EPA 44071-74/ 034
Development Document for
Proposed Effluent Limitations Guidelines
and New Source Performance Standards
for the
PRESSED AND BLOWN GLASS
Segment of the
GLASS MANUFACTURING
Point Source Category
UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
^y1
*
AIGUST 1974
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ABSTRACT
This document presents the findings of an extensive study of the
pressed and blown glass manufacturing industry by Sverdrup & Parcel
and Associates, Inc., for the Environmental Protection Agency for
the purpose of developing effluent limitations guidelines, Federal
standards of performance, and pretreatment standards for the in-
dustry, to implement Sections 304, 306, and 307 of the "Act".
Effluent limitations guidelines contained herein set forth the
degree of effluent reduction attainable through the application of
the best practicable control technology currently available and the
degree of effluent reduction attainable through the application of
the best available technology economically achievable which must be
achieved by existing point sources by July 1, 1977 and July 1, 1983,
respectively. The standards of performance for new sources
contained herein set forth the degree of effluent reduction which is
achievable through the application of the best available
demonstrated control technology processes, operating methods, or
other alternatives.
The development of data and recommendations in this document relate
to the pressed and blown glass segment of the glass manufacturing
industry. This segment has been divided into six subcategories on
the basis of production processes and waste water characteristics.
Separate effluent limitations are proposed for each subcategory on
the basis of the raw waste loading and the degree of treatment
attainable by suggested model systems. This technology includes in-
plant modifications, recirculation, precipitation, coagulation,
sedimentation, flotation, stripping, filtration, and adsorption.
The total investment cost to the industry for implementing the best
practicable control technology currently available is estimated to
be 2.67 million dollars and the additional cost for implementing the
best available technology economically achievable is estimated to be
27.7 million dollars.
Supportive data and rationale for the development of the proposed
effluent limitations guidelines and standards of performance are
contained in this document.
ill
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TABLE OF CONTENTS
SECTION PAGE
I Conclusions 1
II Recommendations 3
III Introduction 7
Purpose and Authority 7
Summary of Methods 8
General Description of Industry 23
Production and Plant Location 2h
General Process Description 26
IV Industry Categorization 37
V Water Use and Waste Characterization ^1
Auxiliary Wastes ^1
Glass Container Manufacturing ^2
Machine Pressed and Blown Glass
Manufacturing H6
Glass Tubing Manufacturing 51
Television Picture Tube Envelope
Manufacturing 55
Incandescent Lamp Glass Manufacturing 60
Hand Pressed and Blown Glass
Manufacturing 64
VI Selection of Pollutant Parameters 73
VII Control and Treatment Technology 85
Applicable Treatment Technology 85
Suggested Treatment Technology 94
Glass Container Manufacturing 94
Machine Pressed and Blown Glass
Manufacturing 97
Glass Tubing Manufacturing 98
Television Picture Tube Envelope
Manufacturing 100
Incandescent Lamp Glass Manufacturing 103
Hand Pressed and Blown Glass
Manufacturing 107
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TABLE OP CONTENTS (.Continued)
SECTION
VIII
IX
XI
XII
XIII
XIV
Cost, Energy, and Nonwater Quality Aspects
Cost and Reduction Benefits
Energy Requirements
Nonwater Quality Aspects
Best Practicable Control Technology
Currently Available
Introduction
Identification of Technology
Effluent Reduction Attainable
Rationale for Selection
Best Available Technology Economically
Achievable
Introduction
Identification of Technology
Effluent Reduction Attainable
Rationale for Selection
New Source Performance Standards
Acknowledgements
References
Glossary
Conversion Table
PAGE
119
119
130
134
137
137
237
140
142
145
145
145
148
150
153
155
157
161
VI.
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FIGURES
NUMBER PAGE
1 Data Retrieval Form 10
2 Sample Computer Format 13
3 Location of Participating Glass Container
Manufacturing Plants 20
U Location of Participating Pressed and Blown
Glass Manufacturing Plants 21
5 Glass Container Manufacturing ^3
6 Machine Pressed and Blown Glass Manufacturing ^8
7 Glass Tubing Manufacturing 52
8 Television Picture Tube Envelope
Manufacturing 56
9 Incandescent Lamp Glass Manufacturing 6l
10 Hand Pressed and Blown Glass Manufacturing 65
11 Waste Water Treatment -
Glass Container Manufacturing 95
Machine Pressed and Blown Glass
Manufacturing 95
12 Waste Water Treatment -
Glass Tubing Manufacturing 99
13 Waste Water Treatment -
Television Picture Tube Envelope
Manufacturing 102
1^ Waste Water Treatment -
Incandescent Lamp Glass Manufacturing 104
15 Waste Water Treatment -
Hand Pressed and Blown Glass
Manufacturing 109
vii
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FIGURES (Continued)
NUMBER PAGE
16 Wastewater Treatment -
Hand Pressed and Blown Glass Manufacturing 110
viii
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TABLES
NUMBER
1 Glass Container Plants 14
2 Pressed and Blown Glass Plants 17
3 Plants Visited 22
k Pressed and Blown Glass Manufacturing
Production Data 25
5 Raw Waste ₯ater, Glass Container
Manufacturing ^5
6 Raw Waste Water, Machine Pressed and Blown
Glass Manufacturing 50
7 Raw Waste Water, Glass Tubing Manufacturing 5^
8 Raw Waste Water, Television Picture Tube
Envelope Manufacturing 58
9 Raw Waste Water, Incandescent Lamp Glass
Manufacturing 6 3
10 Raw Waste Water, Hand Pressed and Blown
Glass Manufacturing 69
11 Concentration of Waste Water Parameters
Pressed and Blown Glass Manufacturing 7^
12 Concentration of Waste Water Parameters
Incandescent Lamp Glass Manufacturing 75
13 Concentration of Waste Water Parameters
Hand Pressed and Blown Glass Manufacturing 76
llt Current Treatment Practices Within the Hand
Pressed and Blown Glass Manufacturing ,,,
Subcategory
15 Current Operating Practices Within the Hand
Pressed and Blown Glass Manufacturing
Subcategory
16 Water Effluent Treatment Costs
Glass Container Manufacturing 117
ix
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TABLES (Continued)
NUMBER PAGE
17 Water Effluent Treatment Costs
Machine Pressed and Blown Glass Manufacturing 119
18 Water Effluent Treatment Costs
Glass Tubing Manufacturing 121
19 Water Effluent Treatment Costs
Television Picture Tube Envelope
Manufacturing 122
20 Water Effluent Treatment Costs
Incandescent Lamp Envelope Manufacturing 124
21 Water Effluent Treatment Costs
Hand Pressed and Blown Glass Manufacturing 127
22 Water Effluent Treatment Costs
Hand Pressed and Blown Glass Manufacturing
Suspended Solids Removal 128
23 Known Surface Dischargers
Glass Container Manufacturing Subcategory 131
24 Known Surface Dischargers
Machine Pressed and Blown Glass Manufacturing
Subcategory 132.
25 Known Surface Dischargers
Glass Tubing Manufacturing Subcategory 132
26 Known Surface Dischargers
Television Picture Tube Envelope
Manufacturing Subcategory 132
27 Known Surface Dischargers
Incandescent Lamp Envelope Manufacturing
Subcategory 133
28 Known Surface Dischargers
Hand Pressed and Blown Glass Manufacturing
Subcategory 133
29 Recommended Monthly Average Effluent
Limitations Using Best Practicable
Control Technology Currently Available 138
X
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TABLES (Continued)
NUMBER PAGE
30 Recommended Monthly Average Effluent
Limitations Using Best Available
Control Technology Economically
Achievable 147
xi
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SECTION I
CONCLUSIONS
The pressed and blown glass segment of the glass manufacturing
category has been classified into six subcategories. The first
three subcategories include only the forming of products from molten
glass while the last three include both the forming and finishing of
glass products. The subcategorization is based on (a) production
process and (b) waste water characteristics. Factors such as raw
materials, age and size of production facilities/ and applicable
treatment technology do not provide significant bases for
differentiation. The subcategories indicated are as follows:
1. Glass Container Manufacturing
2. Machine Pressed and Blown Glass Manufacturing
3. Glass Tubing Manufacturing
4. Television Picture Tube Envelope Manufacturing
5. Incandescent Lamp Envelope Manufacturing
a. Forming
b. Frosting
6. Hand Pressed and Blown Glass Manufacturing
a. Leaded and Hydrofluoric Acid Finishing
b. Non-Leaded and Hydrofluoric Acid Finishing
c. Non-Hydrofluoric Acid Finishing
Recommended effluent limitations and waste control technologies to
be achieved by July 1, 1977 and July 1, 1983, are summarized in
Section II. The estimated investment cost for all plants in the
industry to achieve the 1977 limitations is estimated to be 2.67
million dollars excluding the cost of land. The cost of achieving
the 1983 level is estimated to be an additional 27.7 million dollars
over the 1977 level.
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SECTION II
RECOMMENDATIONS
The recommended effluent limitations for pollutants of major sig-
nificance are summarized below for the portion of the pressed and
blown glass segment included in this document. The values listed
are the maximum allowable average loading for any 30 consecutive
calendar days. Maximum allowable daily averages are 2.0 times the
values listed below.
The effluent limitations to be achieved with the best
control technology currently available are as follows:
practicable
Glass Containers
g/metric ton
fib/ton)
Machine Press and
Blown Glass
g/metric ton
(lb/ton)
Glass Tubing
g/metric ton
(lb/ton)
Television Picture
Tube Envelope
g/metric ton
(lb/ton)
Incandescent Lamp
Envelopes
Forming
g/metric ton
(lb/ton)
Suspended
Solids
70
0.14
140
0.28
230
0.46
130
0.26
Oil Fluoride Lead Ammonia
30
0.06
56
.112
85
0.17
130 65 4.5
0.26 0.13 0.009
115
0.23
115
0.23
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Suspended
Solids
85
0.17
Oil Fluoride Lead
68
0.14
Ammonia
100
0.20
Frosting
g/metric ton frosted
(lb/ton frosted)
Hand Pressed and
Blown
Leaded & Hydrofluoric
Acid Finishing
mg/1 25 - 15 1.0 -
Non-Leaded and
Hydrofluoric Acid
Finishing
mg/1 25 - 15
Non-Hydrofluoric
Acid Finishing
mg/1 25 - -
PH Between 6.0 and 9.0 (all subcategories)
Using the best available control technology economically achievable,
the effluent limitations are as follows:
Suspended
Solids Oil Fluoride Lead Ammonia
Glass Containers
g/metric ton 0.4 0.4
(lb/ton) 0.0008 0.0008 -
Machine Press and
Blown Glass
g/metric ton 1.8 1.8
(lb/ton) 0.0036 0.0036
Glass Tubing
g/metric ton 0.1 0.1
(lb/ton) 0.0002 0.0002
Television Picture
Tube Envelope
g/metric ton 60 130 9 0.45
(lb/ton) 0.12 0.26 0.018 0.0009
Incandescent Lamp
Envelopes
Forming
g/metric ton 23 23
(lb/ton) 0.045 0.045
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Frosting
g/metric ton frosted
Ob/ton frosted)
Hand Pressed and
Blown
Leaded & Hydrofluoric
Acid Finishing
mg/1
Non-Leaded and
Hydrofluoric Acid
Finishing
mg/1
Non-Hydrofluoric
Acid Finishing
mg/1
pH
Suspended
Solids
17
0.034
Oil
Fluoride
7
0.014
Lead
Ammonia
100
0.20
0.1
Between 6.0 and 9.0 (all subcategories)
Recommended effluent limitations and standards of performance for
new point sources are the best available control technology
economically achievable.
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SECTION III
INTRODUCTION
PURPOSE AND AUTHORITY
Section 301(b) of the Act requires the achievement by not later than
July 1, 1977, of effluent limitations for point sources, other than
publicly owned treatment works, which are based on the application
of the best practicable control technology currently available as
defined by the Administrator pursuant to Section 304 (b) of the Act.
Section 301(b) also requires the achievement by not later than July
1, 1983, of effluent limitations for point sources, other than
publicly owned treatment works, which are based on the application
of the best available technology economically achievable which will
result in reasonable further progress toward the national goal of
eliminating the discharge of all pollutants, as determined in
accordance with regulations issued by the Administrator pursuant to
Section 304(b) of the Act. Section 306 of the Act requires the
achievement by new sources of a Federal standard of performance
providing for the control of the discharge of pollutants which
reflects the greatest degree of effluent reduction which the
Administration determines to be achievable through the application
of the best available demonstrated control technology, processes,
operating methods, or other alternatives, including, where
practicable, a standard permitting no discharge of pollutants.
Section 304(b) of the Act requires the Administrator to publish
within one year of enactment of the Act, regulations providing
guidelines for effluent limitations setting forth the degree of
effluent reduction attainable through the application of the best
practicable control technology currently available and the degree of
effluent reduction attainable through the application of the best
control measures and practices achievable including treatment
techniques, process and procedure innovations, operation methods and
other alternatives. The regulations proposed herein set forth
effluent limitations guidelines pursuant to Section 304(b) of the
Act for certain subcategories of the glass and asbestos manufac-
turing source category. They include the glass container
manufacturing, machine pressed and blown glass manufacturing, glass
tubing manufacturing, television picture tube envelope
manufacturing, incandescent lamp envelope manufacturing, and hand
pressed and blown glass manufacturing subcategories.
Section 306 of the Act requires the Administrator, within one year
after a category of sources is included in a list published pursuant
to Section 306(b) (1) (A) of the Act, to propose regulations estab-
lishing Federal standards of performance for new sources within such
categories. The Administrator published in the Federal Register of
January 16, 1973 (38 F.R. 1624), a list of 27 source categories.
Publication of the list constituted announcement of the
Administrator's intention of establishing, under Section 306,
standards of performance applicable to new sources within the
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pressed and blown glass segment of the glass manufacturing category
as delineated above, which was included with the list published
January 16, 1973.
