

503.80
581.20
404.20
397.80
187.40
609.20
318.60
552.60
3,554.80

4,876.00
1,898.40
3,077.60
912.60
5,580.80
1,070.00
22,415.40
*  These dry weights can be  converted to wet weights by applying a factor
   of  5 for a  sSudge containing 20 percent solids.

Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                    E-36

-------
                             TABLE E-18. (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Plant
16

30.40
15.20
76.00
106.40
699.20
927.20

228.00
212.80
456.00
45.60
942.40

212.80
15.20
0.00
15.20
91.20
0.00
334.40

167.20
1216.00
15.20
60.80
1459.20

0.00
45.60
152.00
304.00
501.60
Size (Employees)
38

70.0
35.0
35.0
35.0
490.0
665.0

105.0
0.0
210.0
70.0
385.0

105.0
0.0
0.0
0.0
35.0
0.0
140.0

140.0
1,190.0
0.0
0.0
1,330.0

0.0
0.0
35.0
140.0
175.0
87

81.0
0.0
0.0
162.0
648.0
891.0

324.0
567.0
729.0
0.0
1620.0

405.0
0.0
0.0
0.0
0.0
0.0
405,0

81.0
1215.0
0.0
0.0
1296.0

0.0
0.0
243.0
0.0
243.0
Total

181. 40
50.20
111.00
303.40
1,837.20
2,483.20

657.00
779.80
1,395.00
115.60
2,947.40

722.80
15 . 2 0
0.00
15.20
126.20
0.00
879. 4c

388.20
3,621.00
15.20
60.80
4,085.20

0.00
45.60
430.00
444.00
919.60
Total U. S.
18,437.60   19,250.0    18,711.0
56,398.60
                                  E-37

-------
        TABLE E-19.  QUANTITY OF TOTAL INDUSTRY AND POTENTIALLY HAZARDOUS
                     PROCESS WASTES GENERATED FROM THE ELECTROPLATING AND
                     METAL FINISHING INDUSTRY (JOB SHOPS);  METRIC TONS;
                     DRY WFIQIT*; 1077
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

678.16
702.38
0.00
36.33
24.22
24.22
1,465.31

1,029.35
1,186.78
2,216.13

12.11
133.21
835.59
0.00
96.88
1,077.79

169.54
314.86
72.66
48.44
84.77
133.21
96.88
96.88
1,017.24

1,332.10
569.17
1,489.53
217.98
1,743.84
242,20
5,594.82
Size (Employe
38

784.61
632.75
1,797.01
0.00
0.00
25.31
3,239.68

531.51
1,138.95
1,670.46

0.00
50.62
582.13
50.60
101.24
784.59

151.86
75.93
50.62
126.55
0.00
202.48
25.31
253.10
885.85

911.16
329.03
2,556.31
227.79
1,164.26
202.48
5,391.03
OS)
87

351.48
644.38
351.48
0.00
58.58
0.00
1,405.92

351.48
1,230.18
1,581.66

0.00
0.00
644.38
58.58
117.16
820.12

58.58
58.58
175.74
117.16
58.58
117.16
117.16
58.58
761.54

1,405.92
527.22
1,933.14
234.32
1,288.76
351.48
5,740.84
Total

1,814.25
1,979.51
2,148.49
36.33
82.80
49.53
6,110.91

1,912.34
3,555.91
5,468.25

12.11
183.83
2,062.10
109. 18
315.28
2, 68'?. 50

379.98
449.37
299.02
292.15
143.35
A52.85
239.35
408.56
2,664.63

3,649.18
l,425.<+2
5,978.98
68C.09
4,196.86
796. 16
16,726.69
*  Dry Weight = Wet Weight
Note:  Total Industry Wnstes = Potentially Hazardous Wastes.
                                   E-38

-------
TABLE E-19.  (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
16

24.22
12.11
60.55
84.77
557.06
738.71

181.65
169.54
363.30
36.33
750.82

169.54
12.11
0.00
12.11
72.66
0.00
266.42

133.21
968.80
12.11
48.44
1,162.56

0.00
36.33
121.10
242.20
399.63
14,689.43
38

50.62
25.31
25.31
25.31
354.34
480.89

75.93
0.00
151.86
50.62
278.41

75.93
0.00
0.00
0.00
25.31
0.00
101.24

101.24
860.54
0.00
0.00
961.78

0.00
0.00
25.31
101.24
126.55
13,920.48
87

58.58
0.00
0.00
117.16
468.64
644.38

234.32
410.06
527.22
0.00
1,171.60

292.90
0.00
0.00
0.00
0.00
0.00
292.90

58.58
878.70
0.00
0.00
937.28

0.00
0.00
175.74
0.00
175.74
13,531.98
Total

133.42
37.42
85.86
227.24
1,380.04
1,863.98

491.90
579.60
1,042.38
86.95
2,200.83

538.37
12.11
0.00
12.11
97.97
O.'OO
660.56

293.03
2,708.04
12.11
48.44
3,061.62

0.00
36.33
322 . 15
343.44
701.92
42,141.89
         E-39

-------
      TABLF E-20.  QUANTITY OF TOTAL INDUSTRY AND POTENTIALLY HAZARDOUS
                   DEGREASER SLUDGES GENERATED FROM THE ELECTROPLATING
                   AflU MliT/VL FINISHING INDUSTRY (JOB SHOPS); METRIC TONS;
                   DRY WEIGHT*; 1977
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
VJest Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

114.80
118.90
0.00
6.15
4.10
4.10
248.05

174.25
200.90
375.15

2.05
22.55
141.45
0.00
16.40
182.45

28.70
53.30
12.30
8.20
14.35
22.55
16.40
16.40
172.20

225.50
96.35
252.15
36.90
295.20
41.00
947.10
Size (Employ
38

111.29
89.75
254.89
0.00
0.00
3.59
459.52

75.39
161.55
236.94

0.00
7.18
82.57
7.18
14.36
111.29

21.54
10.77
7.18
17.95
0.00
28.72
3.59
35.90
125.65

129.24
46.67
362.59
32.31
165.14
28.72
764.67
cos)
87

25.26
46.31
25.26
0.00
4.21
0.00
101.04

25.26
88.41
113.67

0.00
0.00
46.31
4.21
.8.42
58.94

4.21
4.21
12.63
8.42
4.21
8.42
8.42
4.21
54.73

101.04
37.89
138.93
16.84
92.62
25.26
412.58
Total

251.35
254.96
280.15
6.15
8.31
7.69
808.61

274.90
450.86
725.76

2.05
29.73
270.33
11.39
39.18
352.68

54.45
68.28
32.11
34.57
18.56
59.69
28.41
56.51
352.58

455.78
180.91
753.67
86.05
552.96
94.98
2,124.35
*Dry Weight = WeL Weight
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                    E-40

-------
                            TABLE  E-20.  (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
VJyoniing
Region VIII Total
Region IX
Arizona
Cali fornia
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
16

4.10
2.05
10.25
14.35
94.30
125.05

30.75
28.70
61.50
6.15
127.10

28.70
2.05
0.00
2.05
12.30
0.00
45.10

22.55
164.00
2,05
8.20
196.80

0.00
6.15
20.50
41.00
67.65
38

7.18
3.59
3.59
3.59
50.26
68.21

10.77
0.00
21.54
7.18
39.49

10.77
0.00
0.00
0.00
3.59
0.00
14.36

14.36
122.06
0.00
0.00
136.42

0.00
0.00
3.59
14.36
17.95
87

4.21
0.00
0.00
8.42
33.68
46.31

16.84
29.47
37.89
0.00
84.20

21.05
0.00
0.00
0.00
0.00
0.00
21.05

4.21
63.15
0.00
0.00
67.36

0.00
0.00
12.63
0.00
12.63
Total

15.49
5.64
13.84
26.36
178.24
239.57

58.36
58.17
120.93
13 . 33
250.79

60.52
2.05
o.no
2.05
15.89
0.00
80.51

41.12
349.21
2.05
8.20
400.58

0.00
6.15
36.72
55, .36
98.23
Total U. S.
2,486.65    1,974.50
972.51
5,433.66
                                    E-41

-------
        TABLE E-21.  QUANTITY OF TOTAL INDUSTRY AND POTENTIALLY HAZARDOUS
                     ELECTROLESS NICKLL PLATING WASTES GENERATED FKOM THL
                     ELECTROPLATING AND METAL FINISHING INDISTRY (JOB SHOPS):
                     METRIC TONS; DRY WEIGHT*;  1977
                                 Plant  Siy.e  (Employees)
EPA Region and State           16          38           87             Total

Region I
   Massachusetts               0.00       453.38       87.75         541.13
   Connecticut                 0.00       365.63      160.88         526.51
   Rhode Island                0.00     1,038.38       87.75       1,126.13
   New Hampshire               0.00         0.00        0.00           0.00
   Maine                       0.00         0.00       14.63          14.63
   Vermont                     0.00        14.63        0.00          14.63
   Region I Total              0.00     1,872.02      351.01       2:223.03

Region II
   New Jersey                  0.00       307.13       87.75         394.88
   New York                    0.00       658.13      307.13         965.26
   Region II Total             0.00       965.26      394.88       1,360.14

Region III
   Delaware                    0.00         0.00        0.00           0.00
   Maryland                    0.00        29.25        0.00          29.25
   Pennsylvania                0.00       336.38      160.88         497.26
   Virginia                    0.00        29.25       14.63          43.88
   West Virginia               0.00        58.50       29.25          87.75
   Region III Total            Q.OO       453.38      204.76         65G.14

Region IV
   Alabama                     0.00        87.75       14.63         102.38
   Florida                     0.00        43.88       14.63          58.51
   Georgia                     0.00        29.25       43.88          73.13
   Kentucky                    0.00        73.13       29.25         102.38
   Mississippi                 0.00         0.00       14.63          14.63
   North Carolina              0.00       117.00       29.25         146.25
   South Carolina              0.00        14.63       29.25          43.88
   Tennessee                   0.00       146.25       14.63         160.88
   Region IV Total             0.00       511.89      190.15         702.04
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total

0.00
0.00
0.00
0.00
0.00
0.00
0.00

526.50
190.13
1,477.13
131.63
672.75
117.00
3,115.14

351.00
131.63
482.63
58.50
321.75
87.75
1,433.26

877.50
321.76
1,959.76
190.13
994.50
204.75
4,548.40
*  These dry weights can be converted to wet weights by applying a factor
   of two for a sludge containing 50 percent solids after filtration.

Note:   Total  Industry Wastes =  Potentially Hazardous Wastes.
                                    E-42

-------
TABLE E-21.  (Continued)
Plant Size (Kmployces)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
16

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
38

29.25
14.63
14.63
14.63
204.75
277.89

43.88
0.00
87.75
29.25
]60.88

43.88
0.00
0.00
0.00
14.63
0.00
58.51

58.50
497.25
0.00
0.00
555.75

0.00
0.00
14.63
58.50
73.13
8,043.85
87

14.63
0.00
0.00
29.25
117.00
160.88

58.50
102.38
131.63
00.00
2 92 . 5 1

73.13
0.00
0.00
0.00
0.00
0.00
73.13

14.63
219.38
0.00
0.00
234.01

0.00
0.00
43.88
0.00
43.88
3,378.47
Total

43.88
14.63
14.63
43.88
321.75
438.77

102.38
102.38
219.38
29.25
453.39

117.00
0.00
0.00
0.00
14.63
0.00
131.64

73.13
716.63
0.00
0.00
789.76

0.00
0.00
58.51
58.50
117.01
11,422.32
       E-43

-------





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-------
       TABLE E-23.  TOTAL QUANTITY OF CHROMIUM HYDROXIDE WASTES GENERATED
                    IN THE WATER POLLUTION' CONTROL SLUDGES FROM ELECTROPLATING
                    AND METAL FINISHING INDUSTRY; (JOB SHOPS); METRIC TONS;
                    DRY WEIGHT; 1977
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

135.68
140.53
0.00
7.27
4.85
4.85
293.18

205.94
237.44
443.38

2.42
26.65
167.18
0.00
19.38
215.63

33.92
62.99
14.54
9.69
16.96
26.65
19.38
19.38
203.51

266.51
113.87
298.01
43.61
348.89
48.46
1,119.35
Size (umployces)
38

136.84
110.35
313.40
0.00
0.00
4.41
565.00

92.70
198.64
291.34

0.00
8.83
101.52
8.83
17.66
136.84

26.48
13.24
8.83
22.07
0.00
35.31
4.41
44.14
154.48

158.91
57.38
445.83
39.73
203.05
35.31
940.21
87

59.14
108.42
59.14
0.00
9.86
0.00
236.56

59.14
206.99
266.13

0.00
0.00
108.42
9.86
19.71
137.99

9.86
9.86
29.57
19.71
9.86
19.71
19.71
9.86
128.14

236.56
88.71
325.27
39.43
216.85
59.14
965.96
Total

331.66
359.30
372.54
7.27
14.71
9.26
1,094.74

357.78
643.07
1,000.85

2.42
35.48
377.12
18.69
56.75
490.46

70.26
86.09
52.94
51.47
26.82
81.67
43.50
73.38
486.13

661.98
259.96
1,069.11
122.77
768.79
142.91
3,025.52
Note:  Total Industry Wastes = Potentially Hazardous Wastes
                                      E-46

-------
                            TABLE  E-23.  (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Plant
16

'4.85
2.42
12.11
16.96
111.45
147.79

36.34
33.92
72.69
7.27
150.22

33.92
2.42
0.00
2.42
14.54
0.00
53.30

26.65
193.83
2.42
9.69
232.59

0.00
7.27
24.23
48.46
79.96
Size (Employees)
38

8.83
4.41
4.41
4.41
61.80
83.86

13.24
0.00
26.48
8.83
48.55

13.24
0.00
0.00
0.00
4.41
0.00
17.65

17.66
150.08
0.00
0.00
167.74

0.00
0.00
4.41
17.66
22.07
87

9.86
0.00
0.00
19.71
78.85
108.42

39.43
69.00
88.71
0.00
197.14

49.28
0.00
0.00
0.00
0.00
0.00
49.28

9.86
147.85
0.00
0.00
157.71

0.00
0.00
29.57
0.00
29.57
Total

23.54
6.83
16.52
41.08
252.10
340.07

89.01
102.92
187.88
16.10
395.91

96.44
2.42
0.00
2.42
18.95
0.00
120.23

54.17
491.76
2.42
9.69
558.04

0.00
7.27
58.21
66.12
131.60
Total U. S.
2,938.93    2,427.74    2,276.90
7,643.55
                                   E-47