SUMMARY OF METHODS USED FOR DEVELOPMENT OF THE EFFLUENT LIMITATIONS
GUIDELINES AND STANDARDS OF PERFORMANCE
Methodology
The effluent limitations guidelines and standards of performance
proposed herein were developed in the following manner. The point
source category was first categorized for the purpose of determining
whether separate limitations and standards are appropriate for
different segments within the point source category. Such subcate-
gorization was based upon raw material used, product produced,
manufacturing process employed, and other factors. The raw waste
characteristics for each subcategory were then identified. This
included an analysis of (1) the source and volume of water used in
the process employed and the sources of waste and waste water in the
plant; and (2) the constituents (including thermal) of all waste
waters, including toxic constituents and other constituents which
result in taste, odor, and color in water or aquatic organisms. The
constituents of waste waters which should be subject to effluent
limitations guidelines and standards of performance were identified.
The full range of control and treatment technologies existing within
each subcategory was identified. This included an identification of
each distinct control and treatment technology, including both in-
plant and end-of-process technologies, which are existent or capable
of being designed for each subcategory. It also included an
identification in terms of the amount of constituents (including
thermal) and the chemical, physical, and biological characteristics
of pollutants, of the effluent level resulting from the application
of each of the treatment and control technologies. The problems,
limitations and reliability of each treatment and control technology
and the required implementation time was also identified. In
addition, the non-water quality environmental impact, such as the
effects of the application of such technologies upon other pollution
problems, including air, solid waste, noise and radiation were also
identified. The energy requirements of each of the control and
treatment technologies were identified as well as the cost of the
application of such technologies.
The information, as outlined above, was then evaluated in order to
determine what levels of technology constituted the "best practic-
able control technology currently available", "best available
technology economically achievable", and the "best available
demonstrated control technology, processes, operating methods, or
other alternatives". In identifying such technologies, various
factors were considered. These included the total cost of applica-
tion of technology in relation to the effluent reduction benefits to
be achieved from such application, the age of equipment and
facilities involved, the process employed, the engineering aspects
of the application of various types of control techniques, process
8
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changes, non-water quality environmental impact (including energy
requirements), and other factors.
Basis for Guideline Development
The data for identification and analyses were derived from a number
of sources. These sources included EPA and industry-supplied
information; published literature; and on-site visits, interviews,
and sampling at typical or exemplary plants throughout the United
States. References used in the guidelines for effluent limitations
and standards of performance on new sources reported herein are
included in Section XIII of this document.
Several types of waste water data were analyzed. These include:
RAPP data, information supplied by industry and state pollution
control agencies, and data derived from the sampling of typical or
exemplary plants. The data retrieval form illustrated in Figure 1
was developed to aid in the collection of data during interviews and
plant visits and was supplied to the industry to indicate the types
of information required for the study.
The data were analyzed with the aid of a computer program which
provided the capability for summing the data for each plant where
multiple discharges existed, averaging the data for each plant where
multiple data sets were available, and comparing and averaging the
data for all plants within each subcategory to determine values
characteristic of a typical plant. Input to the computer for each
plant consisted primarily of the plant production rate, the waste
water flow rate, the concentration of each constituent of the plant intake
water, the average and maximum concentrations of each constituent in
the waste water, and some descriptive information regarding existing
waste treatment methods, subcategory type, and sampling methods.
An example of the computer printout is the hypothetical summary of
effluent oil and grease concentration data for glass container
plants without treatment illustrated in Figure 2. The pound per day
increase, mg/1 increase, and pounds added per day per production
unit are calculated. Data from all of the plants listed are
summarized in terms of the average, standard deviation (SIGMA), and
minimum and maximum values for the data listed. The weighted
average listed on the final line was used when the data from a
single plant was summarized. Multi-sample data summaries, such as
weekly or monthly averages, were thereby averaged in proportion to
the number of individual samples included in the summary.
The name and location of the plants for which data were available
are listed in Tables 1 and 2r and their geographic location is
indicated on Figures 3 and 4. Seventy-eight plants supplied some
type of usable information or data for computer analysis. RAPP data
were available and used for 52 plants.
Thirteen plants covering various manufacturing processes were
visited. The subcategories are listed in Table 3 along with the
type of data collected. Seven plants were sampled, including two
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TABLE 1
GLASS CONTAINER PLANTS
COMPANY NAME
Anchor Hocking
Ball
Brockway Glass
Chattanooga Glass
Columbine Glass
Foster-Forbes Glass
Gayner Glass Works
Glass Containers
PLANT LOCATION
Jacksonville, Fla.
Houston, Texas
Gurnee, 111.
Connellsville, Pa.
Salem, N. J.
Winchester, Ind.
San Leandro, Calif.
Mundelein, 111.
El Monte, Calif.
Muskogee, Okla.
Clarksburg, ₯. Va.
Lapel, Ind.
Ada, Okla.
Freehold, N. J.
Zanesville, Ohio
Chattanooga, Tenn.
Corsicana, Texas
Gulfport, Miss.
Mt. Vernon, Ohio
Keyser, W. Va.
Wheat Ridge, Colo.
Marion, Ind.
Salem, N. J.
Indianapolis, Ind.
Danville, Conn.
Jackson, Miss.
Parker, Pa.
Marienville, Pa.
Knox, Pa.
Forest Park, Ga.
Palestine, Texas
Antioch, Calif.
Gas City, Ind.
Hayward, Calif.
Yernon, Calif.
14
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TABLE 1 CContd.)
GLASS CONTAINER PLANTS
COMPANY NAME
Glenshaw Glass
Kerr Glass Mfg.
Latchford Glass
Laurens Glass
Liberty Glass
Madera Glass
Maryland Glass
Metro Containers
Midland Glass
Northwestern Glass
Obear-Nestor
Pierce Glass
Owens-Illinois
PLANT LOCATION
Glenshaw, Pa.
Millville, N. J.
Plainfield, 111.
Dunkirk, Ind.
Santa Ana, Calif.
Sand Springs , Okla.
Los Angeles, Calif.
Henderson, N. C.
Laurens , S. C.
Ruston, La.
Sapulpa, Okla.
Madera, Calif.
Baltimore, Md.
Jersey City, N. J.
Carteret, N. J.
Dolton, 111.
Washington, Pa.
Shakopee, Minn.
Seattle, Wash.
E. St. Louis, 111.
Lincoln, 111.
Port Allegany, Pa.
Huntington, ₯. Va.
Fairmont, V. Va.
Alton, 111.
Streator, 111.
Gas City, Ind.
Bridgeton, N. J.
Waco, Texas
Oakland, Calif.
15
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TABLE 1 (Contd.)
GLASS CONTAINER PLANTS
COMPANY NAME
Owens-Illinois (Contd.)
Puerto Rico Glass
Thatcher Glass Mfg.
PLANT LOCATION
Clarion, Pa.
Los Angeles, Calif.
Brockport, W. J.
Charlotte, Mich.
New Orleans, La.
Atlanta, Ga.
North Bergen, N. J.
Lakeland, Fla.
Portland, Ore.
Tracy, Calif.
San Juan, P. R.
Lawrencelburg, Ind.
Saugus, Calif.
Elmira, N. Y.
Whoaton, N. J.
Tampa, Fla.
Streator, 111.
16
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TABLE 2
PRESSED AND BLOWN GLASS PLANTS
COMPANY NAME
Anchor Hocking
Brockway Glass
Corning Glass Works
Federal Glass
General Electric
Ovens-Illinois
Corning Glass Works
General Electric
GTE-Sylvania
Westinghouse Electric
Corning Glass Works
Owens-Illinois
Machine Pressed and Blown Glassware Plants
PLANT LOCATION
Lancaster, Ohio (Plant #l)
Lancaster, Ohio (Plant #2)
Clarksburg, W. Va.
Corning, N. Y.
Muskogee, Okla.
Greenville, Ohio
Danville, Va.
Harrodsburg, Ky.
Columbus, Ohio
Niles, Ohio
Somerset, Ky.
Toledo, Ohio
Walnut, Calif.
Tubing Plants
Blacksburg, Va.
Danville, Ky.
Bucyrus, Ohio
Logan, Ohio
Jackson, Miss.
Bridgeville, Pa.
Greenland, W. H.
Fairmont, W. Va.
Television Picture Tube Envelope Plants
Albion, Mich.
Bluffton, Ind.
State College, Pa.
Columbus, Ohio
Pittston, Pa.
17
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TABLE 2 (Contd.)
PRESSED AND BLOWN GLASS PLANTS
COMPANY NAME
Corning Glass Works
General Electric
The Beaumont Co.
Blenko Glass
Canton Glass Division
Colonial Glass
Crescent Glass
Davis-Lynch Glass
Elite Co.
EMC Glass
Erie Glass
Erskine Glass
Fenton Art Glass
Fostoria Glass
Gillender Brothers
Glassworks, Inc.
Harvey Industries
Imperial Glass
Jeannette Shade & Novelty
Johnson Glass and Plastic
Kanawha Glass
Kessler, Inc.
Kopp Glass, Inc.
Lenox Crystal, Inc.
Lewis County Glass
Louie Glass
Minners Glass
Overmyer-Perram Glass
Pennsboro Glass
Pilgrim Glass
Raylite Glass
St. Clair Glassworks
Scandia Glassworks
Scott Depot Glass
Seneca Glass
Sinclair Glass
Sloan Glass, Inc.
Smith Glass
Incandescent Lamp Envelope Plants
PLANT LOCATION
Central Falls, R.I.
Wellsboro, Pa.
Lexington, Ky.
Niles, Ohio
Cleveland, Ohio
Hand Pressed & Blown Glassware Plants
Morgantown, W.Va.
Milton, W.Va.
Hartford City, Ind.
Deanville, W.Va.
Wellsburg, W.Va.
Star City, W.Va.
New York, N.Y.
Decatur, Texas
Parkridge, 111.
Wellsburg, W.Va.
Williamstown, W.Va.
Moundsville, W.Va.
Port Jervis, N.Y.
Huntington Beach, Ca.
Clarksburg, W.Va.
Bellaire, Ohio
Jeannette, Pa.
Chicago, 111.
Dunbar, W.Va.
Bethpage, L.I.
Pittsburgh, Pa.
Mt. Pleasant, Pa.
Jane Lew, W.Va.
Weston, W.Va.
Salem, W.Va.
Tulsa, Okla.
Pennsboro, W.Va.
Ceredo, W.Va.
Southgate, Ca.
Elwood, Ind.
Kenova, W.Va.
Fort Smith, Ark.
Morgantown, W.Va.
Hartford City, Ind.
Culloden, W.Va.
Mt. Pleasant, Pa.
18
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TABLE 2 (Contd.)
PRESSED AND BLOWN GLASS PLANTS
Company Name Hand Pressed & Blown Glassware Plants
Super Glass Brooklyn, N.Y.
Viking Glass New Martinsville, W.Va.
Viking Glass Huntington, W.Va.
Westmoreland Glass Grapeville, Pa.
Wheaton Industries Millville, N.J.
West Virginia Glass Specialty Weston, W.Va.
19
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TABLE 3
PLANTS VISITED
Plant Types No. of Plants Type of Data Obtained
Glass Container 3 (l) (2)
Machine Pressed and Blcxwn 2 (l) (2)
Tubing 1 (2)
TV Picture Tube Envelope 2 (l) (2)
Incandescent Lamp Envelope 1 (l) (2)
Hand Pressed and Blown k (l) (2)
(l) - Individual process or subcategory.
(2) - End-of-pipe including all process and auxiliary vastes.
22
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glass container plants, one machine pressed and blown glass plant,
one television picture tube envelope plant, one incandescent lamp
envelope plant, and two hand pressed and blown glass plants. Plant
sampling provided significant data on raw and treated waste water
volumes and characteristics and verified the data obtained from the
industry.
GENERAL DESCRIPTION OF THE INDUSTRY
Production Classification
The U.S. Bureau of Census, Census of Manufacturers, classifies the
glass container manufacturing and pressed and blown glass
manufacturing industries as Standard Industrial Classifications
(SIC) group code numbers 3221 and 3229, respectively. Both group
numbers are under the more general category of Stone, Clay, Glass,
and Concrete Products, (Major Group 32) and more specifically under
Glass and Glassware, Pressed or Blown (Group Number 322). The four-
digit classification code (3221) covers industrial establishments
engaged in manufacturing glass containers for commercial packing and
bottling, and for home canning. The classification code (3229)
comprises all industrial establishments primarily engaged in
manufacturing glass and glassware, pressed, blown, or shaped from
glass produced in the same establishment. Establishments also
covered by code (3229) include those manufacturing textile glass
fibers and pressed lenses for vehicular lighting, beacons, and
lanterns. Effluent limitations guidelines and new source
performance standards for textile glass fiber manufacturing have
previously been promulgated by the EPA.
Origin and History
The origin and history of glass is thought to have begun with the
Egyptians in 4000 B.C. The first glass articles manufactured by the
Egyptians were small, decorative, glass-covered objects. The first
true glass vessels - small bottles, goblets, or vases - come from
the Egyptian royal graves of the period around 1555-1350 B.C. The
glass vessels were made by the sand core technique in which a sand
core is stuck to a metal rod, fired or fritted, and coated by a
thick layer of viscous glass. Further forming was accomplished by
reheating and using simple tools such as pinchers, but not by
blowing.
Glass blowing originated in the Eastern Mediterranean at the
beginning of the first century B.C. The glass blow-pipe was
introduced to the Western Mediterranean around 30 B.C. The blow-
pipe method of forming glass was used from this time on and has only
gradually been replaced by mechanical processes since the end of the
19th Century.
The glass pressing machine was introduced in America in 1827. In
this process the molten glass is pressed into a mold manually with a
plunger. Several other glass manufacturing innovations occurred in
the 19th Century. The first successful bottle-blowing machine was
23
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invented by Ashley of England in 1888. Several other bottle-making
machines were developed during the next years. In 1889 Michael J.
Owens conceived the first fully automatic bottle machine, which in
less than 20 years revolutionized glass container manufacturing.
Another major manufacturing breakthrough was the introduction of the
Corning ribbon machine in the early 1900's. The ribbon machine can
manufacture as many as 2200 bulbs per minute. The Hartford I.S.
(Individual Section) machine, developed in 1925, remains the most
popular method for manufacturing glass containers. Techniques for
forming glass containers and machine pressed products have
essentially remained the same since the 1920's. Most recent
developments in the glass industry are in the application of glass
into new areas such as conductive coatings, electrical components,
and photosensitive glasses.
Description of Manufacturing Methods
There are four manufacturing steps that are common to the entire
pressed and blown glass industry. The four steps include weighing
and mixing of raw materials, melting of raw materials, forming of
molten glass, and annealing of formed glass products. Forming
methods vary substantially, depending on the product and
subcategory, and range from hand blowing to centrifugal casting of
picture tube funnels. Following forming and annealing, the glass
may be prepared for shipment or may be further processed in what is
referred to as finishing. There is little or no finishing involving
waste water in the glass container and machine pressed and blown
subcategories, while extensive finishing is required in television
picture tube envelope, incandescent lamp envelope, and hand pressed
and blown glassware manufacturing. Finishing of glass tubing is not
covered by this study.
PRODUCTION AND PLANT LOCATION
There are approximately 30 firms with a total of 140 plants
presently manufacturing glass containers in the United States. The
eight largest firms in the industry produce about 78 percent of the
glass container shipments and operate two-thirds of the individual
plants. Plants are located throughout the United States to service
regional customers, but a large number are concentrated in the
northeastern United States. The industry originally located in the
Northeast because convenient sources of raw materials and fuel were
available.
The glass container industry employs over 70,000 persons and has a
daily processing capacity of 50,500 metric tons (55,500 tons) of
glass pulled. The average glass container plant capacity is 388
metric tons (427 tons). Plants range in size from 122 metric tons
(13U tons) per day to 1320 metric tons (1450 tons) per day (Table
4).
There are about 50 machine pressed and blown glass manufacturing
plants in the United States and the average capacity is 91 metric
tons (100 tons) pulled per day. Machine pressed and blown ware
24
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plant capacities range from 40 metric tons (44 tons) to 349 metric
tons (384 tons) .
About 30 plants manufacture glass tubing in the United States.
Production, expressed as furnace pull per day, ranges from 40 metric
tons (44 tons) per day to 164 metric tons (180 tons) per day and
averages 100 metric tons (110 tons).
Approximately 10 television picture tube envelope factories are
located in the United States. The average amount of glass pulled
per day is 208 metric tons (229 tons). Plant production varies from
142 metric tons (156 tons) pulled per day to 255 metric tons (280
tons) pulled per day.
Incandescent lamp envelopes are manufactured at 18 plants in the
United States. Plant production in terms of furnace pull ranges
from 141 metric tons (155 tons) per day to 245 metric tons (270
tons) per day. The average plant production is 193 metric tons (212
tons) per day.
Hand pressed and blown glass manufacturing plants are small and
primarily located in West Virginia, western Pennsylvania, and Ohio.
Approximately fifty handmade glassware plants are located in the
United States. A number of hand pressed and blown ware plants also
have facilities to manufacture machine-made glassware. The average
amount of finished product produced per day at a hand pressed and
blown ware plant is 3.6 metric tons (4.0 tons). The range of
production varies from 0.7 metric tons (0.8 tons) per day to 6.5
metric tons (7.2 tons) per day.
GENERAL PROCESS DESCRIPTION
Pressed and blown glass and glassware are covered in this study.
The pressed and blown glass industry has been characterized as glass
container, machine pressed and blown glass, glass tubing, television
picture tube envelope, incandescent lamp envelope, and hand pressed
and blown glass manufacturing. Pressed and blown glass
manufacturing consists of raw material mixing, melting, forming,
annealing, and, in some cases, finishing.
The basic unit of production for all subcategories, except hand
pressed and blown glass manufacturing, is the metric ton (or ton in
English units) and is based on the amount of glass drawn from the
melting tank. These units were chosen because they relate directly
to plant size and waste water production and will be readily
available to enforcement personnel. The number of metric tons
(tons) of finished product is a more convenient unit for hand
pressed and blown glass manufacturing because waste water
characteristics are related to finishing operations rather than
metric tons (tons) pulled from the furnace. The number or pieces
produced is also a common unit, but does not appear to correlate
with waste water production as well as the number of metric tons
(tons) of finished product.
26
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Raw Materials-
Soda-lime glass is used to some extent in all subcategories except
television picture tube envelope manufacturing. The basic composi-
tion of the batch mix remains the same; however, there may be minor
variations in raw material composition depending on the manufacturer
and the product. Sand (silica) is the major ingredient and accounts
for about 70 percent of the batch. Another major ingredient is soda
(sodium oxide) or soda ash which is about 13 to 16 percent of the
batch. Soda and sometimes small quantities of potash (potassium
oxide) are added as fluxing agents which reduce the viscosity of the
mixture greatly below that of the silica. This permits the use of
lower melting temperatures and thereby improves the process by which
undissolved gases are removed from the molten glass. Lime (calcium
oxide) and small amounts of alumina (aluminum oxide) and magnesia
(magnesium oxide) are added to improve the chemical durability of
the glass; iron or other materials may be added as coloring agents.
The usual batch also has between 10 and 50 percent cullet. The
quantity of cullet added depends on the availability and allowable
levels in the total batch.
Cullet is waste glass that is produced in the glass manufacturing
process. Principal sources are product rejects, breakage, or
intentional wasting of molten glass to produce cullet. The addition
of cullet improves the melting qualities of the batch because of its
tendency to melt faster than the other ingredients, thus providing
starting points from which the melting can proceed.
Other glass types used by pressed and blown glass manufacturers
include lead-alkali silicate glass and borosilicate glass. Lead
oxide replaces the lime of the soda^lime glass to form lead-alkali
silicate glasses. The lead oxide acts as a fluxing agent and lowers
the softening point below that of the soda-lime glass. The lead
oxide also improves the working qualities of the glass when the lead
oxide proportion is less than about 50 percent. Lead-alkali
silicate glass is used in the production of television picture tube
envelopes and lead crystal. Lead apparently limits radiation in the
television picture tube application.
Boric oxide acts as the fluxing agent for silica in borosilicate
glasses. Boric oxide has less effect than soda in lowering the
viscosity of silica and in raising the coefficient of expansion. A
higher melting temperature is required for borosilicate glasses than
for soda-lime and lead-alkali silicate glasses. The borosilicate
glass is also more difficult to fabricate than the other two glass
types. The primary advantages of borosilicate glass are its
coefficients of expansion and its greater resistance to the
corrosive effects of acids. The lower coefficient of expansion
allows the glass to be used at higher temperatures. Borosilicate
glass is used for machine pressed products such as lenses and
reflectors, for some incandescent lamp envelopes, and for tubing
that is to be fabricated into laboratory and scientific glassware.
27
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Raw Material Storage and Mixinq-
Raw materials are shipped to the glass manufacturers in bulk
quantities. The raw materials are conveyed automatically to large
storage silos or holding bins. Gullet is transported from the
points where it is produced, and then sent to segregated storage
areas according to the type and color of the cullet.
Batch weighing and mixing is usually done according to formulas
which are based on either 454 kilograms (1000 pounds) of glass or on
454 kilograms (1000 pounds) of sand. The type of mixing systems
used at the pressed and blown glass manufacturing plants range from
hand batching at small hand pressed and blown glass plants to fully
automatic systems. Water is also added to the batch at some plants
to reduce segregation of the batch and to control dust emissions
during mixing. After mixing, the glass batch is charged into the
glass furnace manually or automatically. Furnace charging can be
either continuous or intermittent.
Melting-
Melting is done in three types of units, according to the amount of
glass required. Continuous furnaces are standard at the glass
container, machine pressed and blown, glass tubing, television
picture tube envelope, and incandescent lamp envelope plants, but
clay pots and day tanks are used in the manufacture of hand pressed
and blown ware.
Pots and day tanks are well suited for the variable composition and
small quantities of glass required in handmade glass plants. The
multi-pot furnace is the primary method of melting in these plants.
Eight or more pots may be grouped in a circular arrangement as part
of one furnace. Temperatures as high as 1400 degrees centigrade
(2550 degrees Fahrenheit) may be achieved. Pot capacities range
from 9 kilograms (20 pounds) to 1820 kilograms (two tons). A day
tank is a single furnace and is somewhat larger than a pot,
generally having a capacity of several metric tons (tons). Both
pots and day tanks are batch fed at the end of the working day and
allowed to melt overnight.
Continuous tanks range in holding capacity from 0.9 to 1270 metric
tons (one to 1400 tons), and outputs may be as high as 273 kkg/day
(300 tons/day). The continuous tank consists of two areas, a
melting chamber and a fining chamber. The chambers are separated by
an internally cooled wall built across the tank. The fining chamber
allows gas bubbles to leave the melt. Extensions from the fining
chamber called forehearths are used to condition the glass before
forming.
Forming-
Several methods are used to form pressed and blown glassware. These
include blowing, pressing, drawing, and casting.
28
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BlowingThe individual section (I.s.) forming machine is the most
widely used method for making glass containers. Forming of the
glass container involves several blowing steps. The molten glass is
cut into gobs by a set of shear cutters as the glass leaves the
forehearth of the melting tank. Chutes direct the gobs into blank
molds. The shear cutter and chutes are lubricated and cooled with a
spray of emulsified oil. The molten glass gob is settled with
compressed air and preformed with a counter blow. The preformed gob
(parison) is then inverted and transferred into a blow mold where
the glass container is finished by final blowing.
A pressing and blowing action is used to form wide-mouthed
containers. The molten glass gob is cut and delivered to the mold,
and the gob is then pressed and puffed. The preformed gob is in-
verted for final blowing to complete the forming of the container.
A few Owens machines are still in use but these are slowly being
replaced by I. S. machines, owing to the higher production and lower
operating expense associated with these units. The Owens machine
consists of a number of molds arranged around a central axis. The
entire machine rotates and glass is sucked by vacuum into the
parison mold. The parison is then transfered to the blow mold for
final blowing. Shear or chute sprays are not required for these
machines.
Incandescent lamp glass envelopes are formed using a ribbon machine.
The ribbon machine employs modified blowing techniques to form the
envelopes. The molten glass is discharged from the melting tank in
a continuous stream and passes between two water cooled rollers.
One roller is smooth while the other has a circular depression. The
ribbon produced by the rollers is then redirected horizontally on a
plate belt. The plate belt runs at the same speed as the forming
rollers. Each plate on the plate belt has an opening and the pill
shaped glass portion of the ribbon sags through the openings due to
gravity. The glass ribbon is met by a continuous belt .of blow
heads; the blow heads aid the sag of the glass by properly timed
compressed air impulses. After the glass has been premolded, it is
enclosed by blow molds which are brought up under the premolded
glass on a continuous belt. The blow molds are pasted and rotate
about their own axis to obtain seamless smooth surfaces. Both the
blow heads and molds are lubricated with a spray of emulsified oil
(shear spray). The formed envelopes (bulbs) are separated from the
ribbon by scribing the neck of the bulb and tapping the bulb against
a metal bar. Residual glass is collected as cullet.
Hand blow glassware is made using a blowpipe. Molten glass is
gathered on the end of the blowpipe and, utilizing lung power or
compressed air, is blown into its final shape. After the main sec-
tion is formed, additional parts such as handles and stems can be
added. This is accomplished by gathering a piece of molten glass,
joining it to the molded piece and then forming the joined pieces
with special glassworking tools.
29
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PressingMuch glassware is manufactured using presses. A press
mold consists of three sections: the mold bottom, the plunger, and
an enclosing ring that seals the mold between the mold bottom and
the plunger. Pressing is done manually in the handmade subcategory
or by machine in the remainder of the industry.
In manual pressing of glassware, molten glass is collected on a
steel rod and allowed to drop into the mold bottom. When the proper
amount of glass is deposited in the mold, the glass remaining on the
rod is separated from that in the mold by cutting with a pair of
shears. The plunger is then forced into the mold with sufficient
pressure to fill the mold cavities. The glass is allowed to set-up
before the plunger is withdrawn and the pressed glass is removed
from the mold.
Machine pressing is done on a circular steel table. The glass is
fed to the presses in pulses from a refractory bowl following the
forehearth of the melting tank. The molten glass is cut into gobs
by oil-lubricated shear cutters beneath the orifice of the
refractory bowl. The motions of the shear cutters and the press
table are synchronized such that the gobs fall into successive molds
on the press table. After the gob is received in the mold, it moves
to the next station on the press table, where it is pressed by a
plunger. In the remaining stations, the pressed glass is allowed to
cool before it is removed from the press and conveyed to the
annealing lehr.
The mold bottoms are usually cooled by air jets and the plunger
sections are cooled with non-contact cooling water. The mold
temperature is critical; if the mold is too hot, the molded piece
will stick to the mold and if it is too cold, the piece may have an
uneven surface. In some cases, the mold is sprayed with water prior
to receiving the glass. The steam formed when the molten glass is
introduced helps prevent sticking. Machine pressed glass products
include tableware, lenses, reflectors, and television picture tube
faceplates.
Shear SprayIn the manufacture of most machine-made pressed or
blown glass products, blow heads, molds, and shearcutters are
lubricated and cooled with a spray of emulsified oil (shear spray) .
This may be made up of petroleum or synthetic oils of an animal of
vegetable nature. The trend in recent years has been to utilize
synthetic biodegradable shear spray oils.
DrawingGlass tubing may be formed using three different processes.
In the Banner process, a regulated amount of glass falls upon the
surface of a rotating mandrel which is inclined to the horizontal.
Air is blown through the center of the mandrel continuously to
maintain the bore and the diameter of the tubing as it is drawn away
from the mandrel. The tubing is pulled away from the mandrel on
rollers by the gripping action of an endless chain. Tubing
dimensions are controlled by the drawing speed and the quantity of
air blown through the center of the mandrel. The tubing is scribed
by a cutting stone that is accelerated to the drawing speed and
30
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pressed vertically against the tubing and then cut by bending
against a spring controlled roller.
The Velio and Updraw processes can also be used to form tubing. In
the Velio process, the molten glass passes downward through the
annular space between a vertical mandrel and a refractory ring set
in the bottom of a special forehearth section of the melting tank.
The tubing is drawn away from the Velio machine and cut in a manner
similar to that used for the Banner Process.