-------
          TABLE E-24. TOTAL QUANTITY OF NICKEL HYDROXIDE WASTES GENERATED
                      IN THE WATER POLLUTION CONTROL SLUDGES FROM THE
                      ELECTROPLATING AND METAL FINISHING INDUSTRY (JOB
                      SHOPS); METRIC TONS;  DRY WEIGHT;  1977
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Is land
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

61.00
63.18
0.00
3.27
2.18
2.18
131.81

92.59
106.75
199.34

1.09
11.98
75.16
0.00
8.71
96.94

15.25
28.32
6.54
4.36
7.62
11.98
8.71
8.71
91.49

119.82
51.19
133.98
19.61
156.85
21.78
503.23
Size (Employ
38

55.07
44.41
126.12
0.00
0.00
1.78
227.38

37.30
79.94
117.24

0.00
3.55
40.86
3.55
7.11
55.07

10.66
5.33
3.55
8.88
0.00
14.21
1.78
17.76
62.17

63.95
23.09
179.41
15.99
81.71
14.21
378.36
cos)
87

46.87
85.93
46.87
0.00
7.81
0.00
187.48

46.87
164.04
210.91

0.00
0.00
85.93
7.81
15.62
109.36

7.81
7.81
23.43
15.62
7.81
15.62
15.62
7.81
101.53

187.48
70.30
257.78
31.25
171.85
46.87
765.53
Total

162.94
193.52
172.99
3.27
9.99
3.96
546.67

176.76
350.73
527.49

1.09
15.53
201.95
11.36
31.44
261.37

33.72
41.46
33.52
28.86
15.43
41.81
26.11
34.28
255.19

371.24
144.59
571.17
66.84
410.42
82.86
1,647.12
Note:  Total Industry Wastes = Potentially Hazardous Wastes
                                    E-48

-------
                            TABLE  E-24.  (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Plant
16

2.18
1.09
5.45
7.62
50.11
66.45

16.34
15.25
32.68
3.27
67.54

15.25
1.09
0.00
1.09
6.54
0.00
23.97

11.98
87.14
1.09
4.36
104.57

0.00
3.27
10.89
21.78
35.94
Size (Employees)
38

3.55
1.78
1.78
1.78
24.87
33,76

5.33
0.00
10.66
3.55
19.54

5.33
0.00
0.00
0.00
1.78
0.00
7.11

7.11
60.40
0.00
0.00
67.51

0.00
0.00
1.78
7.11
8.89
87

7.81
0.00
0.00
15.62
62.49
85.92

31.25
54.68
70.30
0.00
156.23

39.06
0.00
0.00
0.00
0.00
0.00
39.06

7.81
117.17
0.00
0.00
124.98

0.00
0.00
23.43
0.00
23.43
Total

13.54
2.87
7.23
25.02
137.47
186.13

52.92
69.93
113.64
6.82
243.31

59.64
1.09
0.00
1.09
8.32
0.00
70.14

26.90
264.71
1.09
4.36
297.06

0.00
3.27
36.10
28.89
68.26
Total U. S.
1,321.28
977.03    1,804.43
4,102.74
                                 E-49

-------
       TABLE E-25.  TOTAL QUANTITY OF 7.TNC HYDROXIDE WASTES GENERATED
                    IN THE WATER POLLUTION CONTROL SLUDGES FROM THE
                    ELECTROPLATING AND METAL FINISHING INDUSTRY (JOB
                    SHOPS); METRIC TONS; DRY WEIGHT; 1977
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

42.73
42.25
0.00
2.29
1.53
1.53
90.33

64.86
74.77
139.63

.76
8.39
52.65
0.00
6.10
67.00

10.68
-19.84
4.58
3.05
5.34
8.39
6.10
6.10
64.08

83.93
35.86
93.85
13.73
109.87
15.26
352.50
Size (Employees)
38

69.33
55.91
158.78
0.00
0.00
2.24
286.26

46.96
100.64
147.60

0.00
4.47
51.44
4.47
8.95
69.33

13.42
6.71
4.47
11.18
0.00
17.89
2.24
22.36
78.27

80.51
29.07
225.87
20.13
102.87
17.89
476.34
87

19.68
36.09
19.68
0.00
3.28
0.00
78.73

19.68
68.89
88.57

0.00
0.00
36.09
3.28
6.56
45.93

3.28
3.28
9.84
6.56
3.28
6.56
6.56
3.28
42.64

78.73
29.53
108.26
13.12
72.17
19.68
321.49
Total

131.74
134.25
178.46
2.29
4.81
3.77
455.32

131.50
244.30
375.80

.76
12.86
140.18
7.75
21.61
183.16

27.38
29.83
18.79
20.79
8.62
32.84
14.90
31.74
184.99

243.17
94.46
427.98
46.98
284.91
52.83
1,150.33
Note:  Total Industry Wastes = Potentially Hazardous  Wastes
                                  E-50

-------
TABLE E-25.  (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Plant
16

'1.53
.76
3.82
5.34
35.10
46.55

11.45
10.68
22.89
2.29
47.31

10.68
.76
0.00
.76
4.58
0.00
16.78

8.39
61.04
.76
3.05
73.24

0.00
2.29
7.63
15.26
25.18
923.50
Size (Employees)
38

4.47
2.24
2.24
2.24
31.31
42.50

6.71
0.00
13.42
4.47
24.60

6.71
0.00
0.00
0.00
2.24
0.00
8.95

8.95
76.04
0.00
0.00
84.99

0.00
0.00
2.24
8.95
11.19
1,230.03
87

3.28
0.00
0.00
6.56
26.24
36.08

13.12
22.96
29.53
0.00
65.61

16.40
0.00
0.00
0.00
0.00
0.00
16.40

3.28
49.21
0.00
0.00
52.49

0.00
0.00
9.84
0.00
9.84
757.78
Total

9.28
3.00
6.06
14.14
92.65
125.13

31.28
33.64
65.84
6.76
137.52

33.79
.76
0.00
.76
6.82
0.00
42.13

20.62
186.29
.76
3.05
210.72

0.00
2.29
19.71
24.21
46.21
2,911.31
        E-51

-------
       TABLE E-26.  TOTAL QUANTITY OF IRON HYDROXIHE PASTES GENERATE!)
                    IN THE WATER POLLUTION CONTROL SLUDGES FROM THE
                    ELECTROPLATING A^'D METAL FINISHING INDUSTRY (JOB
                    SHOPS); METRIC TOMS; DRY WEIGHT; 1977
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Planf
16

27.84
28.83
0.00
1.49
.99
.99
60.14

42.26
48.72
90.98

.50
5.47
34.30
0.00
3.98
44.25

6.96
12.93
2.98
1.99
3.48
5.47
3.98
3.98
41.77

54.69
23.37
61.15
8.95
71.59
9.94
229.69
Size (Employees)
38

71.18
57.41
163.03
0.00
0.00
2.30
293.92

48.22
103.33
151.55

0.00
4.59
52.81
4.59
9.18
71.17

13.78
6.89
4.59
11.48
0.00
18.37
2.30
22.96
80.37

82.66
29.85
231.92
20.67
105.63
18.37
489.10
87

26.24
48.11
26.24
0.00
4.37
0.00
104.96

26.24
91.84
118.08

0.00
0.00
48.11
4.37
8.75
61.23

4.37
4.37
13.12
8.75
4.37
8.75
8.75
4.37
56.85

104.96
39.36
144.32
17.49
96.21
26.24
428.58
Total

125.26
134.35
189.27
1.49
5.36
3.29
459.02

116.72
243 . 89
360.61

.50
10.06
135.22
8.96
21.91
176.65

25.11
24.19
20.69
22.22
7.85
32.59
15.03
31.31
178.99

242.31
92.58
437.39
47.11
273.43
54.55
1,147.37
Note:  Total Industry Wastes = Potentially Hazardous Wastes
                                E-52

-------
TABLE E-26. (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Kebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Plant
16

.99
.50
2.49
3.48
22.87
30.33

7.46
6.96
14.91
1.49
30.82

6.96
.50
0.00
.50
2.98
0.00
10.94
5.47
39.77
.50
t.99
47.73

0.00
1.49
4.97
9.94
16.41
603.06
Size (Employees)
38

4.59
2.30
2.30
2.30
32.15
43.64

6.89
0.00
13.78
4.59
25.26

6.89
0.00
0.00
0.00
2.30
0.00
9.19
9.18
78.07
0.00
0.00
87.25

0.00
0.00
2.30
9.18
11.48
1,262.93
87

4.37
0.00
0.00
8.75
34.99
48.11

17.49
30.61
39.36
0.00
87.46

21.87
0.00
0.00
0.00
0.00
0.00
21.87
4.37
65.60
0.00
0.00
69.97

0.00
0.00
13.12
0.00
13.12
1,010.23
Total

9.95
2.80
4.79
14.53
90.01
122.08

31.84
37.57
68.05
6.08
143.54

35.72
.50
0.00
.50
5.28
0.00
42.00
19.02
183.44
.50
1.99
204.95

0.00
1.49
20.39
19.13
41.01
2,876.22
        E-53

-------
         TABLE E-27.  TOTAL QUANTITY OF ALUMINUM HYDROXIDE WASTES
                      GENERATED IN THE WATER POLLUTION CONTROL SLUDGES
                      FROM THE ELECTROPLATING AND METAL FINISHING
                      INDUSTRY (JOB SHOPS):  METRIC TONS;  DRY WEIGHT;  1977
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

20.14
20.86
0.00
1.08
.72
.72
43.52

30.57
35.25
65.82

.36
3.96
24.82
O.CO
2.88
32.02

5.04
9.35
2.16
1.44
2.52
3.96
2.88
2.88
30.23

39.56
16.90
44.24
6.47
51.79
7.19
166.15
Size (employees)
38

63.92
51.55
146.41
0.00
0.00
2.06
263.94

43.30
92.79
136.09

0.00
4.12
47.43
4.12
8.25
63.92

12.37
6.19
4.12
10.31
0.00
16.50
2.06
20.62
72.17

74.23
26.81
208.27
18.56
94.86
16.50
439.23
87

22.59
41.41
22.59
0.00
3.76
0.00
90.35

22.59
79.05
101.64

0.00
0.00
41.41
3.76
7.53
52.70

3.76
3.76
11.29
7.53
3.76
7.53
7.53
3.76
48.92

90.35
33.88
124.23
15.06
82.82
22.59
368.93
Total

106.65
113.82
169.00
1.08
4.48
2.78
397.81

96.46
207.09
303.55

.36
8.08
113.66
7,89
18.65
148.64

21.17
19.30
17.57
19.28
6.28
27.99
12.47
27.26
151.32

204.14
77.59
376.74
40.09
229.47
46.28
974.31
Note:  Total Industry Wastes = Potentially Hazardous Wastes
                                     E-54

-------
TABLE E-27. (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Plant
16

.71
.36
1.80
2.52
16.54
21.93

5.40
5.04
10.79
1.08
22.31

5.04
.36
0.00
.36
2.16
0.00
7.92

3.96
28.77
..36
1.44
34.53

0.00
1.08
3.60
7.19
11.87
436.30
Size (Employees)
38

4.12
2.06
2.06
2.06
28.87
39.17

6.19
0.00
12.37
4.12
22.68

6.19
0.00
0.00
0.00
2.06
0.00
8.25

8.25
70.11
0.00
0.00
78.36

0.00
0.00
2.06
8.25
10.31
1,134.12
87

3.76
0.00
0.00
7.53
30.12
41.41

15.06
26.35
33.88
0.00
75.29

18.82
0.00
0.00
0.00
0.00
0.00
18.82

3.76
56.47
0.00
0.00
60.23

0.00
0.00
11.29
0.00
11.29
869.58
Total

8.59
2.42
3.86
12.11
75.53
102.51

26.65
31.39
57.04
5.20
120.28

30.05
.36
0.00
.36
4.22
0.00
34.99

15.97
155.35
.36
1.44
173.12

0.00
1.08
16.95
15.44
33.47
2,440.00
      E-55

-------
       TABLE E-28. TOTAL QUANTITY OF COPPER HYDROXIDE WASTES  GENERATED
                   IN THE WATER POLLUTION CONTROL SLUDGES  FROM THE
                   ELECTROPLATING AND METAL FINISHING INDUSTRY (JOB
                   SHOPS); METRIC TONS;  DRY WEIGHT;  1977
Plant Size (Employees)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

25.53
26.44
0.00
1.37
.91
.91
55.16

38.75
44.68
83.43

.46
5.01
31.46
0.00
3.65
40.58

6.38
11.85
2.74
1.82
3.19
5.01
3.65
3.65
38.29

50.15
21.43
56.08
8.21
65.65
9.12
210.64
38

22.11
17.83
50.63
0.00
0.00
.71
91.28

14.98
32.09
47.07

0.00
1.43
16.40
1.43
2.85
22.11

4.28
2.14
1.43
3.57
0.00
5.71
.71
7.13
24.97

25.67
9.27
72.03
6.42
32.80
5.71
151.90
87

28.37
52.01
28.37
0.00
4.73
0.00
113.48

28.37
99.29
127.66

0.00
0.00
52.01
4.73
9.46
66.20

4.73
4.73
14.18
9.46
4.73
9.46
9.46
4.73
61.48

113.48
42.55
156.03
18.91
104.02
28.37
463.36
Total

76.01
96.28
79.00
1.37
5.64
1.62
259.92

82.10
176.06
258.16

.46
6.44
99.87
6.16
15.96
128,89

15.39
18.72
18.35
14.85
7.92
20.18
13.82
15.51
124.74

189.30
73.25
284.14
33.54
202.4?
43.20
825.90
Note:  Total Industry Wastes = Potentially Hazardous  Wastes
                              E-56

-------
TABLE E-28. (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Plant
16

.91
.46
2. 20
3.19
20.97
27.81
6.84
6.38
13.68
1.37
28.27

6.38
.46
0.00
.46
2.74
0.00
10.04

5.01
36.47
.46
1.82
43.76

0.00
1.37
4.56
9.12
15.05
553.03
Size (F.mployeos^
38

1.43
.71
.71
.71
9.98
13.54
2.14
0.00
4.28
1.43
7.85

2.14
0.00
0.00
0.00
.71
0.00
2.85

2.85
24.25
0.00
0.00
27.10

0.00
0.00
.71
2.85
3.56
392.23
87

4.73
0.00
0.00
9.46
37.83
52.02
18.91
33.10
42.55
0.00
94.56

23.64
0.00
0.00
0.00
0.00
0.00
23.64

4.73
70.92
0.00
0.00
75.65

0.00
0.00
14.18
0.00
14.18
1,092.23
Total

7.07
1.17
2.99
13.36
68.78
93.37
27.89
39.48
60.51
2.80
130.68

32.16
.46
0.00
.46
3./5
0.00
36.53

12.59
131.64
.46
1.82
146.51

0.00
1.37
19.45
11.97
32.79
2,037.49
     E-57

-------
         TABLE E-29. TOTAL QUANTITY OF LEAD HYDROXIDE WASTES GENERATED
                     IN THE WATER POLLUTION CONTROL SLUDGES FROM THE '
                     ELECTROPLATING AND METAL FINISHING INDUSTRY (JOB
                     SHOPS); METRIC TONS; DRY WEIGHT; 1977
Plant Size (Employees)
ETA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
Kew Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
38

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
87

11.83
21.68
11.83
0.00
1.97
0.00
47.31

11.83
41.40
53.23

0.00
0.00
21.68
1.97
,3.94
27.59

1.97
1.97
5.91
3.94
1.97
3.94
3.94
1.97
25.61

47.31
17.74
65.05
7.89
43.37
11.83
193.19
Total

11.83
21.68
11.83
0.00
1.97
0.00
47.31

11.83
41.40
53.23

0.00
0.00
21.68
1.97
3.94
27.59

1.97
1.97
5.91
3.94
1.97
3.94
3.94
1.97
25.61

47.31
17.74
65.05
7,89
43.37
11.83
193.19
Note:  Total Industry Wastes = Potentially Hazardous Wastes
                                    E-58

-------
TABLE E-29. (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
16

'0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
38

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
87

1.97
0.00
0.00
3.94
15.77
21.68

7,89
13.80
17.74
0.00
39.43

9.86
0.00
0.00
0.00
0.00
0.00
9.86

1.97
29.57
0.00
0.00
31.54

0.00
0.00
5.91
0.00
5.91
455.35
Total

1.97
0.00
0.00
3.94
15.77
21.68

7.89
13.80
17.74
0.00
39.43

9.86
0.00
0.00
0.00
0.00
0.00
9.86

1.97
29.57
0.00
0.00
31.54

0.00
0.00
5.91
0.00
5.91
455.35
         E-59

-------
          TABLE E-30.  TOTAL QUANTITY OF CADMIUM HYDROXIDE WASTES GENERATED
                       IN THE WATER POLLUTION CONTROL SLUDGES FROM THE
                       ELECTROPLATING AND METAL FINISHING INDUSTRY (JOB
                       SHOPS); METRIC TONS; DRY WEIGHT;  1977
Plant Size (Employees)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Caro li na
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

12.04
12.47
0.00
.64
.43
.43
26.01

18.27
21.07
39.34

.21
2.36
14.83
0.00
1.72
In i o
./ • +. *-

3.01
5.59
1.29
.86
1.50
2.36
1.72
1.72
18.05

23.64
10.10
26.44
3.87
30.95
4.30
99.30
38

5.71
4.61
13.08
0.00
0.00
.18
23.58

3.87
8.29
12.16

0.00
.37
4.24
.37
.74
5.72

1.11
.55
.37
.92
0.00
1.47
.18
1.84
6.44

6.63
2.40
18.61
1.66
8.48
1.47
39.25
87

.88
1.60
.88
0.00
.15
0.00
3.51

.88
3.06
3.94

0.00
0.00
1.60
.15
..29
2.04

.15
.15
.44
.29
.15
.29
.29
.15
1.91

3.50
1.31
4.81
.58
3.21
.88
14.29
Total

18.63
18.68
13.96
.64
.58
.61
53.10

23.02
32.42
55.44

.21
2.73
20.67
.52
2.75
76.. f 3

4.27
6.29
2.10
2.07
1.65
4.12
2.19
3.71
26.40

33.77
13.81
49.86
6.11
42.64
6.65
152.84
Note:   Total Industry Wastes  = Potentially  Hazardous Wastes
                                      E-60

-------
TABLE E-30. (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
16

.43
.21
1.07
1.50
9.89
13.10

3.22
3.01
6.45
.64
13.32

3.01
.21
0.00
.21
1.29
0.00
4.72

2.36
17.20
.21
'.86
20.63

0.00
.64
2.15
4.30
7.09
260.68
38

.37
.18
.18
.18
2.58
3.49

.55
0.00
1.11
.37
2.03

.55
0.00
0.00
0.00
.18
0.00
.73

.74
6.26
0.00
0.00
7.00

0.00
0.00
.18
.74
.92
101.32
87

.15
0.00
0.00
.29
1.17
1.61

.58
1.02
1.31
0.00
2.91

.73
0.00
0.00
0.00
0.00
0.00
.73

.15
2.19
0.00
0.00
2.34

0.00
0.00
.44
0.00
.44
33.72
Total

.95
.39
1.25
1.97
13.64
18.20

4.35
4.03
8.87
1.01
18.26

4.29
.21
0.00
.21
1.47
0.00
6.18

3.25
25.65
.21
.86
29.97

0.00
.64
2.77
5.04
8.45
395.72
       E-61

-------
       TABLE E-31.  TOTAL QUANTITY OF TIN HYDROXIDE WASTES GENERATED
                    IN THE WATER POLLUTION CONTROL SLUDGES FROM THE
                    ELECTROPLATING AMD METAL FINISHING INDUSTRY (JOB
                    SHOPS); METRIC TONS; DRY WEIGHT; 1977
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total.
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
C.OG

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
Size (Employees]
38

0,00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
)
87

.85
1.56
.85
0.00
.14
0.00
3.40

.85
2.98
3.83

0.00
0.00
1.56
.14
.28
1.98

.14
.14
.43
.28
.14
.28
.28
.14
1.83

3.40
1.28
4.68
.57
3.12
.85
13.90
Total

.85
1.56
.85
0.00
.14
0.00
3.40

.85
2.98
3.83

0.00
0.00
1.56
.14
.28
1.98

.14
.14
.43
.28
.14
.28
.28
.14
1.83

3.40
1.28
4.68
.57
3.12
.85
13.90
Note:  Total Industry Wastes = Potentially Hazardous Wastes
                                  E-62

-------
TABLE E-31.  (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
16
'0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
6.00
0.00
otoo
0.00
0.00
0.00
0.00
0.00
38
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
87
.14
0.00
0.00
.28
1.13
1.55
.57
.99
1.28
0.00
2.84
.71
0.00
0.00
0.00
0.00
0.00
.71
.14
2.13
0.00
0.00
2.27
0.00
0.00
.43
0.00
.43
32.74
Total
.14
0.00
0.00
.28
1.13
1.55
.57
.99
1.28
0.00
2.84
.71
0.00
0.00
0.00
0.00
0.00
.71
.14
2.13
0.00
0.00
2.27
0.00
0.00
.43
0.00
.43
32.74
        E-63

-------
          TABLE E-32.
TOTAL QUANTITY OF MANGANESE HYDROXIDE WASTES GENERATED
IN Tin: UATF.R POLLUTION CONTROL SLUDGES FROM THE
ELECT'iOPIATING AND METAL FINISHING INDUSTRY (JOB
SHOPS); METRIC TONS; DRY WEIGHT; 1977
Plant Si.ze. (Employees)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
38

.34
.27
.77
0.00
0.00
.01
1.39

.23
.49
.72

0.00
.02
.25
.02
.04
.33

.06
.03
.02
.05
0.00
.09
.01
.11
.37

.39
.14
1.09
.10
.50
.09
2.31
87

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0,00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
Total

.34
.27
.77
0.00
0.00
.01
1.39

.23
.49
.72

0.00
.02
.25
.02
.04
.33

.06
.03
.02
.05
0.00
.09
.01
.11
.37

.39
.14
1.09
.10
.50
.09
2.31
Note:  Total Industry Wastes = Potentially Hazardous Wastes
                                   E-64

-------
TABLE E-32. (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
16

'0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
d.oo
0.00

0.00
0.00
0.00
0.00
0.00
0.00
38

.02
.01
.01
.01
.15
.20

.03
0.00
.06
.02
.11

.03
0.00
0.00
0.00
.01
0.00
.04

.04
.37
0.00
0.00
.41

0.00
0.00
.01
.04
.05
5.93
87

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
Total

.02
.01
.01
.01
.15
.20

.03
0.00
.06
.02
.11

.03
0.00
0.00
0.00
.01
0,00
.04

.04
.37
0.00
0.00
.41

0.00
0.00
.01
.04
.05
5.93
        E-65

-------
    TABLE E-33.   QUANTITY Of TOTAL INDUSTRY AND POTENTIALLY HAZARDOUS
                 WASTES  DESTINED  FOR  LAND  DISPOSAL  FROM THE ELECTROPLATING
                 AND METAL FINISHING  INDUSTRY  (JOB  Sl'OPS);  METRIC  TONS'
                 DRY WEIGHT;  1983
Plant Sizo (Employees)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
WecL Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

2,153.85
2,230.77
0.00
115.38
76.92
76.92
4,653.84

3,269.24
3,769.24
7,038.48

38.46
423.08
2,653.85
0.00
307.69
3,423.08

538.46
1,000.00
230.77
153.85
269.23
423.08
307.69
307.69
3,230.77

4,230.78
1,807.70
4,730.78
692.31
5,538.47
769.23
17,769.27
38

3,188.90
2,571.69
7,303.61
0.00
0.00
102.87
13,167.07

2,160.2.2
4,629.05
6,789.27

0.00
205.74
2,365.96
205.74
411.47
3,188.91

617.21
308.60
205.74
514.34
0.00
822.94
102.87
1,028.68
3,600.38

3,703.24
1,337.28
10,389.64
925.81
4 , 73 1 . 92
822.94
21,910.83
87

1,235.14
2,282.76
1,245.14
0.00
207.52
0.00
4,970.56

1,245.14
4,358.00
5,603.14

0.00
0.00
2,282,76
207.52
415.05
2,905.33

207.52
207.52
622.57
4 15 . 05
207.52
415.05
415.05
207.52
2,697.80

4,980.57
1,867.71
6,848.28
830.09
4,565.52
1,245.14
20,337.31
Total

6,577.89
7,085.22
8,548.75
115.38
284.44
179.79
22,791.47

6,674.60
12,756.29
19,430.89

38.46
628.82
7,302.57
413.26
1,134.21
9,517.32

1,363.19
1,516.12
1,059.08
1,083.24
476.75
1,661.07
825.61
1,543.89
9,528.95

12 , 9 14 . 5 9
5,012.69
21,968.70
2,448.21
14,835.91
2,837.31
60,017.41
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                    E-66

-------
TABLE E-33. (Continued)
EPA Region and State
Regiort VI
Arkansas
Loviisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Plant
16

76.92
38.46
I9n.31
269.23
1,769.23
2,346.15

576.92
538.46
1,153.85
115.38
2,384.61

538.46
38.46
0.00
38.46
230.77
0.00
846.15

423.08
3,076.93
38.46
153.85
3,692.32

0.00
115.38
384.62
769.23
1,269.23
46,653.90
Sizo (r.nploy
38

205.74
102.87
102.87
102.87
1,440.15
1,954.50

308.60
0.00
617.21
205.74
1,131.55

308.60
0.00
0.00
0.00
102.87 i
0.00
411.47

411.47
3,497.50
0.00
0.00
3,908.97

0.00
0.00
102.87
411.47
514.34
56,577.29
ocs)
87

207.52
0.00
C.OO
415.05
1,660.19
2,282.76

830.09
1,452.67
1,867.71
0.00
4,150.47

1,037.62
0.00
0.00
0.00
0.00
0.00
1,037.62

207.52
3,112.85
0.00
0.00
3,320.37

0.00
0.00
622.57
0.00
622.57
47,927.93
Total

490.18
141.33
295.18
787.15
4,869.57
6, 583. -U

1,715.61
1,991.13
3,638.77
321.12
7,666.63

1,884.08
38.46
0.00
38.46
333.64
0.00
2,?95.?A

1,042.07
9,687.2?,
38.46
153.85
10, 921. (16

0.00
115.38
1,110.06
1,180.70
2 ,406. 14
151,159.12
       E-67

-------
        TABLE E-34.  QUANTITY OF TOTAL INDUSTRY AND POTENTIALLY HAZARDOT'S
                     WATER POLLUTION CONTROL  SLUDGES GENERATED FROM VHE
                     ELECTROPLATING AND METAL FINISHING  INDUSTRY  (JOB
                     SHOPS);  METRIC TONS;  DRY WEIGHT; 1983
EPA Region and State
                                Plane Size (I>ployce3)
16
38
87
Total
Region I
   Massachusetts           1,115.07     1,421.35      636.66        3,173.08
   Connecticut             1.154.90     1,146.25    1,167.21        3,468.36
   Rhode Island                0.00     3,255.35      636.66        3,892.01
   New Hampshire              59.74         0.00        0.00           59.74
   Maine                      39.82         0.00      106.11          145.93
   Vermont                    39.82       45.85        0.00           85.67
   Region I Total          2,409.35     5,868.80   2,546.64       10,824.79

Region II
   New Jersey              1,692.52      636.66      636.66        2,965.84
   New York                1,951.38     2,063.25    2,228.31        6,242.94
   Region II Total         3,643.90     2,699.91    2,864.97        9,208.78

Region III
   Delaware                   19.91         0.00        0.00           19.91
   Maryland                  219.03       91.70        0.00          310.73
   Pennsylvania            1,373.93     1,054.55    1,167.21        3,595.69
   Virginia                    0.00       91.70      106.11          197.81
   West Virginia             159.30      183.40      212.22          554.92
   Region III Total        1,772.17     1,421.35    1,485.5'        4,679.06

Region IV
   Alabama                   278.77      275.10      106.11          659.98
   Florida                   517.71      137.55      106.11          761.37
   Georgia                   119.47       91.70      318.33          529.50
   Kentucky                   79.65      229.25      212.22          521.12
   Mississippi               139.38         0.00      106.11          245.49
   North Carolina            219.29      366.80      212.22          798.31
   South Carolina            159.30       45.85      212.22          417.37
   Tennessee                 159.30      458.50      212.22          830.02
   Region IV Total         1,672.87     1,604.75    1,485.54        4,763.16
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total

2,190.32
935.86
2,449.18
358.42
2,867.33
398.24
9,199.35

1,650.60
596.05
4,630.85
412.65
2,109.10
366.80
9,766.05
lft*l«l HI II 1 ., -- „.