The Updraw process is used to make large diameter tubing and glass
pipe. In the Updraw process, the tubing is drawn upward from a
refractory cone. Air is blown up through the cone to control
dimensions and cool the tubing. The tubing is cut into lengths at
the top of the draw.
CastingTelevision picture tube envelope funnels are formed by
casting. Molten glass is cut into gobs by oil-lubricated shear
cutters. The glass gob is then dropped into the mold. The mold is
spun sufficiently fast that the centrifugal force causes the glass
to flow up the sides of the mold to form a wall of uniform
thickness. A sharp-edged wheel is used to trim the upper edge of
the funnel at the end of the spinning operation.
Gullet Quenching-
Cullet is waste glass that is produced both intentionally and
inadvertently. Gullet results from breakage, wasting of molten and
formed glass during production interruptions or machine maintenance,
rejection of formed pieces because of imperfections, and intentional
wasting. Wasting of glass during production interruptions is
necessary to maintain a steady flow of glass through the melting
furnace. All portions of the pressed and blown glass segment except
for hand pressed and blown glass manufacturing are effected by this
requirement. Gullet is conveyed from the manufacturing operation by
chutes into carts or tanks located in the furnace basement.
A continuous stream of water is discharged through the chutes and
into the quench carts and tanks to cool or quench the hot glass.
Excess water overflows from the quench cart or tank and is
discharged into the sewer. When the cart or tank is filled with
glass, it is removed from the quench stream, allowed to drain, and
conveyed to a storage area where the cullet is dumped. In some
plants, quench carts have been replaced by water-filled vibrating
conveyors that automatically remove cullet to the storage area.
Cullet is segregated according to type and color.
Annealing-
After the glass is formed, annealing is required to relieve strains
that might weaken the glass or cause it to fail. The entire piece
of glassware is brought to a uniform temperature high enough to
permit the release of internal stresses and then cooled at a uniform
rate to prevent new strains from developing. Annealing is done in
31
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long continuous ovens called lehrs. The dimensions of the lehr
depend upon the type of glass to be annealed.
Finishing-
Following annealing, the pressed and blown glass is either finished
or inspected, packaged, and shipped. Glassware from all subcate-
gories may, in some cases, be finished but many finishing steps
require no water and produce no waste water. This study includes
the major waste water producing finishing steps that are normally
employed at the same location where the glass is produced. These
are television picture tube envelope finishing, incandescent lamp
envelope frosting, and hand pressed and blown glass finishing.
Television picture tube envelopesTelevision picture tube envelopes
are manufactured in two pieces, referred to as the screen and
funnel. Both pieces require the addition of components prior to
annealing and several finishing steps which follow annealing. After
forming and prior to annealing, the seam on the screen is fire
polished and mounting pins are installed employing heat. The
mounting pins are required for proper alignment when the electronic
components are placed into the picture tube.
The stem portion and an anode to be used as a high voltage source
are added to the funnel prior to annealing. Both components are
fused onto the funnel using heat.
Following annealing, screens and funnels are visually inspected for
gross defects such as large stones, blisters and entrapped gas
bubbles. The screen dimensions and mounting pin locations are then
gaged to check for exactness of assembly. The funnel portion is not
gaged until all finishing steps are completed.
Screens and funnels are finished separately using different
equipment. The first finishing step applied to the television
screen section is abrasive polishing. Polishing is required to
assure a flawless and parallel surface alignment so that an un-
distorted picture will be produced when the tube is assembled. The
edge of both the screen and funnel must be perfectly smooth so that
a perfect seal will be formed when the two sections are glued
together. The seal must be sufficiently tight to hold a vacuum.
Abrasive polishing is accomplished in four steps using rough and
smooth garnet, pumice, and rouge or serium oxide. The abrasive
compounds are in a slurry form and are applied to the screen surface
by circular polishing wheels of varying texture. Between each
polishing step the screen is rinsed with water. The slurry
solutions are generally recycled through hydroclones or settling
tanks and only fine material too small to be useful for grinding or
polishing is wasted. Following abrasive polishing, the screen edge
is ground, beveled, and rinsed with water. This edge is then dipped
in a hydrofluoric acid solution to polish and remove surface
irregularities. This step may be referred to in the industry as
32
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fortification. Following rinsing, which removes residual acid, and
drying, the screen receives a final inspection.
The front edge of the funnel is polished with a diamond wheel
polisher. The polishing surface is bathed in oil and, therefore,
the funnel must be rinsed with water to remove the oily residue.
The edge of the funnel is then beveled and dipped in a combination
of hydrofluoric and sulfuric acids to polish or fortify. Following
the acid dip, the funnel is rinsed with water and dried before final
gaging and inspection.
Incandescent lamp envelopesAn incandescent lamp envelope may be
defined as the glass portion of a light bulb. Generally, envelopes
are not manufactured in the same plant where the bulbs are
assembled, and assembly is not covered by this study. Envelopes may
be clear, coated, or frosted, but either by habit or for esthetic
reasons, frosted bulbs are the most popular with consumers.
Frosting improves the light diffusing capabilities of the envelope.
Generally, lamp envelopes are frosted at the plant where the
envelope is produced and coatings are applied where the bulb is
assembled.
After annealing, the lamp envelopes are placed in racks for
processing through the frosting operation. The envelope interior is
sprayed successively with several frosting solutions. The specific
formulation of these solutions is proprietary, but primary
constituents include hydrofluoric acid and other fluoride compounds,
ammonia, water, and soda ash. Residual frosting solution is removed
in several rinse stages.
Hand pressed and blownThe manufacture of hand pressed and blown
glass involves several finishing steps including: crack-off,
washing, grinding and polishing, cutting, acid polishing, and acid
etching. The extent to which these methods are employed varies
substantially from plant to plant. Many plants use only a few of
the finishing methods. Washing and grinding and polishing are the
most prevalent.
Crack-off is required to remove excess glass that is left over from
the forming of hand blown glassware. Crack-off can be done manually
or by machine. When a machine is used for stemware, the stemware is
inserted into the crack-off machine in an inverted position. The
bowl of the stemware is scribed by a sharp edge, the scribed edge
passes by several gas flames and the excess glass is broken off.
The scribed surface is then beveled on a circular grinding medium
similar to sandpaper. Carborundum sheets are used in most cases.
The grinding surface is sprayed with water for lubrication and to
flush away glass and abrasive particles.
Hydrofluoric acid polishing of the beveled edge may follow crack-
off. This operation involves rinsing the glassware in dilute
hydrofluoric acid and city water, and in some cases, a final
deionized water rinse.
33
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Miscellaneous washing is employed throughout a handmade glass plant
and is associated with many finishing steps. Generally the
glassware receives a final washing before packaging and shipment.
In many cases this is done by hand in a small sink and the glassware
is hand-dried.
Mechanical washers are used in the larger plants. These units may
include several washes and rinses. In one such system, a
recirculating acid rinse is followed by a caustic rinse, a city
water rinse, and finally a steam spray to heat the glassware and
thus facilitate drying.
Abrasive grinding is used to remove sharp surfaces from the formed
glass products. Grinding is accomplished using a large circular
stone wheel. The glassware is placed in a rack, and weights are
added to hold it against the rotating stone. The grinding surface
is lubricated with slowly dripping water.
Abrasive polishing is used to polish the glass surfaces and edges of
some types of handmade glassware. The glassware is placed in a bath
of abrasive slurry and brushed by circular mechanical brushes or
polishing belts. After polishing, the ware is rinsed with water in
a sink and dried.
Cutting as applied to handmade glassware manufacturing may be
defined as the grinding of designs onto the glassware or as the
removal of excess glass left over from forming. Designs may be
placed onto the glassware manually or by machine. In mechanical
design cutting, the ware is placed on a cutting machine and is
rotated in a circular motion. Designs are cut into the surface at
the desired points using a cutting edge. In the second form of
cutting, a saw may be used to remove excess glass from some handmade
products. Water is used in both machine design cutting and sawing
to lubricate the cutting surface and to remove cutting residue.
Acid polishing may be employed to improve the appearance or to
remove the rough edges from glassware. Automatic machines or
manually dipped racks may be employed. In the manual operation, the
glassware is placed in racks and treated with one or more
hydrofluoric acid dips followed by rinsing. The complexity and
number of steps is determined by the product. Many plants use a
one- or two-step acid treatment followed by two rinses. At least
one plant has a more complicated system using a series of
hydrofluoric acid, sulfuric acid, and water rinses.
Some of the larger plants employ automatic polishing techniques.
The glassware is loaded into acid-resistant plastic drums and placed
in the treatment vessel. Acid contact and rinsing is accomplished
automatically according to a preset cycle.
Complicated designs may be etched onto handmade stemware with
hydrofluoric acid. The design is first made on a metal template and
is transferred from the template to a piece of tissue paper by
placing a combination of beeswax and lampblack in the design and
34
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then pressing the tissue paper against the design. The tissue paper
is placed on the stemware and then removed leaving the pattern in
wax. All parts of the ware except for the pattern are then coated
with wax. The wax-coated stemware is placed in racks and immersed
in a tank of hydrofluoric acid where the exposed surfaces are
etched. Following a rinse to remove residual acid, the ware is
placed in a hot water tank where the wax melts and floats to the
surface for skimming and recycling. Several additional washes and
rinses are required to clean the ware and to remove salt deposits
from the etched surfaces. In some cases a nitric acid bath may be
used to dissolve these deposits. Deionized water may be used for
the final rinse to prevent spotting.
Miscellaneous finishingNumerous finishing steps that do not
produce waste water are employed throughout the industry. These are
not of direct concern to this study and therefore are not covered in
detail. These finishing operations may be generally classified as
decorating or in the container industry as labeling. In most cases,
some form of paint or coating is applied and then baked onto the
glass surface. This procedure is referred to as glazing in the
handmade industry.
35
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SECTION IV
INDUSTRY CATEGORIZATION
The segments of the pressed and blown glass industry, covered by
this study, include a large and diverse group of products with
distinctly different manufacturing methods and waste water char-
acteristics. Subcategorization into smaller segments was necessary
in order to develop meaningful and workable effluent limitations
guidelines and new source performance standards.
The following factors were given major consideration with respect to
subcategorization:
1. Raw materials
2. Age and size of production facilities
3. Products and production processes
U. Waste water characteristics
5. Applicable treatment methods
It is concluded that six subcategories are necessary to adequately
subdivide the industry and that, owing to variable finishing
requirements, two of these subcategories should be further
categorized. The subcategories are:
1. Glass Container Manufacturing
2. Machine Pressed and Blown Glass Manufacturing
3. Glass Tubing Manufacturing
U. Television Picture Tube Envelope Manufacturing
5. Incandescent Lamp Envelope Manufacturing
a. Forming
b. Frosting
6. Hand Pressed and Blown Glass Manufacturing
a. Leaded and Hydrofluoric Acid Finishing
b. Non-Leaded and Hydrofluoric Acid Finishing
c. Non-Hydrofluoric Acid Finishing
Production methods and waste water characteristics are the primary
bases for subcategorization.
37
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Raw Materials
Several types of glass are required in the pressed and blown glass
industry. Soda-lime glass is used wherever possible, as it is the
least expensive to produce. Borosilicate glass is required where
the thermal coefficient of soda-lime glass is not satisfactory.
Borosilicate glass is used for some machine pressed and blown
products, tubing that is to be made into scientific glassware, and
for some incandescent lamp envelopes. Lead-alkali silicate glass is
required for television picture tube envelopes and for many types of
handmade glassware.
Available data do not show any relationship between raw materials
and waste water characteristics except where leaded glass is fin-
ished, such as in a television picture tube or handmade glass plant.
The soluble and insoluble lead is discharged as a result of cutting,
grinding and polishing, or hydrofluoric acid treatment. Because
lead is discharged as a result of finishing operations and appar-
ently is not discharged as a result of forming, raw materials do not
provide a significant basis for subcategorization.
Age and Size of Production Facilities
Many pressed and blown glass manufacturing processes and techniques
have been used since the early part of this century. Improvements
in automation and water conservation have been made over the years
but because furnaces are rebuilt every three to six years, these
improvements have generally been applied to new and old plants
alike.
Waste water volume and characteristics expressed per unit of
production do not vary significantly with respect to plant size.
Equipment of the same type and size is generally used throughout the
industry to manufacture a given product. Plant size or production
output is increased by operating more units in parallel. For these
reasons, the age or size of production facilities provides no basis
for subcategorization.
Products and Production Processes
The pressed and blown glass industry is readily categorized into
distinct products and production processes. Each product is unique
to a particular subcategory. These differences in production
methods provide a basis for subcategorization. Glass container
manufacturing is characterized by multi-blow forming techniques;
machine pressed and blown glass manufacturing by the automated press
or multi-blow forming techniques; tubing manufacturing by mandrel
forming and drawing; television picture tube envelope manufacturing
by funnel casting and abrasive and acid polishing; incandescent lamp
envelope manufacturing by ribbon machine forming and frost
finishing; and hand pressed and blown glass manufacturing by hand
blowing and hand pressing and by numerous finishing steps applied to
the glassware. The typical plant production, expressed as tons per
day, for these manufacturing methods also varies significantly.
38
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All of the manufacturing methods except those employed for handmade
glassware may be broadly classified as machine pressing or blowing,
but subcategorization is necessary because of the distinct variation
in manufacturing methods, typical production rates, and waste water
characteristics. The machine pressed and blown subcategory is
intended to cover the forming of products not covered under the
other subcategories.
Further categorization of the incandescent lamp envelope
manufacturing subcategory is necessary because not all of the
products formed are finished. The percentage of incandescent lamp
envelopes frosted varies from plant to plant. Forming waste water
characteristics are influenced by the tons pulled from the furnace,
while frosting waste water characteristics are governed by the tons
frosted.
Further categorization of the hand pressed and blown glass
manufacturing subcategory is necessary to take into account the
various finishing operations which are applied to the various types
of glass. Certain plants apply hydrofluoric acid finishing
techniques to either leaded or unleaded glass while other plants do
not utilize hydrofluoric acid. The further categorization is
recommended in order that effluent limitations guidelines be applied
only to those parameters which are consistent with the discharge
from an individual hand pressed and blown glass manufacturing plant.