2,546.64
954.99
3,501.63
424.44
2,334.42
636.66
10,398.78

6,387.56
2,486.90
10,581.66
1,195.51
7,310.85
1,401.70
29,364.18
*  These dry weights can be converted to wet weights by applying a factor of
   five for a sludge containing 20 percent solids.

 Note:  Total Industry  Wastes  = Potentially  Hazardous Wastes.
                                  E-68

-------
                            TABLE fc-34.  (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Plant
16

39.82
19.91
99 . 56
139.38
915.95
1,214.62

298.68
278.77
597.36
59.74
1,234.55

278.77
19.91
0.00
19.91
119.47
0.00
438.06

219.03
1,592.96
19.91
79.65
1,911.55

0.00
59.74
199.12
398.24
657.10
Size (Rmplov
38

91.70
45.85
45.85
45.85
641.90
871.15

137.55
0.00
275.10
91.70
504.35

137.55
0.00
0.00
0.00
45.85
0.00
183.40

183.40
1,558.90
0.00
0.00
1,742.30

0.00
0.00
45.85
183.40
229.25
•OPS)
87

106.11
0.00
0.00
212.22
848.88
1,167.21

424.44
742.77
954.99
0.00
2,122.20

530.55
0.00
0.00
0.00
0.00
0.00
530.55

106.11
1,591.65
0.00
0.00
1,697.76

0.00
0.00
318.33
0.00
318.33
Total

237.63
65.76
145.41
397.45
2,406.73
3,252.98

860.67
1,021.54
1,827.45
151.44
3,861.10

946.87
19.91
0.00
19.91
165.32
0.00
1,152.01

508.54
4,743.51
19.9).
79.65
5,351.61

0.00
59.74
563.30
581.64
1,204.68
Total U. S.
24,153.52   24,891.31  24,617.52
73,662.35
                                   E-69

-------
        TABLE E-35.   QUANTITY  OF  TOTAL AND POTENTIALLY HAZARDOUS PROCESS
                     WASTES  GENERATED FROM THE ELECTROPLATING AND METAL
                     FINISHING INDUSTRY  (JOB  SHOPS); METRIC TONS; DRY
                     WEIGHT; 1983
EPA Region and State
Region 1
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Regie n III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georg -a
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region TV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

888.39
920.12
0.00
47.59
31.73
31.73
1,919.56

1,348.45
1,55^.68
2,903.13

15.86
174.51
1,094.62
0.00
126.91
1,4)1,90

222.10
412.47
95.18
63.46
111.05
174.5)
126.91
126.91
1,332.59

1,745.05
745.61
1,951.28
285.55
2,284.43
317.28
7,329.20
Size (Employees)
38

1,027.84
828.90
2,354.08
0.00
0.00
33.16
4,243.98

696.28
1,492.02
2,188.30

0.00
66.31
762.59
66.31
132.62
1,027.83

198.94
99.47
66.31
165.78
0.00
265.25
33.16
331.56
1,160.47

1,193.62
431.03
3,348.77
298.40
1,525.18
265.25
7,062.25
87

460.44
844.14
460.44
0.00
76.74
0.00
1,841.76

460.44
1,611.54
2,071.98

0.00
0.00
844 . 14
76.74
153.48
1,074.36

76.74
76.74
230.22
153.48
76.74
153.48
153.48
76.74
997.62

1,841.76
690.66
2,532.41
306.96
1,688.28
460.44
7,520.51
Total

2,376.67
2,593.16
2,814.52
47.59
108.47
64.89
8,005.30

2,505.17
4,658.24
7,163.41

15.86
240.82
2,701.35
143.05
413.01
3,514.09

497.78
588.63
391.71
38f2.72
187.79
593.24
313.55
535.21
3,490.68

4,780.43
1,867.30
7,832.46
890.91
5,497.89
1,042.97
21,911.96
*  Drv Weight •= Wet Weight.

Note:  Total Industry Wastes = Potentially Hazardous  Wastes.
                                    E-70

-------
                           TABLE E-35.  (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Plant
16

31.73
15.86
79.32
111.05
729.75
967.71

237.96
222.10
475.92
47.59
983.57

222.10
15.86
0.00
15.86
95.18
0.00
349 . 00

174.51
1,269.13
15.86
63.46
1,522.96

0.00
47.59
158.64
317.28
523.51
Size (limployeos)
38

66.31
33.16
33.16
33.16
464.19
629.98

99.47
0.00
198.94
66.31
364.72 1,

99.47
0.00
0.00
0.00
33.16
0.00
132.63

132.62
1,127.31 1,
0.00
0.00
1,259.93 1,

0.00
0.00
33 . 16
132.62
165.78

87

76.74
0.00
0.00
153.48
613.92
844.14

306.96
537.18
690.66
0.00
534.80

383.70
0.00
0.00
0.00
0.00
0.00
383.70

76.74
151.10
0.00
0.00
227.84

0.00
0.00
230.22
0.00
230.22
Total

174.78
49.02
112.48
297.69
1,807.86
2,441.83

644.39
759.28
1,365.52
113.90
2,883.09

705.27
15.86
0.00
15.86
128.34
0.00
865.33

383.87
3,547.54
15.86
63.46
4,010.73

0.00
47.59
422.02
449.90
919.51
Total U. S.
19,243.13    18,235.87     17,726.93
55,205.93
                                   E-71

-------
       TABLE E-36.   QUANTITY  OF  TOTAL  INDUSTRY  AND  POTENTIALLY HAZARDOUS
                    DEGREASER SLUDGES  GENERATED FROM  THE ELECTROPLATING
                    AND METAL FINISHING  INDUSTRY (JOR SHOPS); METRIC TON?;
                    DRY WEIGHT;  1983
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

150.39
155.76
0.00
8.06
5.37
5.37
324.95

228.27
263.18
491.45

2.69
29.54
185.30
0.00
21.48
229.01

37.60
69.82
16.11
10.74
18.80
29.54
21.48
21.48
225.57

295.41
126.22
330.32
48.34
386.71
53.71
1,240.71
Size (Employe^
38

145.79
117.57
333.91
0.00
0.00
4.70
601.97

98.76
211.63
310.39

0.00
9.41
108.17
9.41
18.81
145.80

28.22
14.11
9.41
23.51
0.00
37.62
4.70
47.03
164.60

169.30
61.14
474.99
42.33
216.33
37.62
1,001.71
0
87

33.09
60.67
33.09
0.00
5.52
0.00
132.37

33.09
115.82
148.91

0.00
0.00
60.67
5.52
11.03
77.22

5.52
5.52
16.55
11.03
5.52
11.03
11.03
5.52
71.72

132.36
49.64
182.00
22.06
121.33
33.09
540.48
Total

329.27
334.00
367.00
8.06
10.89
10.07
1,059.29

360.12
590.63
950.75

2.69
38.95
354.14
14.93
51.32
462.03

71.34
89.45
42.07
45.28
24.32
78.19
37.21
74.03
461.89

597.07
236.99
987.31
112.73
724.38
124.42
2,782.90
  Dry Weight = Wet Weight.

Note:  Total Industry Wastes = Potentially Hazardous  Wastes.
                                   E-72

-------
TABLE E-36.   (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Plant
16

5.37
2.69
13.43
18.80
123.53
163.82

40.28
37.60
80.57
8.06
166.51

37.60
2.69
0.00
2.69
16.11
0.00
59.09

29.54
214.84
2.69
10.74
257.81

0.00
8.06
26.86
53.71
88.63
3,257.55
Si/.e (Rmployeor,
38

9.41
4.70
4.70
4.70
65.84
89.35

14.11
0.00
28.22
9.41
51.74

14.11
0.00
0.00
0.00
4.70
0.00
18.81

18.81
159.90
0.00
0.00
178.71

0.00
0.00
4.70
18.81
23.51
2,586.59
)
87

5.52
0.00
0.00
11.03
44.12
60.67

22.06
38.61
49.64
0.00
110.31

27.58
0.00
0.00
0.00
0.00
0.00
27.58

5.52
82.73
0.00
0.00
88.25

0.00
0.00
16.55
00.00
16.55
1,274.06
Total

20.30
7.39
18.13
34.53
233.49
313.84

76.45
76.21
158.43
17.47
328.56

79.28
2.69
0.00
2.69
20.82
0.00
105.48

53.87
457.47
2.69
10.74
524.77

0.00
8.06
48.11
72.52
128.69
7,118.20
          E-73

-------
         TABLE  E-37.   QUANTITY  OF TOTAL  INDUSTRY AM) POTENTIALLY UAXAKIX'l'S
                      ELECTROLESS NICKEL PLATING WASTES fWERATEl)  F".OM ll'r
                      ELECTROPLATING  AND METAL  FINISHING  INDUSTRY  (JOB SHOPS)
                      METRIC  TONS; DRY WEIGHT*; 1983
EPA Region
and
State
1'lant
16
^ize (Employees)
38
87
Total
Region I
   Massachusetts
   Connecticut
   Rhode Is land
   New Hampshire
   Maine
   Vermont
   Region I Total

Region II
   New Jersey
   New York
   Region II Total

Region III
   Delaware
   Maryland
   Pennsylvania
   Virginia
   West Virginia
   Region III Total

Region IV
   Alabama
   Florida
   Georgia
   Kentucky
   Mississippi
   North Carolina
   South Carolina
   Tennessee
   Region IV Total
0.00
0.00
0.00
0.00
0.00
0.00
0.00
                               0.00
                               0.00
                               0.00
                               0.00
                               0.00
                               0.00
                               0.00
                               0.00
                               O.no
                               0.00
                               0.00
                               0.00
                               0.00
                               0.00
                               0.00
                               0.00
                               0.00
                               0.00
  593.92
  478.97
1,360.27
    0.00
    0.00
   19.16
2,452.32
  402.33
  862.14
1,264.47
    0.00
   38.32
  440.65
   38.32
   76.64
  593.93
  114.95
  57.48
  38.32
  95.79
    0.00
  153.27
  19.16
  191.59
  670.56
                                                      114.95
                                                      210.75
                                                      114.95
                                                        0.00
                                                       19.16
                                                        0.00
                                                      459.81
                       114.95
                       802,33
                       917.28
                         0.00
                         0.00
                       210.75
                        19.16
                        38.32
                       268.23
                        19.16
                        19.16
                        57.48
                        38.32
                        19.16
                        38.32
                        38.32
                        19.16
                       •249.08
                              708.87
                              689.72
                            1,475.22
                                0.00
                               19.16
                               19.16
                            2,912.13
                              517.28
                            1,664.47
                            2,181.75
                                0.00
                               38.32
                              651.40
                               57.48
                              114.96
                              86? . 16
                              134.11
                               76.64
                               95.80
                              134.11
                               19.16
                              191.59
                               57.48
                              210.75
                              919.64
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
0.00
0.00
0.00
0.00
0.00
0.00
0.00
689.72
249.06
1,935.03
172.43
881.30
153.27
4,080.81
459.81
172.43
632.24
76.64
421.49
1 14 . 95
1,877.56
1,149.53
421.49
2,567.27
249.06
1,302.80
268.22
5,958.37
   These dry weights can be converted to wet weights by applying a factor
   of two for a sludge containing 50 percent solids after filtration.
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                    E-74

-------
                             TA'M.E F.-37.  (Continued^
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyomi ng
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Plant
16

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
Size (Kmplo
38

38.32
19.16
19.16
19.16
268.22
364.02

57.48
0.00
114.95
38.32
210.75

57.48
0.00
0.00
0.00
19.16
0.00
76.64

76.64
651.40
0.00
0.00
728.04

0.00
0 00
19.16
76.64
95.80
vccs)
87

19.16
0.00
0.00
38.32
153.27
210.75

76.64
134.11
172.43
0.00
383.18

95.79
0.00
0.00
0.00
0.00
0.00
95.79

19.16
287.38
0.00
0.00
306.54

0.00
0.00
57.48
00.00
57.48
Total

57.48
19.16
19.16
57.48
421.49
574.77

134.12
134.11
287.38
38.32
593.93

153.27
0.00
0.00
0.00
19.16
0.00
172.43

95.80
938.78
0.00
0.00
1,034.58

0.00
0.00
76.64
76.64
153.28
Total U. S.
0.00   10,537.34
4,825.70
                                                                    15,363.04
                                      E-75

-------
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                                                  E-77

-------
          TABLE E-39.   TOTAL  QUANTITY OF CHROMIUM HYDROXIDE WASTES
                       GENERATED  IN  THE WATCH POLLUTION CONTROL SLUDGES
                       FROM THE ELECTROPLATE AND METAL FINISHING
                       INDUSTRY (JOB SHOPS); METRIC TONS; DRY WEIGHT: 1983
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