Water Characteristics
Waste water volumes and characteristics are directly related to the
manufacturing method and the quantity and quality of the product
produced. Forming waste waters may generally be characterized in
terms of oil and suspended solids. Finishing waste characteristics
are variable and depend upon the finishing technique employed. Some
finishing wastes contain only suspended solids, while others contain
suspended solids, fluoride, lead, or ammonia. The volume of waste
water expressed in terms of production is substantially different
within each of the subcategories. Waste water characteristics form
a basis for sufccategorization.
Applicable Treatment Methods
Treatment methods are essentially the same throughout the pressed
and blown glass segment. Gravity separation methods are used to
remove oil from forming waste water; precipitation with lime
addition, followed by coagulation and sedimentation is employed to
remove fluoride, lead, and suspended solids from finishing wastes.
Treatment methods are not a basis for subcategorization because of
similarities of the treatment within the pressed and blown glass
segment.
39
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-------
SECTION V
WATER USE AND WASTE CHARACTERIZATION
Water is used to some extent in all of the subcategories covered by
this study. Cooling water is required at all plants. Water is used
in the glass container manufacturing, machine-pressed and blown
glass manufacturing, and glass tubing manufacturing subcategories
for non-contact cooling and cullet quenching. The television
picture tube envelope manufacturing, incandescent lamp envelope
manufacturing, and hand pressed and blown glass manufacturing
subcategories use water for non-contact cooling, cullet quenching,
and also for product rinsing following the various finishing steps
specific to each subcategory.
Water used in-plant is obtained from various sources including the
city water supply, surface, or ground water. City water is used in
almost all cases, except where a plant-owned source is available.
AUXILIARY WASTES
For the purpose of this study, non-contact cooling, boiler, and
water treatment waste waters are considered auxiliary wastes as
distinguished from process waste waters. Process waste water is
defined as water that has come into direct contact with the glass,
and results from a number of sources involving both forming and
finishing.
Pretreatment requirements depend upon the raw water quality and the
intended water use. Cooling water pretreatment practices may range
from no treatment to coagulation - sedimentation, filtration,
softening, or deionization. Treatment is normally applied to
prevent fouling of the cooling system by clogging, corrosion, or
scaling. Boiler water treatment depends on boiler requirements.
Treatment normally involves the removal of suspended solids and at
least a portion of the dissolved solids. The waste waters developed
from pretreatment systems are highly variable and depend upon the
characteristics of the water being treated.
Auxiliary waste waters generated by the pressed and blown glass
industry are similar to those throughout industry using the same
cooling, boiler, and water pretreatment systems. Owing to highly
variable volumes and characteristics, auxiliary waste waters are not
included in the effluent limitations and standards of performance
developed for process wastes. Auxiliary wastes will be studied at a
later date and characterized separately for industry in general.
The values thus obtained will be added to the limitations for
process waste water to determine the effluent limitations and
standards of performance for the total plant.
It is general practice within the pressed and blown glass segment
that both auxiliary and process wastes are discharged together and
not segregated. The bulk of the data received pertaining to this
41
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industry segment applied to the combined process and auxiliary waste
water streams. For this reason, data presented in this section and
in other sections of this document are carefully referred to as
pertaining to combined non-segregated waste water streams or
segregated waste water streams, whichever is appropriate.
GLASS CONTAINER MANUFACTURING
Glass container manufacturing consists of melting raw materials and
then forming the molten glass using a blow-mold technique. The
major process steps and points of water usage are shown in Figure 5.
A detailed description of the manufacturing process is given in
Section III.
Process Water and Waste Water
Process water is used for cullet quenching and non-contact cooling
of the batch feeders, melting furnaces, forming machines, and other
auxiliary equipment. At some plants, a small amount of water is
also added to the batch to control dust. The volume discharged
depends on the quantity of once-through cooling water and on the
water conservation procedures employed at the glass container plant.
The typical flow is representative of a plant using some once-
through cooling water and practicing reasonable water conservation.
Batch Wetting-
Water is added to the batch for dust suppression at some plants in
all of the subcategories covered by this study, but the practice is
not considered typical for the industry. When water is added, it is
generally at a rate of about 11.5 I/metric ton (2.75 gal/ton).
CQQling-
Non-contact cooling water is used to cool batch feeders, melting
furnaces, forming machines, and other auxiliary equipment. The
typical flow of cooling water is 1380 I/metric ton (330 gal/ton).
This represents U7 percent of the total flow. Reported and
calculated heat rejection rates vary from 361,000 kg-cal/metric ton
(1,300,000 BTU/ton) to 13,900 kg-cal/metric ton (50,000 BTU/ton).
Owing to the wide variation and absence of sufficient information to
explain the differences, it is not possible to define a typical heat
rejection value. The average value is 97,300 kg-cal/metric ton
(350,000 BTU/ton).
Cullet Quenching-
Cullet quench water is required to dissipate the heat of molten
glass that is intentionally wasted or discharged during production
interruptions, or to quench hot pieces which are imperfect. Some
plants use non-contact cooling water for the dual purposes of
furnace and equipment cooling and cullet quenching. The typical
cullet quench water flow is 1540 I/metric ton (370 gal/ton) or 53
percent of the total flow.
42
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RAW MATERIAL STORAGE
MIXING
COOLING
WATER
I
MELTING
COOLING
WATER
1380 L/METRICTON
330 GAL/ TON
47%
:OOLING
WATER I
FORMING
WASTE
WATER
1540 L/METRC TON
370 GAL/ TON
53%
ANNEALING
INSPECTION
I
PACKAGING
SHIPPING
CONSUMER
FIGURE 5
GLASS CONTAINER MANUFACTURING
43
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Miscellaneous Wastes-
Repair and maintenance departments are required in all glass con-
tainer plants. Waste water is produced in the maintenance depart-
ments from the cleaning of production machinery. The machinery is
inspected, cleaned, and repaired at specific intervals. The clean-
ing operation includes steam cleaning of large parts and caustic
batch cleaning of items such as molds. The waste water from the
maintenance department is of very low volume and is primarily
occasional rinse water from the cleaning operations.
Several glass container plants have corrugator facilities to manu-
facture boxes. Wastes developed from the corrugator facilities are
of low volume and include cleanup water from the gluing and ink
labeling equipment, lubricating oil, and steam condensate. The
wastes are usually contained at the plant site and treated or
discharged to a municipal sewer system. The corrugator box manu-
facturing operation is not covered in the SIC codes under study in
this report.
Waste Water Volume and Characteristics
Typical characteristics for the combined non-contact cooling and
cullet quench waste water streams for a glass container plant are
listed in Table 5. In all cases, except for pH, the values listed
are the quantities added to the water as a result of glass container
manufacturing; concentrations in the influent water have been
subtracted. The significant parameters are oil and suspended
solids. BOD and COD are a result of oil in the waste water; control
of oil therefore controls oxygen demand.
Flow-
The quantity of waste water produced in the manufacture of glass
containers is highly variable. Flows range from near zero to 6250
I/metric ton (1500 gal/ton) or from near zero to 2460 cu m/day (.65
mgd). Some plants have indicated no discharge, but are apparently
discharging an unknown quantity of blowdown. This blowdown may be
in the form of water carried with the cullet and fed to the furnace
during batching. The typical flow is 2920 I/metric ton (700
gal/ton). The amount of water usage depends, to a certain extent,
on the raw water source and age of the plant. Glass container
plants receive water from various sources including plant-owned
wells, surface water, and municipal water systems. The amount of
water conservation and recirculation is considerably greater at
plants that use water from a municipal system. Plant age is another
factor which may affect water usage. Newer plants may use somewhat
less water because of more attention to water conservation.
Biochemical Oxygen Demand-
A small amount of BOD is added to the waste water as shear spray or
lubricating oil. Shear spray is an oil-water emulsion used to cool
and lubricate the shears and the chutes that convey the glass to the
44
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I.S. machine. Many plants now use a synthetic biodegradable shear
spray to reduce the effects of oil on the receiving stream. Excess
shear spray eventually finds its way into the cullet quench water.
Another potential source of BOD is leakage of lubricating oils into
the cooling water system. The typical raw waste water loading is
0.0145 kg/metric ton (0.029 Ib/ton) of BOD5.
Chemical Oxygen Demand-
The COD is contributed by the same sources that contribute BOD,
namely shear spray oil and lubricating oil. The typical plant waste
water contains 0.145 kg/metric ton (0.29 Ib/ton) of COD.
Suspended Solids-
Suspended solids enter the plant waste water as the result of cullet
quenching and plant cleanup. The cullet quench water picks up fine
glass particles; additional suspended solids are added during
cleanup of the I.S. machine area. A typical plant generates 0.07
kg/metric ton (0.14 Ib/ton) of suspended solids.
Oil-
Oil is added to the plant waste water as shear spray oil and leaking
lubricants. The typical oil loading is 0.03 kg/metric ton (0.06
Ib/ton).
Other Parameters-
Some information is available on the temperature and pH of glass
container plant waste waters. The average rise in temperature over
the plant influent water is 6°C (11°F). The typical pH of the waste
water is 7.5 and reported values range from 6.5 to 8.6.
Discussion-
Glass container plant operation is continuous (24 hr/day, 7
day/week); and, therefore, waste water flows are relatively
constant. No significant variations in waste water volume or
characteristics occur during plant startup or shutdown, and there
are no known toxic materials in the waste water. The melting tanks
must be drained every three to five years for rebuilding and
excessive quantities of cullet quench water are produced for one or
two days during this period. In larger plants with several
furnaces, this discharge may occur several times a year. The very
limited data available indicate that temperature is the only
significant parameter and that receiving stream standards may
necessitate cooling of the quench water in some cases.
MACHINE PRESSED AND BLOWN GLASS MANUFACTURING
Machine pressed and blown glass manufacturing consists of melting
raw materials and then forming the molten glass using presses or
other techniques to manufacture tableware, lenses, reflectors.
46
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sealed headlamp glass parts, and other products not covered in the
other subcategories. The major process steps and points of water
usage are listed in Figure 6. The manufacturing of machine pressed
and blown products is more fully explained in Section III.
Process Water and Waste Water
Water is used in the manufacturing of machine pressed and blown
products primarily for non-contact cooling and cullet quenching.
Gullet quenching is the cooling of molten glass or hot rejects with
water. Some plants use a portion of the non-contact cooling water
for cullet quenching. Water may also be added to the batch for dust
suppression and an oil-water emulsion is used for shear spraying.
Cooling-
Non-contact cooling water is required to cool batch feeders, melting
furnaces, presses, and other auxiliary equipment. The typical flow
of non-contact cooling water is 2710 I/metric ton (650 gal/short
ton). Non-contact cooling water is 48 percent of the combined flow
from this category. Although no heat-rejection data is available
for machine pressed and blown glass plants, it is expected that heat
rejection requirements are similar to those of glass container
plants.
Cullet Quenching-
Quench water is required at all machine pressed and blown glass
plants to cool intentionally wasted molten glass during production
interruptions, and to quench hot pieces that are wasted or rejected
because of imperfections. The configuration of equipment is similar
to a glass container plant. Quench water and waste glass are
discharged into chutes and flow to a cart located in the furnace
basement. Excess quench water overflows the cart and is discharged
to the sewer. The typical quantity of water used for cullet quench-
ing is 2920 I/metric ton (700 gal/ton). This is 52 percent of the
total flow.
Miscellaneous Wagte Water Sources-
Some machine pressed and blown glass plants have small plating shops
where molds are periodically cleaned and chrome-plated. Low volumes
of rinse waters are periodically discharged, but no evidence of
chromium contamination was found in the data collected during this
study. Chromium discharges should be regulated by the effluent
limitations developed for plating wastes.
Finishing may be employed at some machine pressed and blown glass
plants, but most of the finishing techniques produce no waste water.
The great majority of the finishing steps can be classified as deco-»
rating and involve painting or coating and re-annealing. Other
finishing steps may produce small quantities of waste water, but
these are not covered in this study. It is recommended that where
47
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COOLING
WATER
2710 L/METHIC TON
650 GAL/ TON
RAW MATERIAL STORAGE
MIXING
COOLING
WATER
MELTING
COOLING
WATER
FORMING
ANNEALING
PACKAGING
SHIPPING
WATER
GULLET
QUENCH
GULLET
.WASTE
WATER
2920 L/METRIC TON
700 GAL/ TQN
52%
INSPECTION
*
DECORATION
*
ANNEALING
*
INSPECTION
CONSUMER
FIGURE 6
MACHINE PRESSED AND BLOWN GLASS MANUFACTURING
48
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treatment is required, the technology developed for hand pressed and
blown glass finishing be applied.
Waste Water Volume and Characteristics
Typical characteristics of the combined non-contact cooling and
cullet quench waste water streams are listed in Table 6. In all
cases, except for pH, the values listed are the quantities added to
the water as a result of machine pressed and blown glassware
manufacturing. Background concentrations in the influent water have
been subtracted. Oil and suspended solids are the significant
parameters. The COD is contributed by the oil.
Flow-
A variable volume of water is used for machine pressed and blown
glass manufacturing. Flows range from 2210 to 27,500 I/metric ton
(530 to 6600 gal/ton) or 87 to 2650 cu m/day (0.023 to 0.7 mgd).
The typical combined flow of non-contact cooling water and cullet
quench water is 5630 I/metric ton (1350 gal/ton). The variation in
water usage depends on the amount of once-through non-contact
cooling used and also on the water conservation practiced at the
various machine pressed and blown glass plants, Cullet quench water
and non-contact cooling water are generally combined prior to
discharge.
CQD-
The typical COD added to the waste water is 0.28 kg/metric ton (0.56
Ib/ton). The COD results primarily from shear spray and lubricating
oil leaks.
Suspended Solids-*
The suspended solids are fine glass particles picked up by the
cullet quench water. The typical suspended solids loading is 0.14
kg/metric ton (0.28 Ib/ton).
Oil-
Oil is added to the waste water as shear spray and lubricating oil.
Water-soluble oil is used to lubricate the gob shear cutters and the
glass gob chute. The shear spray oil flows from the gob chute and
enters the cullet quench water. Lubricating oil leaks may also
contaminate the cooling water and cullet quench water. The typical
quantity of oil discharged is 0.056 kg/metric ton (0.11 Ib/ton).
Other Parameters-
Some information is also available on the BOD, pH, and temperature.
The typical pH is 7.8 and the typical temperature rise is 10°C
(18°F). The temperature increase resulting from cullet quenching
alone is not known. This data appears in Table 6.
49
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Discussion-
Machine pressed and blown plants operate at various schedules, some
continuously, while others operate for an 8 hr/day, 5 day/week.
Continuous operation is desirable because furnace heat must be
maintained. Some glass must be wasted during the off periods to
maintain the flow of glass through the furnace; therefore, cullet
quench water is always required. No significant variations in waste
volume or characteristics are experienced during plant start-up or
shutdown, and there are no known toxic materials in waste water from
the manufacture of machine pressed and blown glassware. Excessive
quench water volumes will be produced when a tank is drained for
rebuilding or for a change in the composition of the glass. Heat is
the only significant pollutant parameter contained in this waste
water source.
GLASS TUBING MANUFACTURING
The manufacture of tubing consists of melting raw materials and
forming the molten glass on a rotating mandrel or other forming
device. The partially formed tubing is then drawn into lengths and
cut by scribing or by thermal shock. The major process steps and
points of water usage are illustrated in Figure 7. The tubing
manufacturing process is more fully explained in Section III.
Process Water and Waste Water
The only process water used in the manufacturing of glass tubing is
for cullet quenching. Cullet quenching is infrequent compared with
that amount common to the other subcategories and is done only when
a break or disruption occurs in the drawing process. During this
period, glass is wasted at the same rate that tubing is drawn so
that a constant flow through the furnace is maintained.
Cooling-
Cooling water is primarily used for non-contact cooling of furnace
walls and mandrel transmissions. The typical flow of non-contact
cooling water is 7920 I/metric ton (1900 gal/ton) and accounts for
about 95 percent of total plant water usage.
Cullet puenching-
Cullet quenching is required only when there is a break or dis-
ruption in the drawing process. During a stoppage, molten glass
continues to run over the mandrel or forming device, but is formed
into a ribbon by two rollers that are cooled by a spray of water.
The cullet ribbon and quench water drop to a segregated storage area
in the melting tank basement. The quenching system is activated
only when required. The typical flow is 420 I/metric ton (100
gal/ton) and accounts for five percent of the total typical flow.
Some plants use a cullet quench system similar to that employed at
glass container and machine pressed and blown glass plants. A
51
-------
COOLING
WATER
7920 L/METRIC" TON
1900 GAL/
95%
RAW MATERIAL STORAGE
MIXING
COOLING
WATER
I
MELTING
COOLING
WATER
FORMING
WATER
CULLET
QUENCH
CULLET
WASTC
420 L/METRIC TON
100 GAL/ TON
5%
CUTTING
PACKAGING
SHIPPING
FINAL ASSEMBLY
FIGURE 7
GLASS TUBING MANUFACTURING
-------
continuous stream of water is discharged into the quench carts so
that quench water will be available when necessary. This type of
quenching system requires a considerably greater volume of water
than the periodic system and is not considered typical. The
periodic cullet quench system is more applicable to the tubing
manufacturing process because the wasting of cullet is infrequent.
Waste Water Volume and Characteristics
Some typical characteristics of the combined non-contact cooling and
cullet quench waste waters resulting from tubing manufacturing are
listed in Table 7. In all cases, except for pH, the values listed
are the quantities added to the water as a result of the
manufacturing process. Background levels in the influent water have
been subtracted. Oil and suspended solids are the significant waste
water parameters. COD is contributed by the oil.
In most plants, non-contact cooling water and cullet quench water
streams are discharged as a combined waste stream. Flows range from
3340 I/metric ton (800 gal/ton) to 9910 I/metric ton (2380 gal/ton).
The typical flow is 8340 I/metric ton (2000 gal/ton). The high flow
is due to the use of once-through non-contact cooling water.
COD-
Chemical oxygen demand results from oil contamination of the non-
contact cooling water. The typical COD is 0.08 kg/metric ton (0.16
Ib/ton). This is a concentration of 10 mg/1 and is not considered
significant.
Suspended Solids-
Suspended solids are added to the waste water during cullet quench-
ing. Fine glass and miscellaneous solid particles are picked up in
the quench tank and discharge trenches leading to the sewer. The
typical suspended solids loading is 0.225 kg/metric ton (0.45
Ib/ton).
Qil-
The typical oil loading is 0.085 kg/metric ton (0.17 Ib/ton). Oil
enters the waste stream from lubricating oil leaks in the noncontact
cooling water system. The manufacturing methods used to form tubing
do not require shears and, therefore, the oil associated with shear
spraying is not a factor in this system.
Other Parameters-
Some additional information is available on the temperature and pH
of glass tubing manufacturing waste waters. The waste water
temperature increase due to the manufacture of glass tubing is 4.5°C
53
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54
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(8°F). The waste water pH is 7.9 and is in the acceptable range of
six to nine.
Discussion-
No significant variations in waste water volume or characteristics
are experienced during plant start-up or shutdown, and there are no
known toxic materials in the waste water resulting from glass tubing
manufacturing. As with all continuous furnaces, periodic furnace
drainage requires large volumes of cullet quench water; however,
temperature is the only significant pollutant parameter associated
with this waste water source.
TELEVISION PICTURE TUBE ENVELOPE MANUFACTURING
Television picture tube envelope manufacturing consists of melting
the raw materials, forming the screen and funnel sections, adding
the components necessary for the final assembly of the picture tube,
and polishing the necessary screen and funnel surfaces. The major
process steps and points of water usage are illustrated in Figure 8.
A detailed description of the manufacturing process is given in
Section III.
Process Water and Waste Water
Water is used in television picture tube manufacturing for cooling,
quenching, abrasive polishing, edge grinding, and acid polishing.
Cooling Water and Cullet Quenching-
Non-contact cooling water is required in the forming section of the
plant for the batch feeders, furnaces, presses, annealing lehrs, and
other auxiliary equipment such as compressors and pumps. Once-
through systems are used in all of the plants that submitted data.
In most cases, a portion of the water discharged from the above
sources is used as quench water to cool molten glass during
manufacturing interruptions or to quench defective pieces from the
forming operations. In at least one plant, cooling water is recir-
culated as rinse water later in the manufacturing process.
The typical flow for both the non-contact cooling and cullet quench
water streams is 4040 I/metric ton (970 gal/ton). Each of these
sources accounts for 32.5 percent of the total plant flow. Reported
flows for the combined forming waste water stream range from 7230
I/metric ton (1740 gal/ton) to 14,400 I/metric ton (3460 gal/ton) .
The typical flow for a plant practicing reasonable water
conservation is 8080 I/metric ton (1940 gal/short ton) and accounts
for approximately 65 percent of total water usage.
Abrasive Polishinq-
The funnel portion of the picture tube is abrasively polished using
a diamond wheel machine with an oil lubricated grinding surface.
After grinding, the funnel is rinsed with water.
55
-------
RAW ft
MTMAL STORAGE
MIXING
COOUNO
I
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CULLETT FUi»>tL« X
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4040 L/METRC TON STEM "-ACCMENT
32.5% I
ANODE INSTALLATION
1
ANNEALING
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INSPECTION
^ mm ^ I
^ WATER ^ 1 OH. POLISH
500 GAL/ TON 1 WMTCR
17% ^ ^T
?un L/MFTWT TOM AC*° ^^U,'*8
580 GAL/ TON 1
INSPECTION
*
PAtJMGMG
FIGURE 8
TELEVISION PICTURE TUBE ENVELOPE MANUFACTURING
56
-------
The outer face of the picture tube screen is also abrasively
polished. The screen face plate is polished in a step process using
garnet, pumice, and rouge; all of the grinding compounds are in the
form of a slurry. Between grindings with the various compounds,
each screen is rinsed with water. The grinding compound slurry is
recycled and only the blowdown from the slurry system is discharged.
After the face has been ground, the connecting edge is ground and
then beveled. The typical flow of abrasive waste water is 2080
I/metric ton (500 gal/ton) and is 17 percent of the total flow.
Edge Grinding and Acid Polishing-
Following abrasive polishing and beveling, the connecting edges of
both the funnel and screen are acid polished or fortified. The
funnel is dipped into a combination of sulfuric acid and
hydrofluoric acid. The two sections are then rinsed with water to
remove the residual acid. Constant overflow-type rinse tanks are
generally used. The acid polishing step removes irregularities from
the joining surfaces and allows a perfect seal when the screen and
funnel are joined. Fume scrubbers are required in the acid
polishing area and contribute significant amounts of fluoride to the
waste water. The combined typical waste water flow for funnel and
screen acid polishing is 2340 I/metric ton (560 gal/ton) or 18
percent of the total flow.
Waste Water Volume and Characteristics
Typical characteristics for the combined non-contact cooling, cullet
quenching, abrasive and acid polishing waste waters resulting from
television picture tube envelope manufacturing are listed in Table
8. In all cases, except for pH, the values listed are the
quantities added to the water as a result of the process.
Background levels in the influent water have been subtracted. The
significant parameters are suspended solids, oil, dissolved solids,
fluoride, and lead.
Flow-
Total waste water flows, including non-contact cooling water, range
from 11,100 to 14,400 I/metric ton (2670 to 3460 gal/ton) or 1590 to
3260 cu m/day (0.42 to 0.86 mgd) . The typical flow is 12,500
I/metric ton (3000 gal/ton). The variation in flow rate depends
primarily upon the amount of water used for once-through cooling.
Suspended Solids-
Suspended solids are added to the waste water in the form of glass
particles and grinding slurry solids from edge grinding and abrasive
polishing. Typical plant waste water contains 4.2 kg/metric ton
(8.4 Ib/ton) of suspended solids.
57
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Dissolved Splids-
Dissolved solids are contributed to the waste water stream from acid
polishing and abrasive polishing. The typical loading is 3.25
kg/metric ton (6.5 Ib/ton) of dissolved solids.
Fluoride-
Fluoride is contributed by the rinse waters following acid polish-
ing, fume scrubbing, and the periodic dumping of the concentrated
acid. Hydrofluoric acid is used to polish the edges of both the
screen and funnel portions of the picture tube envelope. The
typical loading is 1.8 kg/metric ton (3.6 Ib/ton) of fluoride.
Lead-
Lead results from both abrasive and acid polishing. It is not clear
if the lead in the abrasive waste stream is truly dissolved or in
the form of colloidal particles, but standard analytical procedures
show a significant concentration. Lead in the acid waste is assumed
to result from the dissolution of the glass. The typical quantity
of lead added to the waste water is 0.385 kg/metric ton (0.77
Ib/ton).
Oil-
Oil is added to the waste water as shear spray drippage into the
quench water during forming operations, as lubrication leaks, and as
funnel rinse water. The typical oil loading is 0.125 kg/metric ton
(0.25 Ib/ton) .
Other Parameters-
Some information is also available on temperature, pH, and COD. The
typical increase in COD is 0.435 kg/metric ton (0.87 Ib/ton). The
low organic content indicated by the COD is not considered
significant. Owing to the segregation of the various waste streams,
a typical value for the pH of the combined waste streams from a
picture tube envelope plant is not available. Typical pH values for
the various process streams are acid polishing, 3.0; abrasive
polishing, 9.5; cooling and quenching, 7.6. The cooling and
quenching water contributes 65 percent of the combined plant flow.
Owing to this high flow, it is estimated that the raw waste water pH
should be in the range of six to nine.
Discussion-^
Television picture tube envelope manufacturing plants generally
operate continuously, and no significant variations in waste water
volume or characteristics are experienced during plant start-up or
shutdown. An additional source of waste water from a picture tube
envelope plant may be chrome plating waste water resulting from mold
repair. This is a very low volume waste and is usually batch
treated at the plant or trucked from the plant for disposal.
Available data indicate no chromium is added to the waste water.
59
-------
Where applicable, the effluent limitations developed for plating
wastes should be used.
INCANDESCENT LAMP ENVELOPE MANUFACTURING
Incandescent lamp envelope manufacturing consists of melting raw
materials and forming the molten glass with ribbon machines into
clear incandescent lamp envelopes. Many of the clear envelopes are
then frosted or etched with a hydrofluoric acid solution. The major
process steps and points of water usage are listed in Figure 9. The
incandescent lamp envelope manufacturing process is more fully
explained in Section III.
Process. Water and Waste Water
Process water is used in the manufacturing of incandescent lamp
envelopes for cullet quenching and for rinsing frosted bulbs. The
frosting waste water stream is the major source of pollutants and
contains high concentrations of both fluoride and ammonia. Cullet
quench water is required to cool the wasted molten glass and to
quench imperfect lamp envelopes. Quenching practices are similar to
those of other pressed and blown glass plants.
Cullet Quenching-
Non-contact cooling water from batch feeders, melting furnaces,
ribbon machines, and other auxiliary equipment is used as a source
of quench water. Additional waste water is contributed by the
emulsified oil solution that is sprayed on the ribbon machine
blowpipes and bulb molds. The excess of this oil-water emulsion
flows to the cullet quenching area and is discharged with the quench
water. Cullet quenching contributes approximately 57 percent of the
total waste water flow in the typical plant.
Frosting-
Frosting imparts an etched surface inside the lamp envelope that
improves the light diffusing capabilities of the light bulb. The
frosting solution contains hydrofluoric acid, fluoride compounds,
ammonia, and other constituents, but the exact formulation is pro-
prietary. The percentages of lamp envelopes frosted at a given
plant range from 40 to 100 percent.
In the frosting operations, the solution is sprayed on the inside of
the bulb and then removed by several countercurrent water rinses.
High fluoride and ammonia concentrations in the rinse water result
from frosting solution carry-over. Fume scrubbers are required in
the frosting area and contribute significant amounts of fluoride and
ammonia to the frosting waste water. Frosting waste water accounts
for approximately 43 percent of the total flow in a plant where 100
percent of the envelopes are frosted.