177.74
184.09
0.00
9.52
6.35
6.35
384.05

269.78
311.05
580.83

3.17
34.91
219.00
0.00
25.39
282.47

44.44
82.52
19.04
12.70
22.22
34.91
25.39
25.39
266.61

349.13
.149.17
390.39
57.13
457.05
63.48
1,466.35
Size (Employees)
38

179.26
144.56
410.56
0.00
0.00
5.78
740.16

121.43
260.21
381.64

0.00
11.57
133.00
11.57
23.13
179.27

34.70
17.35
11.57
28.91
0.00
46.26
5.78
57.83
202.40

208.17
75.17
584.03
52.04
266.00
46.26
1,231.67
87

77.47
142.04
77.47
0.00
12.91
0.00
309 o 89

77.47
271.16
348.63

0.00
0.00
142.04
12.91
25.82
180.77

12.91
12.9,
38.74
25.82
12.91
25.82
25.82
12.91
167.84

309.89
116.21
426.11
51.65
284.07
77.47
1,265.40
Total

434.47
470.69
488.03
9.52
19.26
12.13
1,434.10

468,68
842.42
1,311.10

3.17
46.48
494.04
24.48
74.34
642.51

92.05
112.78
69.35
67.43
35.13
106.99
56.99
96.13
636.85

867.19
340 . 55
1,400.53
160.82
1,007.12
187.21
3,963.42
Note:  Total Industry Wastes = Potentially Hazardous  Wastes,
                                 E-78

-------
                          TABLE E-39.  (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
16

6.35
3.17
15.87
22.22
146.00
193.61

47.61
44.44
95.22
9.52
196.79

44.44
3.17
0.00
3.17
19.04
0.00
69.82

34.91
253.91
3.17
12.70
304.69

0.00
9.52
31.74
63.48
104.74
38

11.57
5.78
5.78
5.78
80.96
109.87

17.35
0.00
34.70
11.57
63.62

17.35
0.00
0.00
0.00
5.78
0.00
23.13

23.13
196.61
0.00
0.00
219.74

0.00
0.00
5.78
23.13
28.91
87

12.91
0.00
0.00
25.82
103.30
142.03

51.65
90.39
116.21
0.00
258.25

64.56
0.00
0.00
0.00
0.00
0.00
64.56

12.91
193.68
0.00
0.00
206.59

0.00
0.00
38.74
0.00
38.74
Total

30.83
8.96
21.65
53.82
330.25
445.51

116.61
134.83
246.13
21.09
518.66

126.35
3.17
0.00
3.17
24.82
o'.oo
157.51

70.95
644 . 20
3.17
12.70
731.02

0.00
9.52
76.26
86.61
172.39
Total U. S.
3,849.96    3,180.41     2,982.70
                                                                  10,013.07
                                  E-79

-------
          TABLE K-40.  TOTAL QUANTITY 01- NICKEL HYDROXIDE WASTES
                       GENERATED IN THE WATER POLLUTION CONTROL SLUDGES
                       FROM THE ELECTROPLATING AND METAL FINISHING
                       INDUSTRY (JOB SHOPS); METRIC TON'S; DRY WEIGHT; 1983
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region HI
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

79.91
82,76
C.OO
4.28
2.85
2.85
172.65

121.29
139.84
261.13

1.43
15.70
98.46
0.00
11.42
127.01

19.98
37.10
8.56
5.71
9.99
15.70
11.42
11.42
119.88

156.96
67.06
175.51
25.68
205.47
28.54
659.22
Si ZP (Employees)
38

72.14
58.18
165.22
0.00
0.00
2.33
297.87

48.87
104.72
153.59

0.00
4.65
53.52
4.65
9.31
72.13

13.96
6.98
4.65
11.64
0.00
18.62
2.33
23.27
81.45

83.77
30.25
235.03
20.94
107.04
18.62
495.65
87

61.40
112.56
61.40
0.00
10.23
0.00
245.59

61.40
214.89
276.29

0.00
0.00
112.56
10.23
20.47
143.26

10.23
10.23
30.70
20.47
10.23
20.47
20.47
10.23
133.03

245.59
92.10
337.69
40.93
225.13
61.40
1,002.84
Total

213.44
253.50
226.62
4.28
13.09
5.18
716.11

231.56
459.45
691.01

1.43
20.35
264.54
14.88
41.20
342.40

44.17
54.31
43.91
37.82
20.22
54.79
34.22
44.92
334.36

486.32
189.41
748.23
87.55
537.64
108.56
2,157.71
Note:  Total Industry Wastes - Potentially Hazardous Wastes.
                                    E-80

-------
                           TABLE E-40.   (Continiu-d)
Plant Si/.e (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
16

-2. 85
1.43
7.13
9.99
65.64
87.04

21.40
19.98
42.81
4.28
88.47

19.98
1.43
0.00
1.43
8.56
0.00
31.40

15.70
114.15
1.43
5.71
136.99

0.00
4.28
14.27
28.54
47.09
38

4.65
2.33
2.33
2.33
32.58
44.22

6.98
0.00
13.96
4.65
25.59

6.98
0.00
0.00
0.00
2.33
0.00
9.31

9.31
79.12
0.00
0.00
88.43

0.00
0.00
2.33
9.31
11.64
87

10.23
0.00
0.00
20.47
81.86
112.56

40.93
71.63
92.10
0.00
204.66

51.17
0.00
0.00
0.00
0.00
0,00
51.17

10.23
153.50
0.00
0.00
163.73

0.00
0.00
30.70
0.00
30.70
Total

17.73
3.76
9.46
32.79
180.08
243.82

69.31
91.61
148.87
8.93
318.72

78.13
1.43
0.00
1.43
10.89
0.00
91.88

35.24
346.77
1.43
5.71
389.15

0.00
4.28
47.30
37.85
89.43
Total U. S.
1,730.88    1,279.88    2,363.83
5,374.59
                                   E-81

-------
       TAI5LF. E-41.  TOTAL QUANTITY OF ZINC HYDROXIDE WASTES GENERATED
                    IN THE WATER POLLUTION CONTROL SLUDGES FROM THE
                    ELECTROPLATING AND METAL FINISHING INDUSTRY (JOB
                    SHOPS); METRIC TON'S; DRY WEIGHT: 1983
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

55.97
57.97
0.00
3.00
2.00
2.00
120.94

84.96
97.95
182.91

1.00
10.99
68.97
0.00
8.00
88.96

13.99
25.99
6.00
4.00
7.00
10.99
8.00
8.00
83.97

109.95
46.98
122.94
17.99
143.93
19.99
461.78
Size (Employees)
38

90.82
73.24
208.01
0.00
0.00
2.93
375.00

61.52
131.83
193.35

0.00
5.86
67.38
5.86
11.72
90.82

17.58
8.79
5.86
14.65
0.00
23.44
2.93
29.30
102.55

105.47
38.09
295.90
26.37
134.76
23.44
624.03
87

25.79
47.27
25.79
0.00
4.30
0.00
103.15

25.79
90.25
116.04

0.00
0.00
47.27
4.30
8.60
60.17

4.30
4.30
12.89
8.60
4.30
8.60
8.60
4.30
55.89

103.14
38.68
141.82
17.19
94.55
25.79
421.17
Total

172.58
178.48
233.80
3.00
6.30
4.93
599.09

172.27
320.03
492.30

1.00
16.85
183.62
10.16
28.32
239.95

35.87
39.08
24.75
27.25
11.30
43.03
19.53
41.60
242.41

318.56
123.75
560.66
61.55
373.24
69.22
1,506.98
Note:  Total Industry Wastes = Potentially Hazardous Wastes.
                                 E-82

-------
TABLE F.-41.   (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Plant
16

'2.00
1.00
S.OO
7.00
45.98
60.98

14.99
13.99
29.99
3.00
61.97

13.99
1.00
0.00
1.00
6.00
0.00
21.99

10.99
79.96
1.00
4.00
95.95

0.00
3.00
10.00
19.99
32.99
1,212.44
S i 7 e (Km plovocs)
38

5.86
2.93
2.93
2.93
41.02
55.67

8.79
0.00
17.58
5.86
32.23

8.79
0.00
0.00
0.00
2.93
0.00
11.72

11.72
99.61
0.00
0.00
111.33

0.00
0.00
2.93
11.72
14.65
1,611.35
87

4.30
0.00
0.00
8.60
34.38
47.28

17.19
30.08
38.68
0.00
85.95

21.49
0.00
0.00
0.00
0.00
0.00
21.49

4.30
64.46
0.00
0.00
68.76

0.00
0.00
12.89
0.00
12.89
992.79
Total

12.16
3.93
7.93
18.53
121.38
163.93

40.97
44.08
86.24
8.86
180.15

44.27
1.00
0.00
1.00
8,93
0.00
55.20

27.01
244.03
1.00
4.00
276.04

0.00
3.00
25.82
31.71
60.53
3,816.58
        E-83

-------
        TABU'  E-42.   TOTAL QUANTITY OF IRON HYDROXIDE WASTES GENERATED
                     IN THE WATER POLLUTION CONTROL SLUDGES  FROM THE
                     ELECTROPLATING AKIJ METAL FINISHING INDUSTRY (JOB
                     SHOPS); METRIC TONS;  DRY WEIGHT;  1983
EPA Region and State
Region I
Massachusetts
Connect j cut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

36.47
37.77
0.00
1.95
1.30
1.30
78.79

55.36
63.82
119.18

.65
7.16
44.94
0.00
5.21
57.96

9.12
16.93
3.91
2.61
4.56
7.16
5.21
5.21
54.71

71.64
30.61
80.11
11.72
93.78
13.03
300.89
Size (Employees)
38

93.25
75.20
213.57
0.00
0.00
3.01
385.03

63.17
135.36
198.53

0.00
6.02
69.19
6.02
12.03
93.26

18.05
9.02
6.02
15.04
0.00
24.06
3.01
30.08
105.28

108.29
39.10
303.81
27.07
138.37
24.06
640.70
87

34.37
63.02
34.37
0.00
5.73
0.00
137.49

34.37
120.31
154.68

0.00
0.00
63.02
5.73
11.46
80.21

5.73
5.73
17.19
11.46
5.73
11.46
11.46
5.73
74.49

137.50
51.56
189.06
22.92
126.04
34.37
561.45
Total

164.09
175.99
247.94
1.95
7.03
4.31
601.31

152.90
319.49
472.39

.65
13.18
177.15
11.75
28.70
231.43

32.90
31.68
27-12
29.11
10.29
42.68
19.68
41.02
234.48

317.43
121.27
572.98
61.71
358.19
71.46
1,503.04
Note:  Total Industry Wastes = Potentially Hazardous Wastes,
                                    E-84

-------
TABLE E-42.   (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Kebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
16

i.30
.65
3.26
4.56
29.96
39.73

9.77
9.12
19.54
1.95
40.38

9.12
.65
0.00
.65
3.91
0.00
14.33

7.16
52.10
.65
2.61
62.52

0.00
1.95
6.51
13.03
21.49
789.98
38

6.02
3.01
3.01
3,01
42.11
57.16

9.02
0.00
18.05
6.02
33.09

9.02
0.00
0.00
0.00
3.01
0.00
12.03

12.03
102.27
0.00
0.00
114.30

0.00
0.00
3.01
12.03
15.04
1,654.42
87

5.73
0.00
0.00
11.46
45.83
63.02

22.92
40.10
51.56
0.00
114.58

28.65
0.00
0.00
0.00
0.00
0.00
28.65

5.73
85.94
0.00
0.00
91.67

0.00
0.00
17.19
0.00
17.19
1,323.43
Total

13.05
3.66
6.27
19.03
117.90
159.91

41.71
49.22
89.15
7.97
188.05

46.79
.65
0.00
-.65
6.92
0.00
55.01

24.92
240.31
.65
2.61
268.49

0.00
1.95
26.71
25.06
53.72
3,767.83
       E-85

-------
TABLE E-43.  TOTAL QUANTITY OF ALUMINUM HYDROXIDE WASTES
             GENERATED IN THE WATER POLLUTION CONTROL SLUDGE'S
             FROM THE ELECTROPLATING AND METAL FINISHING
             INDUSTRY (JOB SHOPS);  METRIC TONS;  DRY WEIGHT;  1983

EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
Weet Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Note: Total Industry
Plant
16

26.39
27.33
0.00
1.41
.94
.94
57.01

40.05
46.17
86.22

.47
5.18
32.51
0.00
, 3.77
41.93

6.60
12.25
2.83
1.88
3.30
5.18
3.77
3.77
39.58

51.83
22.15
57.95
8.48
67.85
9.42
217.68
Size (Employee
38

83.74
67.53
191.79
0.00
0.00
2.70
345.76

56.73
121.56
178.29

0.00
5.40
62.13
5.40
10.81
83.74

16.21
8.10
5.40
13.51
0.00
21.61
2.70
27.01
94.54

97.25
35.12
272.83
24.31
124.26
21.61
575.38
Wastes = Potentially Hazardous
s)
87

29.59
53.25
39.59
0.00
4.93
0.00
127.36

29.59
103.56
133.15

0.00
0.00
54.25
4.93
9.86
69.04

4.93
4.93
14.79
9.86
4.93
9.86
9.86
4.93
64.09

118.35
44.38
162.74
19.73
108.49
29.59
483.28
Wastes,

Total

139.72
148.11
231.38
1.41
5.87
3.64
530.13

126.37
271.29
397.66

.47
10.58
148.89
10.33
24.44
194.71

27.74
25.28
23.02
25.25
8.23
36.65
16.33
35.71
198.21

267.43
101.65
493.52
52.52
300.60
60.62
1,276.34

                            E-86

-------
TABLE E-43,   (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Plant
16

.94
.47
2.36
3.30
21.67
28.74

7.07
6.60
14.14
1.41
29.22

6.60
.47
0.00
.47
2.83
0.00
10.37

5.18
37.69
.47
1.88
45.22

0.00
1.41
4.71
9.42
15.54
571.51
Size (Employees)
38

5.40
2.70
2.70
2.70
37.82
51.32

8.10
0.00
16.21
5.40
29.71

8.10
0.00
0.00
0.00
2.70
0.00
10.80

10.81
91.84
0.00
0.00
102.65

0.00
0.00
2.70
10.81
13.51
1,485.70
87

4.93
0.00
0.00
9.86
39.45
54.24

19.73
34.52
44.38
0.00
98.63

24.66
0.00
0.00
0.00
0.00
0.00
24.66

4.93
73.97
0.00
0.00
78.90

0.00
0.00
14.79
0.00
14.79
1,148.14
Total

11.27
3.17
5.06
15.86
98.94
134.30

34.90
41.12
74.73
6.81
157.56

39.36
.47
0.00
.47
5.53
0.00
45.83

20.92
203.50
.47
1.88
226.77

0.00
1.41
22.20
20.23
43.84
3,205.3!
             E-87

-------
           TABLE E-44.  TOTAL QUANTITY OF COPPER HYDROXIDE WASTES GENERATED
                        IN THE WATER POLLUTION CONTROL SLUDGES FROM THE
                        ELECTROPLATING ANT) METAL FINISHING INDUSTRY (JOB
                        SHOPS); METRIC TONS; DRY WEIGHT; 1983
Plant Size (I'mployoes)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