60
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RAW (MATERIAL STORAGE
MIXING
COOLING
WATER
I
MELTING
COOLING
WATER
COOLING
WATER
WATER
GULLET
QUENCH
BULB BLOWING
(RIBBON MACHINE)
I
ANNEALING
INSPECTION
I
PACKAGING
SHIPPING
CULLET
WASTE
* WATER
4500 L/METRIC TON
1080 GAL/ TON
57%
WATER
ETCHING PROCESS
(FROSTING)
WASTE
WATER
3420 L/METRIC TON
820 GAL/ JON
43%
FINAL ASSEMBLY
FIGURE 9
INCANDESCENT LAMP GLASS MANUFACTURING
6-1
-------
Water Volume and Character isticg
Gullet quenching waste water and frosting waste water from an incan-
descent lamp envelope manufacturing plant must be classified and
characterized separately because the percentage of bulbs frosted
varies from plant to plant. The discharge from each of these
sources must be added to obtain the total plant discharge. Gullet
quenching waste water is characterized by low concentrations of oil,
suspended solids, and COD, while the frosting waste contains high
concentrations of fluoride and ammonia. Typical waste water volumes
and characteristics are summarized in Table 9.
The typical cullet quenching waste water flow is 4500 I/metric ton
(1080 gal/ton) and the typical frosting waste water flow is 3420
I/metric ton frosted (820 gal/ton frosted) . The flow is variable in
accordance with water conservation practices and the quantity of
once-through cooling water used. Reported combined quenching and
frosting waste water flows range from 5420 I/metric ton pulled (1300
gal/ton pulled) to 8340 I/metric ton pulled (2000 gal/ton pulled) or
570 to 1510 cu m/day (0.15 to 0.4 mgd) .
Suspended Solids-
Suspended solids are generated by cullet quenching and by frosting
of lamp envelopes. Fine glass particles are discharged with the
cullet quench water and a significant concentration of suspended
solids is contributed by the frosting rinse water. The typical
suspended solids produced by cullet quenching is 0.11 kg/metric ton
(0.23 Ib/ton) and by frosting is 0.34 kg/metric ton frosted (0.68
Ib/ton frosted) .
Oil-
Oil is contained in significant concentrations only in the cullet
quench water and results from the residual emulsified oil used to
spray the ribbon machine blowtips and from lubricating oil leaks.
The typical loading is 0.11 kg/metric ton (0.23 Ib/ton).
Fluoride-
Fluoride is contributed to the waste water by the frosting solution
carry-over and the discharge of fume scrubbing equipment. Spent
frosting solution is usually regenerated and reused or disposed of
separately and is not discharged to the waste water stream. The
typical fluoride content of the frosting waste water is 9.6
kg/metric ton (19.2 Ib/ton).
Ammonia-
Ammonia is added to the plant waste water as a result of frosting
solution carry-over and the discharge from fume scrubbing equipment.
62
-------
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Ammonia is one of the major constituents of the frosting solution
and is apparently necessary in order to get the desired frosted
effect. A considerable amount of ammonia vapors are picked up by
the frosting area fume scrubber and then discharged to the waste
water flow. The typical discharge is 2.2 kg/metric ton (4.4
Ib/ton).
Other Parameters-
Some information pertaining to COD, pH, and temperature is also
included in Table 9. The typical COD concentration in both the
cullet quench and frosting waste water streams is only 25 mg/1 and
is not considered significant. The temperature increase during
cullet quenching is similar to that obtained in the other subcate-
gories. Frosting rinse water is heated and the 38°C (100°F)
discharge temperature remains fairly constant.
Discussion-
Lamp glass envelope plants usually operate 24 hrs/day and 5
days/week. Clear bulb production is continuous throughout the week.
The frosting operation is intermittent and is related to consumer
demand. No significant variations in the waste water volume or
characteristics of cullet quench or frosting waste waters are
experienced during plant start-up or shutdown. Fluoride and ammonia
nitrogen discharged at the concentrations typical of the raw waste
water are toxic and must be reduced. The furnaces are drained every
3 to 5 years for rebuilding and require excessive cullet quench
water during the draining period.
HAND PRESSED AND BLOWN GLASS MANUFACTURING
Hand pressed and blown glass manufacturing consists of melting raw
materials and forming the molten glass with hand presses or by hand
blowing to make high quality stemware, tableware, and decorative
glass products. The major process steps and points of water usage
are listed in Figure 10. The hand pressed and blown glass manufac-
turing process is more fully explained in Section III of this
report.
Process Water and Waste Water
Process water and waste water are used almost entirely for finishing
in the hand pressed and blown glass industry. Negligible quantities
of water are used for forming; non-contact cooling water is not
required. There are at least eight finishing steps that may be
employed in the handmade industry. Some plants employ several
finishing steps while others use only one or two. Finishing steps
that require water and produce waste water include: crack-off and
polishing, grinding and polishing, machine cutting, alkali washing,
acid polishing and acid etching. Several handmade plants also have
machine presses. Waste waters resulting from machine forming are
covered in the machine pressed and blown subcategory. Some of the
64
-------
RAW MATERIAL STORAGE
MIXING
WATER
1
MELTING
FORMING
WASTE
WATER
(NEGLIGIBLE VOLUME)
ANNEALING
I
GLAZING
I
ANNEALING
WATER
DECORATING
WATER
WATER
CRACK-OFF
+ WASTE
WATER
9920 L/METRIC TON
2380 GAL/ TON
WASHING
GRINDING
POLISHING
WASTE
WATER
TON
TON
WASTE WATBI
4795 L/M TON
1150 G/ TON
WATER
CUTTING
WATER
ACID
POLISH
WAST
iTE WATER
10880 L/M TON
2610 G/ TON
WAS'
TE WATER
5380 L/M TON
1290 Gf TON
E WATER
36530L/METRIC TON
8760 GAL/
TON
INSPECTION
1
PACKAGING
SHIPPING
T
CONSUMER
FIGURE 10
HAND PRESSED AND BLOWN GLASS MANUFACTURING
65
-------
machine pressed products are finished using the methods covered
under this subcategory.
Data on waste water volumes and characteristics from the hand
pressed and blown glass industry are almost nonexistent. Almost all
of the data presented in this report were collected during the
sampling program.
Forming-
A negligible amount of water is required for quenching and for
partial cooling of the glass during some types of forming. Small
water-filled tanks are used at some plants to collect waste glass
and rejects. Wheelbarrows with no water may be used at other
plants. Some types of glassware are blown in a mold partially
submerged in water. Small tanks, approximately 19 liters (5
gallons) in size, are used. The quench tanks and forming tanks are
drained periodically.
Crack-Off-
Crack-off is required to remove excess glass left over from the hand
blowing of stemware. Crack-off can be done either manually or by
machine. The top portion of the stemware is scribed, the scribed
surface heated, the excess glass removed, and the cut edge ground on
a carborundum or other type abrasive surface. The grinding surface
is sprayed by a continuous stream of water for cooling and to remove
grinding residue. Grinding may be followed by acid polishing to
remove the scratches and is considered part of the crack-off
operation in this presentation. Polishing is accomplished by two
hydrofluoric acid rinses followed by two water rinses. The combined
cutoff and acid polishing waste water flow is 9920 I/metric ton
(2380 gal/ton) .
Grinding and Polishing-
Abrasive grinding and polishing is a common finishing step and may
be used to repair imperfect glassware. Water is required for cool-
ing and lubrication when grinding wheel stones and belt polishers
are used. Abrasive polishing may also be used and involves
mechanical brushing with an abrasive slurry. The residual slurry is
removed in a booth or wash sink. The grinding and polishing flow
rates observed were 3460 I/metric ton (830 gal/ton).
Cutting-
Designs may be cut into tableware or stemware. Water is required
for lubrication and cooling of the cutting surface and to flush away
glass particles. The observed flow from the machine cutting
operation was 10,880 I/metric ton (2610 gal/ton).
66
-------
Aci d Polishing-
Acid polishing is another finishing operation that may be applied to
handmade glassware. This improves the appearance of the glassware
and removes rough edges. The glassware is dipped in hydrofluoric
acid and then rinsed with water. The type of equipment used for
acid polishing ranges from highly automated equipment to hand-dipped
tubs and, consequently, the required volume of water varies. The
observed acid polishing flow for a plant utilizing countercurrent
rinsing was 5380 I/metric ton (1290 gal/ton).
Acid Etching-
Designs are etched onto some stemware. A pattern is stenciled on
tissue paper using a proprietary mixture. The tissue is placed on
the glass and then removed to leave the pattern. All parts of the
ware, except for the pattern, are then coated with a wax mixture.
At this point the glassware is ready for etching. Etching involves
a number of steps including dipping in the etching solutions,
rinsing, wax removal, additional rinsing, treatment with a cleaning
solution, rinsing, nitric acid treatment to remove spots from the
acid carry-over, and final rinsing. The waste waters result from
the various rinsing steps. The acid and cleaning solution tanks are
not drained. The observed flow from this type of system is 36,500
I/metric ton (8760 gal/ton).
Alkali Washing-
Final washing, prior to packing and shipment may be required for
some products. An acid-alkali cleaning system is used for this
purpose in at least one plant. The glassware first passes through
an acid wash and then an alkali rinse followed by several hot water
rinses. The flow from this unit is 4795 I/metric ton (1150
gal/ton).
Miscellaneous Finishing-
Finishing steps that do not involve water or waste water are
employed at many handmade glass plants and are generally referred to
as glazing or decorating. Paint or some other coating is applied to
the glassware and in many cases is baked onto the glass surface by
reannealing.
Miscellaneous Waste Water Sources-
Abrasive mold cleaning is employed at some plants. An abrasive
slurry is sprayed on the molds at high pressure in a process similar
to sandblasting. A small but undefined volume of high-suspended
solids waste is produced. Following cleaning, the molds may be
dipped in a rust preventative solution. This tank is not drained to
the sewer.
Fume scrubbers are required in the acid treatment areas and con-
tribute significant fluoride to the acid polishing and etching waste
waters.
67
-------
Waste Water Volume and Characteristics
Observed waste water characteristics for the finishing steps
described above are listed in Table 10. In all cases, except for pH
and some of the temperatures, the values listed are the quantities
added to the water as a result of the manufacture of hand pressed
and blown glassware. Concentrations in the influent water have been
subtracted.
Flow-
Waste water flows from hand pressed and blown glass manufacturing
plants are highly variable and depend upon the quantity of glass
finished and the finishing method employed. Reported values range
from 0.15 cu m/day (40 gal/day) to 38 cu m/day (10,000 gal/day).
Owing to the variation in finishing methods and the percentage of
product finished, it is impossible to define a typical flow for the
industry.
Suspended Solids-
Grinding, polishing, and cutting are major sources of suspended
solids. Lesser quantities are generated by the other finishing
steps. Machine cutting and grinding and polishing contribute
approximately 28 kg/metric ton (56 Ib/ton) and 15 kg/metric ton (30
Ib/ton) to the waste waters respectively.
Fluoride-
Fluoride discharges result from crack-off and hydrofluoric acid
polishing, hydrofluoric acid polishing, and hydrofluoric acid
etching. Loadings expressed in terms of production vary
significantly from 1.93 kg/metric ton (3.85 Ib/ton) for crack-off
and polishing to 10.6 kg/metric ton (21.3 Ib/ton) for acid
polishing, and 17 kg/metric ton (34 Ib/ton) for acid etching. The
differences are caused, at least in part, by variations in acid
strength. The crack-off polishing solution is much less
concentrated than the acid polishing or acid etching solutions.
Lead-
Lead is contained in all leaded glass finishing waste waters. It is
not clear if the lead in the abrasive waste streams is truly
dissolved or is in the form of small glass particles, but standard
analytical procedures show a significant concentration. Lead in the
acid wastes is assumed to be in a soluble form.
Other Parameters-
Other parameters that may be of significance include pH, tempera-
ture, dissolved solids, and nitrate. Raw waste water pH values vary
significantly depending on the source. No pH value is available for
grinding and polishing but it is assumed the pH will be in the range
68
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heated rinse waters are used. Dissolved solids are not reported,
but significant concentrations may be anticipated in the acid
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Discussion-
Hand pressed and blown glass manufacturing plants generally operate
only one or two shifts per day, five days per week, and finishing is
done only as necessary and varies with product demand. Rarely is
all the finishing equipment available at a given plant in use at the
same time. For these reasons, it is impossible to generalize the
hand pressed and blown industry in terms of a typical plant.
71
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SECTION VI
SELECTION OF POLLUTANT PARAMETERS
Subcategories with the most significant pollution problems in the
pressed and blown glass industry are television picture tube
envelope manufacturing, incandescent lamp envelope manufacturing,
and portions of the hand pressed and blown glass manufacturing
subcategory. The primary sources of the waste water constituents
are cullet quenching, rinsing following abrasive and acid polishing
of television picture tube envelopes, rinsing following frosting of
incandescent lamp envelopes, and rinsing of handmade glassware
following hydrofluoric acid polishing and etching.
The major parameters of pollutional significance for the combined
group of subcategories are:
1. Fluoride
2. Ammonia
3. Lead
U. Oil
5. COD
6. pH
7. Suspended Solids
8. Dissolved Solids
9. Temperature (Heat)
These parameters are not present in the waste water from every
subcategory, and may be of more significance in one subcategory than
in another. Tables 11, 12, and 13 list the concentrations of each
parameter by subcategory. Fluoride, lead, and ammonia discharged at
the levels present in certain waste water streams associated with
the manufacture of television picture tube envelopes, incandescent
lamp envelopes, and some hand pressed and blown ware are known to be
toxic to aquatic life.
FLUORIDE
As the most reactive non-metal, fluorine is never found free in
nature but as a constituent of fluorite or fluorspar, calcium
fluoride, in sedimentary rocks and also of cryolite, sodium aluminum
fluoride, in igneous rocks. Owing to their origin only in certain
types of rocks and only in a few regions, fluorides in high
concentrations are not a common constituent of natural surface
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waters, but they may occur in detrimental concentrations in ground
waters.
Fluorides are used as insecticides, for disinfecting brewery
apparatus, as a flux in the manufacture of steel, for preserving
wood and mucilages, for the manufacture of glass and enamels, in
chemical industries, for water treatment, and for other uses.