33.44
34 . 64
0.00
1,79
1.19
1.19
72.25

50.76
58.53
109.29

.60
6.57
41.21
0.00
4.78
53.1.6

8.36
15.53
3.58
2.39
4.18
6.57
4.78
4.78
50.17

65.69
28.07
73.46
10.75
86.00
11.94
275.91
38

28.96
23.36
66.33
0.00
0.00
.93
119.58

19.62
42.04
61.66

0.00
1.87
21.49
1.87
3.74
28.97

5.61
2.80
1.87
4.67
0.00
7.47
.93
9.34
32.69

33.63
12.14
94.36
8.41
42.97
7.47
198.98
87

37.16
68.13
37.16
0.00
6.19
0.00
148.64

37.16
130.08
167.24

0.00
0.00
68.13
6,19
12.39
86.71

6.19
6.19
18.58
12.39
6.19
12.39
12.39
6.19
80.51

148.66
55.75
204.40
24.78
136.27
37.16
607.02
Total

99.56
126.13
103.49
1.79
7.38
2.12
340.47

107.54
230.65
338.19

.60
8.44
130.83
8.06
20.91
168.84

20.16
24.52
24.03
19.45
10.37
26.43
18.10
20.31
163.37

247.98
95.96
372.22
43.93
265.24
56.58
1,081.91
Note:  Total Industry Wastes = Potentially Hazardous  Wastes.
                                      E-88

-------
TAbLE E-44.   (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Plant
16

1.19
.60
2.99
It. 18
27.47
36.43

8.96
8.36
17.92
1.79
37,03

8.36
.60
0.00
.60
3.58
0.00
13.14

6.57
47.78
.60
2.39
57.34

0.00
1.79
5.97
11.94
19.70
724.42
Size (r.mployees)
38

1.87
.93
.93
.93
13.08
17.74

2.80
0.00
5.61
1.87
10.28

2.80
0.00
0.00
0.00
.93
0.00
3.73

3.74
31.76
0.00
0.00
35.50

0.00
0.00
.93
3.74
4.67
513.80
87

6.19
0.00
0.00
12.39
49.55
68.13

24.78
43.36
55.75
0.00
123.89

30.97
0.00
0,00
0.00
0.00
0.00
30.97

6.19
92.91
0.00
0.00
99.10

0.00
0.00
18.58
0.00
18.58
1,430.79
Total

9.25
1.53
3.92
17.50
90.10
122.30

36.54
51.72
79.28
3.66
171.20

42.13
.60
0.00
.60
4.51
0.00
47.84

16.50
172.45
.60
2.39
191.94

0.00
1.79
25.48
15.68
42.95
2,669.01
           E-89

-------
       TABLE E-45.   TOTAL QUANTITY  OF  LEAD HYDROXIDE WASTES  GENERATED
                    IN THE WATER  POLLUTION CONTROL SLUDGES FROM IHii
                    ELECTROPLATING  AND METAL  FINISHING  INDUSTRY (JOB
                    SHOPS); METRIC  TONS; DRY  WEIGHT; 1983
Plant Size (Employees)
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucl-y
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
OoOO

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
38

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00

c.oo
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
87

15.49
28.41
15.49
0.00
2.58
0.00
61.97

15.49
54.23
69.72

0.00
0.00
28.41
2.58
5.16
36.15

2.58
2.58
7.75
5.16
2.58
5.16
5.16
2.58
33.55

61.98
23.24
85.22
10.33
56.81
15.49
253.07
Total

15.49
28.41
15.49
0.00
2.58
0.00
61.97

15.49
54.23
69.72

0.00
0.00
28.41
2.58
5.16
36.. 15

2.58
2.58
7.75
5.16
2.58
5.16
5.16
2.58
33.55

61.98
23.24
85.22
10.33
56.81
15.49
253.07
Note:  Total Industry Wastes = Potentially Hazardous  Wastes,
                                 E-90

-------
TABLE E-45.   (Continued)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
''Jyoraing
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
Plant
16

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
Size (Dnployoo
38

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
s)
87

2.58
0.00
0.00
5.16
20.66
28.40

10.33
18.08
23.24
0.00
51.65

12.91
0.00
0.00
0.00
0.00
0.00
12.91

2.58
38.74
0.00
0.00
41.32

0.00
0.00
7.75
0.00
7.75
596.49
Total

2.58
0.00
0.00
5.16
20. G6
28.40

10.33
18.08
23.24
0.00
51.65

12.91
0.00
0.00
0.00
0.00
0,00
12.91

2.58
38.74
0.00
0.00
41.32

0.00
0.00
7.75
0.00
7.75
596.49
         E-91

-------
         TABLE E-46.  TOTAL QUANTITY OF CADMIUM HYDROXIDE WASTES  GENERATED
                      IN THE WATER POLLUTION' CONTROL SLUDGES  FROM THE
                      ELECTROPLATING AND METAL FINISHING  INDUSTRY (JOB
                      SHOPS); METRIC TONS;  DRY WEIGHT;  J983
Plant Si. -/.o (Employees)
EPA Region and Stato.
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
16

15.77
16.33
0,00
.84
.56
.56
34.06

23.93
27.60
51 . 53

.28
3.10
19.43
0.00
2.25
25.06

3.94
7.32
1.69
1.13
1.97
3.10
2.25
2.25
23.65

30.97
13.23
34.63
5.07
40.55
5.63
130.08
38

7.48
6.03
17.14
0.00
0.00
.24
30.89

5.07
10.86
15.93

0.00
.48
5.55
.48
.97
7.48

1.45
.72
.48
1.21
0.00
1.93
.24
2.41
8.44

8.69
3.14
24.38
2.17
11.10
1.93
51.41
87

1.15
2.10
1.15
0.00
.19
0.00
4.59

1.15
4.01
5.16

0.00
0.00
2.10
.19
,.38
2.67

.19
.19
.57
.38
.19
.38
.38
.19
2.47

4.59
1.72
6.31
.76
4.20
1.15
18.73
Total

24.40
24.46
18.29
.84
.75
.80
69.54

30.15
42.47
72.62

.28
3.58
27.08
= 67
3.60
35.21

5.58
8.23
2.74
2.72
2.16
5.41
2.87
4.85
34.56

44.25
18.09
65.32
8.00
55.85
8.71
200 . 2 2
Note:  Total Industry Wastes = Potentially Hazardous Wastes,
                                    E-92

-------
                          TABLE E-46.   (Continued)
EPA Region and State


Region VI
   Arkansas
   Louisiana
   New Mexico
   Oklahoma
   Texas
   Region VI Total

 Region VII
    Iowa
    Kansas
    Missouri
    Nebraska
    Region VII Total

 Region VIII
    Colorado
    Montana
    North Dakota
    South Dakota
    Utah
    Wyoming
    Region VIII Total

 Region IX
    Arizona
    California
    Hawaii
    Nevada
    Region IX  Total

  Region X
    Alaska
     Idaho
     Oregon
    Washington
     Region X Total

  Total U. S.
Planf Size
16
.56
.28
1.41
1.97
12.95
17.17
4.22
3.94
8.45
.84
17.45
3.94
.28
0.00
.28
1.69
0.00
6.19
3.10
22.53
.28
1.13
27.04
0.00
.84
2.82
5.63
9.29
341.52
(Employees)
38
.48
.24
.24
.24
3.38
4.58
.72
0.00
1.45
.48
2.65
.72
0.00
0.00
0.00
.24
0.00
.96
.97
8.21
0.00
0.00
9.18
0.00
0.00
.24
.97
1.21
132.73

87
.19
0.00
0.00
.38
1.53
2.10
.76
1.34
1.72
0.00
3.82
.96
0.00
0.00
0,00
0.00
0,00
.96
.19
2.87
0.00
0.00
3.06
0.00
0.00
.57
0.00
.57
44, 13
Total
1.23
.52
1.65
2.59
17.86
23.85
5.70
5.28
11.62
1.32
23.92
5.62
.28
0.00
.28
1.93
0.00
8.11
4.25
33.61
.28
1.13
39.28
0.00
.84
3.63
6,60
11.07
518.38
                                     E-93

-------
   TABLE E-47.   TOTAL QUANTITY OF TIN HYDROXIDE  WASTES  GENERATED
                IN THE WATER  POLLUTION CONTROL SLUDGES  FROM THE
                ELECTROPLATING AND METAL  FINISHING  INDUSTRY (JOB
                SHOPS); METRIC TONS;  DRY  WEIGHT;  1983
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsylvania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois-
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant
16

0.00
0,00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
Size (Empl
38

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

87

1.11
2.04
1.11
0.00
.19
0.00
4.45

1.11
3.90
5.01

0.00
0.00
2.04
.19
•.37
2.60

.19
.19
.56
.37
.19
.37
.37
.19
2.43

4.46
1.67
6.13
.74
4.09
1.11
18.20
Total

1.11
2.04
1.11
0.00
.19
0.00
4.45

1.11
3.90
5.01

0.00
0.00
2.04
.19
.37
2.60

.19
.19
.56
.37
.19
.37
.37
.19
2.43

4.46
1.67
6.13
.74
4.09
1.11
18.20
Total Industry Wastes = Potentially Hazardous  Wastes.
                            E-94

-------
TABLE E-47.   (Continued)
Plant Size (Employees)
EPA Region and State
Region VI
Arkansas
Louisiana
New Mexico
Oklahoma
Texas
Region VI Total
Region VII
Iowa
Kansas
Missouri
Nebraska
Region VII Total
Region VIII
Colorado
Montana
North Dakota
South Dakota
Utah
Wyoming
Region VIII Total
Region IX
Arizona
California
Hawaii
Nevada
Region IX Total
Region X
Alaska
Idaho
Oregon
Washington
Region X Total
Total U. S.
16

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
38

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0..00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
87

.19
0.00
0.00
.37
1.49
2.05

.74
1.30
1.67
0.00
3.71

.93
0.00
0.00
0.00
0.00
0.00
.93

.19
2.79
0.00
0,00
2.98

0.00
0.00
.56
0.00
.56
41.92
Total

.19
0.00
0.00
.37
1.49
2.05

.74
1.30
1.67
0.00
3.71

.93
0.00
0.00
0.00
0.00
0.00
.93

.19
2.79
0.00
0.00
2.98

0.00
0.00
.56
0.00
.56
41.92
       E-95

-------
   TABLE E-48.  TOTAL QUANTITY OF MANGANESE HYDROXIDE WASTES GENERATED
                IN Tllti WATER POLLUTION CONTROL SLUDGES FROM THE
                ELECTROPLATING AND METAL FINISHING INDUSTRY (JOB SHOPS);
                METRIC TON'S; DRY WEIGHT; 1983
EPA Region and State
Region I
Massachusetts
Connecticut
Rhode Island
New Hampshire
Maine
Vermont
Region I Total
Region II
New Jersey
New York
Region II Total
Region III
Delaware
Maryland
Pennsyl vania
Virginia
West Virginia
Region III Total
Region IV
Alabama
Florida
Georgia
Kentucky
Mississippi
North Carolina
South Carolina
Tennessee
Region IV Total
Region V
Illinois
Indiana
Michigan
Minnesota
Ohio
Wisconsin
Region V Total
Plant-
16

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
Size (]'rn"loyfcs)
38

.44
.35
1.01
0.00
0.00
.01
1.81

.30
.64
.94

0.00
..03
.33
.03
.06
.45

.08
.04
.03
.07
0.00
.11
.01
.14
.48

.51
.18
1.43
.13
.65
.11
3.01

87

0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00

0.00
0.00
0.00
0.00
o.oo
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00

0.00
0.00
0.00
0.00
0.00
0.00
0.00
Total

.44
.35
1.01
0.00
0.00
.01
1.81

.30
.64
.94

0.00
.03
.33
.03
.06
.45

.08
.04
.03
.07
0.00
.11
.01
.14
.48

.51
.18
1.43
.13
.65
.11
3.01
Note:  Total Industry Wastes = Potentially Hazardous Wastes,
                                   E-96

-------
                          TABLE E-48.  (Continued)
EPA Region and State


Region VI
   Arkansas
   Louisiana
   New Mexico
   Oklahoma
   Texa s
   Region  VI Total

 Region  VII
    Iowa
    Kansas
    Missouri
    Nebraska
    Region VII Total

 Region VIII
    Colorado
    Montana
    North Dakota
    South Dakota
    Utah
    Wyoming
    Region Vlil Total

 Region IX
    Arizona
    California
    Hawaii
    Nevada
    Region IX  Total

  Region X
    Alaska
     Idaho
     Oregon
     Washington
     Region X Total

  Total U. S.
Plant Size
16
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
(Kmploycos)
38
.03
.01
.01
.01
.20
.26
.04
0.00
.08
.03
.15
.04
0.00
0.00
0.00
.01
0.00
.05
.06
.48
0.00
0.00
.54
0.00
0.00
.01
.06
.07
7.76
87
0.00
0.00
0.00
0,00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0.00
0,00
Total
.03
.01
.01
.20
.26
.04
0.00
.08
.03
.15
.04
0.00
0.00
0.00
.01
OoOO
.05
.06
.48
0.00
0.00
.54
0.00
0.00
.01
.06
.07
7.76
                                       E-97

-------
               APPENDIX F
DETAILED COST DATA ON SELECTED LEVEL II
(SLUDGE DEWATERING) - LEVEL I (LANDFILL
           BURIAL) CASE STUDIES

-------
                                 APPENDIX F
                   DETAILED COST DATA ON SELECTED LEVEL II
                   (SLUDGE DEWATERING) - LEVEL I (LANDFILL
                              BURIAL) CASE STUDIES
          Detailed capital and operating costs of nine selected Level II
(with regard to sludge dewatering to about 20 percent solids) and Level I
(with regard to landfill disposal) systems are presented in this Appendix.
The detailed costs are based on information furnished by the electroplating
plants.  General descriptions of the plant circumstances are given in Table
F-l.  Detailed cost data for the nine case studies of Level II and I handlin
and disposal systems are presented in Figures F-l through F-9.
                                    F-l

-------



















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F-2

-------
(1) VOLUME OF WASTE HANDLED
liters/day
(gal/day)
(2) CAPITAL COSTS
Design Cost
Land Cost
Site Preparation
Construction and Equipment
Installation
Start-Up Costs
Downtime Losses
Other Costs
Total Capital Cost
(3) ANNUAL COSTS
Annual Capital Costs
Contractor Costs
Labor Cost
Materials Cost
Chemical Cost
Testing and Analysis
Administrative Cost
Energy and Power Cost
Other Costs
Total Operating Cost
' Revenues Received
Net Operating Cost
23.8
(6.3)
_L
300
1,000
175
3,500
—
1,500
- —
6,475
$/year
864
360
300

150
300
112
__
—
2,086



$ liter/day
12. SR
41.92
7.32
146.78
__
62.91
__
271.54
$/liter
0.161
0.069
0.058

0.026
0.058
0.026
*__
__
0.399


$/gal/day
A7.69
158.73
27.73
555.56
_ —
238.10
— —
1,027.79
$/gal
0.61
0.26
0.22

0.10
0.22
0.10
__
— — «
1.51


FIGURE F-l.  BREAKDOWN OF CAPITAL AND ANNUAL COSTS
             FOR CASE STUDY 1: CALIFORNIA 333
                        F-3

-------
(1) VOLUME OF WASTE HANDLED
liters/day
(gal/day)
(2) CAPITAL COSTS
Design Cost
Land Cost
Site Preparation
Construction and Equipment
Installation
Start-Up Costs
Downtime Losses
Other Costs
Total Capital Cost
(3) ANNUAL COSTS
Annual Capital Costs
Contractor Costs
Labor Cost
Materials Cost
Chemical Cost
Testing and Analysis
Administrative Cost
Energy and Power Cost
Other Costs
Total Operating Cost
Revenues Received
Net Operating Cost
2,960
(782)
_L
2,000
1,000
1,000
28,500
—
—
—
32,500
$/year
5,200
17,376
1,500
300
120
200
220
100
—
25,016


$ liter/day
0.68
0.34
0.34
9.63
—
	
—
10.98
$/liter
0.008
0.024
0.003
—
—
—
—
—
—
0.037


$/gal/day
2.56
1.28
1.28
36.45
—
	
—
41.56
$/gal
0.03
0.09
0.01
	
—
—
—
—
—
0.14


FIGURE F-2.  BREAKDOWN OF CAPITAL AND ANNUAL COSTS
             FOR CASE STUDY 2:  CALIFORNIA 3199
                         F-4

-------
(1) VOLUME OF WASTE HANDLED
liters/day
(gal/day)
(2) CAPITAL COSTS
Design Cost
Land Cost
Site Preparation
Construction and Equipment
Installation
Start-Up Costs
Downtime Losses
Other Costs
Total Capital Cost
(3) ANNUAL COSTS
Annual Capital Costs
Contractor Costs
Labor Cost
Materials Cost
Chemical Cost
Testing and Analysis
Administrative Cost
Energy and Power Cost
Other Costs
Total Operating Cost
Revenues Received
Net Operating Cost
2,774
(480)
_J_
480
i ,nnn
36
7,680
—
—
—
9,196
$/year
1,342
6,000
10,500
—
200
1,000
2,000
100
—
21,142


$ liter/day
0.17
n.ifi
0.01
2.77
—
—
—
3.31
$/liter
0.003
0.008
0.016
—
—
—
0.003
—
—
0.032


$/gal/day
0.65
1 .16
0.05
10.48
—
—
—
12.54
$/gal
0.01
0.03
0.06
—
—
—
0.01
—
—
0.12


FIGURE ?-3.   BREAKDOWN OF CAPITAL AND ANNUAL COSTS
             FOR CASE STUDY 3: ILLINOIS 3022
                         F-5

-------
(1) VOLUME OF WASTE HANDLED
liters/day
(gal/day)

(2) CAPITAL COSTS
Design Cost
Land Cost
Site Preparation
Construction and Equipment
Installation
Start-Up Costs
Downtime Losses
Other Costs
Total Capital Cost

(3) ANNUAL COSTS
Annual Capital Costs
Contractor Costs
Labor Cost
Materials Cost
Chemical Cost
Testing and Analysis
Administrative Cost
Energy and Power Cost
Other Costs
Total Operating Cost
Revenues Received
Net Operating Cost
1,378
(364)
_£_
30,000
1,000
25,000
170,000

—
	
226,000
$/year
37,000
1,200
17,000
500
—
5,000
6,700
—
—
67,400



$ liter/day
21.77
0.73
18.15
123.39

—
—
164.04
$/litei
0.108
0.003
0.050
__
__
0.013
0.018
—
—
0.196



$/gal/day
82.42
2.75
68.68
467.03

_ —
—
620.88
$/gal
0.41
0.01
0.19
—
—
0.05
0.07
—
—
0.74


FIGURE F-4.   BREAKDOWN OF CAPITAL AND ANNUAL COSTS
             FOR CASE STUDY 4: INDIANA D
                        F-6

-------
(1) VOLUME OF WASTE HANDLED
liters/day
(gal/day)

(2) CAPITAL COSTS
Design Cost
Land Cost
Site Preparation
Construction and Equipment
Installation
Start-Up Costs
Downtime Losses
Other Costs
Total Capital Cost
(3) ANNUAL COSTS
Annual Capital Costs
Contractor Costs
Labor Cost
Materials Cost
Chemical Cost
Testing and Analysis
Administrative Cost
Energy and Power Cost
Other Costs
Total Operating Cost
Revenues Received
Net Operating Cost
151
(40)
_J_
3,760
—
—
28.000
— —
__
_«.
31,760
$/year
5,200
—
609
38
__
400
— ._„
530
__
6,777



$ liter/day
24.83
—
—
184.94
_— .
_ —
»_
209.77
$/liter
0.137
__
0.016
— . _
__
0.011
__
0.013
_ —
0.180



$/gal/day
94.00
—
—
700.00
— _
_ _ _
__
794.00
$/gal
0.52
-__
0.06
__
__
0.04
__
0.05
__
0.68


FIGURE F-5.  BREAKDOWN OF CAPITAL AND ANNUAL COSTS
             FOR CASE STUDY 5:  ILLINOIS E

-------
(1) VOLUME OF WASTE HANDLED
liters/day
(gal/day)

(2) CAPITAL COSTS
Design Cost
Land Cost
Site Preparation
Construction and Equipment
Installation
Start-Up Costs
Downtime Losses
Other Costs
Total Capital Cost

(3) ANNUAL COSTS
Annual Capital Costs
Contractor Costs
Labor Cost
Materials Cost
Chemical Cost
Testing and Analysis
Administrative Cost
Energy and Power Cost
Other Costs
Total Operating Cost
Revenues Received
Net Operating Cost
10,447
(2,760)
_L
79,520
1,000
9,040
180,806
—
—
—
270,366
$/year
42,500
—
816
156
6,360
—
7,488
93
—
57,413



$ liter/day
7.61
0.10
0.87
17.31
—
—
—
25.88
$/liter
0.016
—
—
—
0.003
—
0.003
—
—
0.021



$/gal/day
28.81
0.36
3.28
65.51
—
—
—
97.96
$/gal
0.06
—
—
—
0.01
—
0.01
—
—
0.08


FIGURE F-6.  BREAKDOWN OF CAPITAL AND ANNUAL COSTS
             FOR CASE STUDY 6: IOWA M
                        F-8

-------
(1) VOLUME OF WASTE HANDLED
liters/day
(gal/day)
(2) CAPITAL COSTS
Design Cost
Land Cost
Site Preparation
Construction and Equipment
Installation
Start-Up Costs
Downtime Losses
Other Costs
Total Capital Cost
(3) ANNUAL COSTS
Annual Capital Costs
Contractor Costs
Labor Cost
Materials Cost
Chemical Cost
Testing and Analysis
Administrative Cost
Energy and Power Cost
Other Costs
Total Operating Cost
Revenues Received
Net Operating Cost
80
(21)
_L
1,300
1,000
620
11,780
—
—
—
14,700
$/year
2,250
2,217
400
25
—
200
778
100
—
5,970



$ liter/day
16.35
12.58
0.11
147.95
—
—
—
184.94
$/liter
0.114
0.111
0.021
—
—
0.010
0.042
0.005
—
0.301



$/gal/day
61.90
47.62
29.52
560.95
—
—
—
699.99
$/gal
0.43
0.42
0.08
—
—
0.04
0.16
0.02
—
1.14


FIGURE F-7.   BREAKDOWN OF CAPITAL AND ANNUAL COSTS
             FOR CASE STUDY 7: MASSACHUSETTS F
                        F-Q

-------
(1) VOLUME OF WASTE HANDLED
liters/day
(gal/day)
(2) CAPITAL COSTS
Design Cost
Land Cost
Site Preparation
Construction and Equipment
Installation
Start-Up Costs
Downtime Losses
Other Costs
Total Capital Cost
(3) ANNUAL COSTS
Annual Capital Costs
Contractor Costs
Labor Cost
Materials Cost
Chemical Cost
Testing and Analysis
Administrative Cost
Energy and Power Cost
Other Costs
Total Operating Cost
Revenues Receivec
Net Operating Cost
174
(46)
_L
210
1,000
1,434
27,298
210
—
__
30,152
$/year
4,750
4,800
1,200
500
—
—
1,725
250
—
13,225


$ liter/day
1.21
5.74
8.24
156.78
1.21
	
—
173.18
$/liter
0.103
0.106
0.029
0.016
—
—
0.040
0.005
—
0.293


$/gal/day
4.57
21.74
31.17
593.43
4.57
__.
-_ —
655.48
0.39
0.40
0.11
0.04
	
__
0.15
0.02
—
1.11


FIGURE F-8.   BREAKDOWN OF CAPITAL AND ANNUAL COSTS
             FOR CASE STUDY 8: MICHIGAN K
                         F-10

-------
(1) VOLUME OF WASTE HANDLED
liters/day
(gal/day)
(2) CAPITAL COSTS
Design Cost
Land Cost
Site Preparation
Construction and Equipment
Installation
Start-Up Costs
Downtime Losses
Other Costs
Total Capital Cost
(3) ANNUAL COSTS
Annual Capital Costs
Contractor Costs
Labor Cost
Materials Cost
Chemical Cost
Testing and Analysis
Administrative Cost
Energy and Power Cost
Other Costs
Total Operating Cost
Revenues Received
Net Operating Cost
4,686
(1,238)
_i_
3,101
1,000
1,452
27,585
—
—
—
33,138
$/year
5r300
42,000
s i fin
? n4n

1.800
3.870
__
4,200
64,370
13,320
51,050
$ liter/day
0.66
0.21
0.31
5.87
—
—
—
7.07
$/liter
0.005
O.OU
0.005
n.nm

0.003
0.003
ri... .^
0.003
0.056
0.011
0.045
$/gal/day
2.50
0.81
1.17
22.28
—
—
—
26.76
$/gal
0.02
0.13
n n?
nrm

0.01
0.01

0.01
0.21
0.04
0.17
FIGURE V-9.   BREAKDOWN OF CAPITAL AND ANNUAL COSTS FOR
             CASE STUDY 9: MINNESOTA N
                          F-ll

-------
                                 APPENDIX G
                         TABULATION OF ORIGINAL DATA
                           AND PLOTS OF PARAMETERS
          The cost data and other parameters selected from the industry
responses are tabulated in Table G-l.   This tabulation shows the extent and
nature of the data supplied by industry.  The interpretation of these data
in terms of nine selected case studies has been described in the section of
the document entitled "Sludge Handling - Disposal Costs from Industry
Responses."

          As part of the approach to the cost analysis, the relationships
between waste disposal costs and various plant operating parameters were
examined.  Some of the plots developed during such an examination are given
in Figures G-l through G-7.  In the case of disposal contractor costs, some
trends were thought to be visible.  On the basis that contractor costs should
be proportional to the quantity of waste disposed of, straight lines of
positive slope were drawn through the data and upper and lower bounds were
established parallel to the "best" line.  It may be noted that, in general,
the upper and lower bounds are approximately one magnitude away from the
"best" line.  For example, in Figure G-l, for a plating rate of 2,325 square
meters per month (25,000 square feet per month), the range of contractor
costs is from $10 to $1000 per month.

          The data plotted in Figures G-5 through G-7 (operating costs)
show no identifiable trends whatsoever.
                                   G-l

-------
























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-------
      93
10,000
Plating Rate, sq m/month
  930                  9,300
93,000
      I xlo3
  lOxlO3                 100x10^
   Plating Rate, sq ft/month
   1000x10-
           FIGURE  G-l.   DISPOSAL  CONTRACTOR COST  VERSUS  PLATING RATE
                                   G-4

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  10,000
   1000
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  100,000                1,000,000

Total Sales Volume, dollars/month
10.000.000
         FIGURE  G-2.   DISPOSAL CONTRACTOR COSTS VERSUS TOTAL SALES VOLUME



                                      G-5

-------
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             FIGURE  G-5.   DISPOSAL OPERATING COST  VERSUS PLATING RATE
                                     Go
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-------



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                       10             100            1000         10.000

                           Sludge Volume, gal/day
          FIGURE G-7.  DISPOSAL OPERATING COST VERSUS SLUDGE VOLUME
                               G-10

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                 APPENDIX H
     WASTE CHARACTERISTICS REPORTED BY
ELECTROPLATING AND METAL FINISHING JOB SHOPS

-------
    TABLE H~1, WASTE CHARACTERISTIC REPORTED BY
                                    N-i '       46 j
                     001         1
                   0 O1 to    0 t> t.j I    4 t. ' 3      1 t:i 3
                    0 G
b2u
62b
b2b
3024
459
627
627
627
389
389
390
521
521
147
552
339
3009
759
759
682
623
623
393
393
.563
3bb
163
13»
61b
720
720
479
4/9
4/9
3030
3030
379
379
746
13
27?
54
:> M
bijb
56 b
5Gb
519
108
1 10
110
IPCU1I520
I PC b09
IPC faOo
IPC GOJ
IPC 10 >
IPC 7jti
IPC 90"
IPt <>.',,
IPL 
IPu 359 )
IPC 3 ..Ml
IPC 3b1
IPC Ibl
kVfC voiij,
Pl.li |'t..,i.'ir.'-
Honi.-.g oils
WPCsludgi
PoUh.nu iljst
WPC s'l.dgt
APC dust
P'dtrr-j solution
WFCsudgi
APC Sludge
P.olng s'adje
Pai.sh 13 dust
Plat,"g sludgs
WpC s-, 1 ,; ,!.,-•
Wt'C V^djr
Fil'i j,,l
P at r,g s!u iui-
B- gh' dip s'ud.j'
Strip SClut en
P.jt.ig ; ud',1
Pldt,nq sludge
WPC sludjf
PUT rg sludge
Plat ng sludge
P.dfi q - ud,j.'
A"C cju-'
Fin s' "J Ib Hues
PicM-q -c'.,t l)n-
Platir-q so'u! on;
WPC s'ud^'
Finish rvj smdu,
B'd,t r.qd.is'
WPC sludge
WPC siudqi
F.' 
-------
ELECTROPLATING  AND METAL  FiNiSHiJVJG JOB SHOPS
        Cydri'de  lie >   Lejd
                                                                                         Oil and
                                                      Selen.um    Zmc  Phosphates  Su"a!ra  Grease   C'J'er    Gold Sil^e-  Pa'ladiun-1    Tin
3~n<.'             ID ')
 1         1      b     1  J
1 u, 3     5 t, E
       66^0              970
0       1        0        3'j
      1-. I, "-.           2 to 33
   M       T '   T     T
                                                                                                           T    T    T
   A       T    P     A       P

           20
        PAT

                        85
   04      MA   0 5
                              MA         NA      1 1       NA      0?      NA         NA      MA
                                                                                                                              0.2
   P       P
   P       P
  0 •')                03
  bi.       N"'\   NA    7
                                                                                                                              P
                                                                                                                              10
                                                                H-2

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                                                                                                                                   TABLE H-1

Natui? of Waste
P.ii ij ' i ' "•
C.1,1 i j sivvc. 11
W.'Cs'uOji.
WFC slud^i
APC di"
SuM . .h.dj,
ftPC s.ii'lg.'
WP._ sludg,
WFL 'iu.k.
F,nis''i,i,, dci.ii
DM.I. .Ub!j!lg
APC sane'
Tumblmy sludyi
Fiht ! siudg«-
Gr.njmg s'udgi
Quaitny
Lb/Veoi



30 43' '
96C1" 14,400



1,320,000


500
1.000
200
500
(d)
G3!'\ed7 Conttfjl Units Asbe^^os Aiscn.: Bsrv^'um Carlrmum Ghnsmium
361' 000 0, g. 6
42000
4' 250 10



82 500 b
82'jOuO 15 »'C
15' Fpm 610
376, /DO
1 20,000 Mg 1 0152

80

90'V
(a)  The reported amounts were ecjdi'ibfjted to ib/vca. ar d d3'\ ta<   The factors used ,
(b)  APC  a-i po'Mior. control
(c)  WPG  water po"uf>on control
(dl  NA  - notanaiv^^d
(e!  M -  major constiturnt
(t)  T  trace consTituent
(g1  P -  present

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                                 APPENDIX I

                                  GLOSSARY
Acid Dip

          An acidic solution used to eliminate a passive condition on a
surface prior to electroplating (especially after the workpiece has been
processed in an alkaline solution).

Alkaline Cleaning

          Removal of grease or other foreign material from a surface by
means of alkaline solutions.

Anode

          The positive electrode in a plating bath; it may be soluble or
insoluble relative to the surrounding solution.

Anode Bag

          Woven textile materials fitting over soluble anodes to collect
the insoluble particles which fall as the anode is consumed.

Anodizing

          The production of a protective oxide film on aluminum or other
light metals by passing a high voltage of electric current through the
bath in which the metal is suspended.  The metal serves as the anode.  The
bath usually contains sulfuric, chromic, or oxalic acid.

Automatic Plating

          (1)  Full - plating in which the cathodes are automatically
                      conveyed through successive cleaning and plating
                      tanks.

          (2)  Semi - plating in which the cathodes are conveyed auto-
                      matically through only one plating tank.

Barrel Plating

          The electroplating of bulk materials (usually small) in rotating
containers which are normally perforated to allow access and change of
plating solutions during processing.

Basis Metal or Material

          That substance of which the workpieces are made aitvl l:Vnt receives
the electroplate and the treatments in preparation for plating,

                                    1-1

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Batch Treatment

          Treatment of the electroplating rinse water which is collected
in holding tanks.  Water is not allowed to leave the tank until treatment
is completed.

Bright Dip

          A solution used to produce a bright surface on a metal.

Buffing

          An operation for producing smoothness, satin, brushed, or lustrous
finishes on metal products.

Captive Operation

          Electroplating facility owned and operated by the same organization
that manufactures the workpieces.

Carbon Adsorption

          The use of activated carbon for the removal of metal ions from
wastewaters by adsorption.

Cathode

          The electrode in an electrolyte solution, on which the reducing
reactions occur, i.e., discharge of positive ions or formation of negative
ions.  In electroplating the cathode recovers the deposit.

Centrifuge

          Equipment used for partial dewatering of sludge up to  20 percent
solids content.

Chelating Agent

          A  compound used as a bath additive, capable of complexing metal
ions by forming  stable, nonionic molecules.

Chemical Brightening

          A  process in which a material is added that induces the formation
of a bright  plate or improves the brightness of the deposit.

Chemical Etching

          The dissolution of a metal coating in part or in  total from its
base.
                                     1-2

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Chemical Metal Coloring

          The production of desired colors on metal surfaces by appropriate
chemical or electrochemical action.

Chemical Polishing

          The smoothing of a metal surface by immersion in a chemical
solution to remove surface irregularities.

Chromating

          A chromate coating, normally produced on zinc, cadmium, aluminum,
magnesium, and copper alloys in solutions to provide corrosion protection
or paint adhesion.

Chrome-Pickle Process

          Forming a corrosion-resistant oxide film on the surface of magne-
sium-base alloys by immersion in a bath of an alkali dichromate solution.

Clarifier

          A baffled tank used to accomplish liquid-solids separation in a
waste treatment process.

Clarifier Under-flow

          A sludge containing 1 to 2 percent solids after liquid-solid
separation.

Closed-Loop Evaporation System

          A system used for the recovery of chemicals and water from a
plating line.  An evaporator concentrates flow from the rinse water holding
tank.  The concentrated portion of the solution is returned to the plating
bath, and the distilled water is returned to the final rinse tank.  The
system is designed for recovering 100 percent of the chemicals, normally
lost in the dragout, for reuse in the plating process.

Continuous Treatment

          A chemical waste treatment operation which operates uninterruptedly
as opposed to batch treatment; sometimes referred to as flow-through treat-
ment.

Conversion Coating

          A coating produced by chemical or electrochemical treatment of the
metallic surface that gives a superficial layer containing a compound of
metal to protect against oxidation or to provide a surface for paint bonding.
                                    1-3

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Current Efficiency

          The percentage of the applied direct current in an electrolytic
process used to produce the coating or prepare the surface.

Deburring

          A finishing operation to remove burrs and break edges by filing,
polishing, tumbling, or electropolishing.

Deoxidizing

          The removal of an oxide film from an alloy such as aluminum oxide.

Descaling

          The process of removing scale or metallic oxide from metallic
surfaces.

Desmutting

          The removal of smut, generally by chemical action.

Dragin

          The water or solution that adheres to the workpieces removed
from the bath, and is thus carried to a subsequent bath.

Dragout

          The solution that adheres to the workpieces removed from the bath,
more precisely defined as that solution which is carried past the edge of
the tank.
          The impregnation of the workpiece surface with organic dyes to
produce color on metals.  The process is not often applied to anodized
aluminum.

EDTA

          Abbreviation for ethylenediamine-tetraacetic acid.

Electrobrightening

          Electrolytic brightening  (electropolishing) produces smooth and
bright surfaces by electrochemical  action similar to those that result  from
chemical brightening.

Electrochemical Machining  (ECM)

          An anodic process  for removing metal at a high rate  (0.025 to

                                     1-4

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0.13 cm/min [0.02 to 0.05 inch per minute]), and to form a predetermined
shape, contour, slot or hole.  The workpiece (anode) is held in a fixture
which confines the electrolyte flowing at fast speeds.

Electrodialysis

          The separation of ions in solution through an ion-specific
membrane with the application of an electrical potential.

Electroless Plating

          Deposition of a metallic coating by a controlled chemical reduc-
tion that is catalyzed by the metal or alloy being deposited.

Electropainting

          The anodic or cathodic deposition of paints on the workpiece
from emulsions used generally as a prime coat for future finishing.

Electroplating

          The electrodeposition of an adherent metallic coating upon the
basis metal or material for the purpose of securing a surface with proper-
ties or dimensions different from those of the basis metal or material.

Electroplating Process

          An electroplating process includes a succession of operations
starting with cleaning in alkaline solutions, acid dipping to neutralize
or acidify the wet surface of the parts, followed by electroplating,
rinsing to remove the processing solution from the workpiece, and drying.

Electropolishing

          An electrolytic corrosion process which increases the percentage
of specular reflectance from a metallic surface.

Electrostatic Precipitation

          The use of an electrostatic field for precipitating or rapidly
removing solid or liquid particles from a gas in which the particles are
carried in suspension.
Filters
           (1)  Equipment used to remove suspended solids from plating
               solutions.

           (2)  Rotary vacuum and pressure filters for partial dewatering
               of sludge up to 45 percent solids content.
                                    1-5

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Grit

          The size of abrasive particles used in metal surface preparation;;
grit size is expressed in various terms including standard sieve mesh sizes,
or various industrial letter or number designations.

Grinding

          The removal of metal or metal coatings from the workpiece by
mechanical abrasion to shape and size.

Heavy Metals

          All metals in the periodic table with the exception of alkali,
alkaline earth, the lanthanide and actinide series,  In waste treatment
technology the term refers to metals which can be separated by precipitation.

Hot Dipping

          A method of coating one metal on another to provide a protective
film.

Hydrogen Embrittlement

          The embrittlement of a metal or alloy caused by the absorption
of hydrogen during the pickling, cleaning, or plating process.

Immersion Plate

          A metallic deposit produced by a displacement reaction in whirh
one metal displaces another from solution, for example:

                    Fe + Cu**	> Cu + Fe"*4" .

Independent Operation

          Job shop or contract shop in which electroplating is done on
workpieces owned by the customer.

Integrated Chemical Treatment

          A waste treatment method in which the chemical rinse tank is
inserted  in the plating line between  the process tank and the water rinse
tank.   The chemical rinse solution is continuously  circulated through the
tank and  removes the dragout while reacting chemicals with it.

Ion-Flotation Technique

          Treatment for electrolyzing the rinse waters  (containing chromium
and cyanide) in which ions are separated from solution by flotation.
                                     1-6

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Job Shop

          A contract shop in which electroplating is done on workpieces
owned by the customer.

Passivating

          Providing a workpiece with a coating or surface condition which
is resistant to oxidation and tarnish.

Phosphating

          The process of forming a rust-resistant coating on iron or steel
by immersing in a hot solution of acid manganese, iron, or zinc phosphate.

Pickle

          An acid solution used to remove oxides or other compounds related
to the basis metal from the surface of the metal by chemical or electro-
chemical action.

Pickling

          The removal of oxides or other compounds related to the basis
metal from its surface by immersion in a pickle.

Polishing

          The smoothing of a surface by abrasive particles which are
attached to a belt or wheel with adhesives.

Precious Metal

          Gold, silver, platinum, etc.

Rack Plating

          Electroplating of the workpieces mounted on racks designed for
the plating operation.

Reverse Osmosis

          A recovery process in which the more concentrated solution is
put under a pressure greater than the osmotic pressure to drive water across
the membrane to the dilute stream while leaving behind the dissolved salts.

Rochelle Salt

          Sodium potassium tartrate:  KNaC.H.P,'4H00 .
                                          4 4 o   /
                                    1-7

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Shot Blasting

          The dry abrasive cleaning of metal surfaces by impacting the
surfaces with high velocity abrasive particles.

Sludge

          The residue in the clarifier of a chemical waste treatment process,
or any accumulation of semisolids at the bottom of a tank or vessel.

Soil

          A generic term applied to metal surfaces contaminated by mineral,
animal, vegetable and compounded oils, buffing compound residues, smuts,
minute particles, cleaning and pickling residues and shop dirt.

Waste

          All wastes generated in metal finishing processes and which are
destined for land disposal.  These wastes consist of metal-hydroxide
sludges, solvents, metal scraps, dusts, chemicals, and polishing and buffing
compounds and materials.

Spent Bath Solution

          Solutions which have become inoperative because of the consumption
of active constituents, decomposition, depletion of active ions, dilution,
and/or an increase in the contaminant concentrations.

Stop-Off

          Organic coatings resistant to solution attack, applied to portions
of a workpiece which is not to be processed in an electroplating and metal
finishing operation; i.e., a "mask".
Strike
          (1)  Noun - a thin coating of metal (usually less than 0.0001
                      inch in thickness) to be followed by other coatings.

          (2)  Noun - a solution used to deposit a strike.

          (3)  Verb - to plate for a short time, usually at a high initial
                      current density.
Stripping
          Removal of an electrodeposit or other coating by a chemical agent
or reversed electrodeposition.
                                     1-8

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Water Treatment Sludge

           The residue in the  clarifier of a chemical waste treatment process
for rinse  waters, solution  dumps and spills from metal finishing  processes.

Workpiece

           The item to be electrocoated, treated,  or finished.
 ya!489
                                      1-9      "U.S. GOVERNMENT PRiNTING OFFICE 1977 720-250/8806 1-3,

-------