Fluorides in sufficient quantity are toxic to humans, with doses of
250 to 450 mg giving severe symptoms or causing death.
There are numerous articles describing the effects of fluoride-
bearing waters on dental enamel of children; these studies lead to
the generalization that water containing less than 0.9 to 1.0 mg/1
of fluoride will seldom cause mottled enamel in children, and for
adults, concentrations less than 3 or 4 mg/1 are not likely to cause
endemic cumulative fluorosis and skeletal effects. Abundant
literature is also available describing the advantages of
maintaining 0.8 to 1.5 mg/1 of fluoride ion in drinking water to aid
in the reduction of dental decay, especially among children.
Chronic fluoride poisoning of livestock has been observed in areas
where water contained 10 to 15 mg/1 fluoride. Concentrations of 30
- 50 mg/1 of fluoride in the total ration of dairy cows is
considered the upper safe limit. Fluoride from waters apparently
does not accumulate in soft tissue to a significant degree and it is
transferred to a very small extent into the milk and to a somewhat
greater degree into eggs. Data for fresh water indicate that
fluorides are toxic to fish at concentrations higher than 1.5 mg/1.
Fluoride is contained at various concentrations in the waste waters
of television picture tube envelope manufacturing, incandescent lamp
envelope manufacturing, and some hand pressed and blown glass
plants. Typical concentrations range from 143 mg/1 for the
television picture tube envelope manufacturing subcategory to 2800
mg/1 for the process waste water stream resulting from the frosting
of incandescent lamp envelopes.
AMMONIA
Ammonia is a common product of the decomposition of organic matter.
Dead and decaying animals and plants along with human and animal
body wastes account for much of the ammonia entering the aquatic
ecosystem. Ammonia exists in its non-ionized form only at higher pH
levels and is the most toxic in this state. The lower the pH, the
more ionized ammonia is formed and its toxicity decreases. Ammonia,
in the presence of dissolved oxygen, is converted to nitrate (NO3)
by nitrifying bacteria. Nitrite (NO2), which is an intermediate
product between ammonia and nitrate, sometimes occurs in quantity
when depressed oxygen conditions permit. Ammonia can exist in
several other chemical combinations including ammonium chloride and
other salts.
77
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Nitrates are considered to be among the poisonous ingredients of
mineralized waters, with potassium nitrate being more poisonous than
sodium nitrate. Excess nitrates cause irritation of the mucous
linings of the gastrointestinal tract and the bladder; the symptoms
are diarrhea and diuresis/ and drinking one liter of water
containing 500 mg/1 of nitrate can cause such symptoms.
Infant methemoglobinemia, a disease characterized by certain
specific blood changes and cyanosis, may be caused by high nitrate
concentrations in the water used for preparing feeding formulae.
While it is still impossible to state precise concentration limits,
it has been widely recommended that water containing more than 10
mg/1 of nitrate nitrogen (NO3-N) should not be used for infants.
Nitrates are also harmful in fermentation processes and can cause
disagreeable tastes in beer. In most natural water the pH range is
such that ammonium ions (NH4+) predominate. In alkaline waters,
however, high concentrations of un-ionized ammonia in undissociated
ammonium hydroxide increase the toxicity of ammonia solutions. In
streams polluted with sewage, up to one half of the nitrogen in the
sewage may be in the form of free ammonia, and sewage may carry up
to 35 mg/1 of total nitrogen. It has been shown that at a level of
1.0 mg/1 un-ionized ammonia, the ability of hemoglobin to combine
with oxygen is impaired and fish may suffocate. Evidence indicates
that ammonia exerts a considerable toxic effect on all aquatic life
within a range of less than 1.0 mg/1 to 25 mg/1, depending on the pH
and dissolved oxygen level present.
Ammonia can add to the problem of eutrophication by supplying
nitrogen through its breakdown products. Some lakes in warmer
climates, and others that are aging quickly are sometimes limited by
the nitrogen available. Any increase will speed up the plant growth
and decay process.
Ammonia is a primary constituent of the raw waste water from the
frosting of incandescent lamp envelopes. The typical ammonia
concentration is 650 mg/1. It is current practice that this waste
is discharged at a very high pH (alkaline). At the high pH, a
considerable amount of ammonia is in the un-ionized. form and as
discussed above can present serious environmental problems. It is
recommended that this discharge must be controlled to ensure
environmental protection.
LEAD
Major concentrations of lead are contributed to television picture
tube envelope manufacturing and handmade glass manufacturing waste
waters from the abrasive polishing of television picture tube
envelopes and the hydrofluoric acid polishing and etching of leaded
handmade glassware. Lead at high concentrations is toxic to aquatic
life. The U.S. Public Health Service Drinking Water Standards
recommend levels of lead in drinking water supplies of not greater
than 0.05 mg/1. Typical raw waste water concentrations are on the
order of 10 mg/1 for handmade plants; concentrations on the order of
78
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30 mg/1 are typical for television picture tube envelope
manufacturing.
OIL
Oil and grease exhibit an oxygen demand. Oil emulsions may adhere
to the gills of fish or coat and destroy algae or other plankton.
Deposition of oil in the bottom sediments can serve to exhibit
normal benthic growths, thus interrupting the aquatic food chain.
Soluble and emulsified material ingested by fish may taint the
flavor of the fish flesh. Water soluble components may exert toxic
action on fish. Floating oil may reduce the re-aeration of the
water surface and in conjunction with emulsified oil may interfere
with photosynthesis. Water insoluble components damage the plumage
and coats of water animals and fowls. Oil and grease in a water can
result in the formation of objectionable surface slicks preventing
the full aesthetic enjoyment of the water.
Oil spills can damage the surface of boats and can destroy the
aesthetic characteristics of beaches and shorelines.
Oil is a constituent of the waste water from all subcategories
except hand pressed and blown glass manufacturing. The typical oil
concentration ranges from 10 mg/1 for glass container manufacturing
to 25 mg/1 for cullet quenching during the manufacture of
incandescent lamp envelopes. The oil is added to waste water as
shear spray oil, by lubricating oil leaks, and by finishing opera-
tions such as oil polishing of television picture tube envelopes.
CHEMICAL OXYGEN DEMAND
COD is contributed by process waste waters from each subcategory.
The COD concentrations range from 10 mg/1 for glass tubing
manufacturing to 50 mg/1 for glass container and machine pressed and
blown glass manufacturing. In most cases the COD is a result of the
oil concentration and can be controlled by limiting the oil.
Because BOD concentrations are low, COD is a more accurate measure
of organic content for pressed and blown glass manufacturing.
PH
The term pH is a logarithmic expression of the concentration of
hydrogen ions. At a pH of 7, the hydrogen and hydroxyl ion
concentrations are essentially equal and the water is neutral.
Lower pH values indicate acidity while higher values indicate
alkalinity. The relationship between pH and acidity or alkalinity
is not necessarily linear or direct.
Waters with a pH below 6.0 are corrosive to water works structures,
distribution lines, and household plumbing fixtures and can thus add
such constituents to drinking water as iron, copper, zinc, cadmium,
and lead. The hydrogen ion concentration can affect the "taste" of
the water. At a low pH water tastes "sour". The bactericidal
effect of chlorine is weakened as the pH increases, and it is
79
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advantageous to keep the pH close to 7. This is very significant
for providing safe drinking water.
Extremes of pH or rapid pH changes can exert stress conditions or
kill aquatic life outright. Dead fish, associated algal blooms, and
foul stenches are aesthetic liabilities of any waterway. Even
moderate changes from "acceptable" criteria limits of pH are
deleterious to some species. The relative toxicity to aquatic life
of many materials is increased by changes in the water pH.
Metalocyanide complexes can increase a thousand-fold in toxicity
with a drop of 1.5 pH units. The availability of many nutrient
substances varies with the alkalinity and acidity. Ammonia is more
lethal with a higher pH.
The lacrimal fluid of the human eye has a pH of approximately 7.0
and a deviation of 0.1 pH unit from the norm may result in eye
irritation for the swimmer. Appreciable irritation will cause
severe pain.
The pH of the waste water from cullet quenching is within the
acceptable range of 6-9. Waste waters produced by rinsing of acid
polished glass and the frosting of incandescent lamp envelopes is
acidic and in the pH range from 2-3. Most plants treat the acidic
waste waters to remove fluoride. Lime is added to a pH level of
about 11-12. Some plants discharge the treated effluent at this
alkaline pH, while other plants use acid to neutralize the treated
effluent back to an acceptable level of about 7.
TOTAL SUSPENDED SOLIDS
Suspended solids include both organic and inorganic materials. The
inorganic components include sand, silt, and clay. The organic
fraction includes such materials as grease, oil, tar, animal and
vegetable fats, various fibers, sawdust, hair, and various materials
from sewers. These solids may settle out rapidly and bottom
deposits are often a mixture of both organic and inorganic solids.
They adversely affect fisheries by covering the bottom of the stream
or lake with a blanket of material that destroys the fish-food
bottom fauna or the spawning ground of fish. Deposits containing
organic materials may deplete bottom oxygen supplies and produce
hydrogen sulfide, carbon dioxide, methane, and other noxious gases.
In raw water sources for domestic use, state and regional agencies
generally specify that suspended solids in streams shall not be
present in sufficient concentration to be objectionable or to
interfere with normal treatment processes. Suspended solids in
water may interfere with many industrial processes, and cause
foaming in boilers, or encrustations on equipment exposed to water,
especially as the temperature rises. Suspended solids are
undesirable in water used in the textile, pulp and paper, beverage,
and dairy products industries and can cause difficulties at
laundries, for dyeing operations, for photographic processes, for
cooling systems, and at power plants. Suspended particles also
80
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serve as a transport mechanism for pesticides and other substances
which are readily sorbed into or onto clay particles.
Solids may be suspended in water for a time, and then settle to the
bed of the stream or lake. These settleable solids discharged with
man's wastes may be inert, slowly biodegradable materials, or
rapidly decomposable substances, while in suspension, they increase
the turbidity of the water, reduce light penetration and impair the
photosynthetic activity of aquatic plants.
Solids in suspension are aesthetically displeasing. When they
settle to form sludge deposits on the stream or lake bed, they are
often much more damaging to the life in water, and they retain the
capacity to displease the senses. Solids, when transformed to
sludge deposits, may do a variety of damaging things, including
blanketing the stream or lake bed and thereby destroying the living
spaces for those benthic organisms that would otherwise occupy the
habitat. When of an organic and therefore decomposable nature,
solids use a portion or all of the dissolved oxygen available in the
area. Organic materials also serve as a seemingly inexhaustible
food source for sludgeworms and associated organisms.
Suspended solids are contributed to the process waste waters from
all subcategories. Typical suspended solids concentrations range
from 25 mg/1 for machine pressed and blown glass manufacturing to
335 mg/1 for television picture tube envelope manufacturing.
DISSOLVED SOLIDS
In natural waters the dissolved solids consist mainly of carbonates,
chlorides, sulfates, phosphates, and possibly nitrates of calcium,
magnesium, sodium, and potassium, with traces of iron, manganese and
other substances.
Many communities in the United States and in other countries use
water supplies containing 2000 to 4000 mg/1 of dissolved salts, when
no better water is available. Such waters are not palatable, may
not quench thirst, and may have a laxative action on new users.
Waters containing more than 4000 mg/1 of total salts are generally
considered unfit for human use, although in hot climates such higher
salt concentrations can be tolerated whereas they could not be in
temperate climates. Waters containing 5000 mg/1 or more are
reported to be bitter and act as bladder and intestinal irritants.
It is generally agreed that the salt concentration of good,
palatable water should not exceed 500 mg/1.
Limiting concentrations of dissolved solids for fresh-water fish may
range from 5,000 to 10,000 mg/1, according to species and prior
acclimatization. Some fish are adapted to living in more saline
waters, and a few species of fresh-water forms have been found in
natural waters with a salt concentration of 15,000 to 20,000 mg/1.
Fish can slowly become acclimatized to higher salinities, but fish
in waters of low salinity cannot survive sudden exposure to high
salinities, such as those resulting from discharges of oil-well
81
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brines. Dissolved solids may influence the toxicity of heavy metals
and organic compounds to fish and other aquatic life, primarily
because of the antagonistic effect of hardness on metals.
Waters with total dissolved solids over 500 mg/1 have decreasing
utility as irrigation water. At 5,000 mg/1 water has little or no
value for irrigation.
Dissolved solids in industrial waters can cause foaming in boilers
and cause interference with cleaness, color, or taste of many
finished products. High contents of dissolved solids also tend to
accelerate corrosion.
Specific conductance is a measure of the capacity of water to convey
an electric current. This property is related to the total
concentration of ionized substances in water and water temperature.
This property is frequently used as a substitute method of quickly
estimating the dissolved solids concentration.
Acid polishing of television picture tube envelopes and handmade
glassware and frosting of incandescent lamp envelopes are the main
sources of the dissolved solids in the raw waste water from plants
within the pressed and blown glass segment. Dissolved solids are
also added to the waste water by the addition of lime for fluoride
removal and the addition of acid for pH control. Dissolved solids
concentrations range from 260 mg/1 for television picture tube
envelope manufacturing to several thousand milligrams per liter for
the process waste water stream from the frosting of incandescent
lamp envelopes. The control and treatment technologies presented in
Section VII of this document do not reduce the level of dissolved
solids discharged. Therefore, no effluent limitations guidelines
are established for this parameter.
TEMPERATURE
Temperature is one of the most important and influential water
quality characteristics. Temperature determines those species that
may be present; it activates the hatching of young, regulates their
activity, and stimulates or suppresses their growth and development;
it attracts, and may kill when the water becomes too hot or becomes
chilled too suddenly. Colder water generally suppresses
development. Warmer water generally accelerates activity and may be
a primary cause of aquatic plant nuisances when other environmental
factors are suitable.
Temperature is a prime regulator of natural processes within the
water environment. It governs physiological functions in organisms
and, acting directly or indirectly in combination with other water
quality constituents, it affects aquatic life with each change.
These effects include chemical reaction rates, enzymatic functions,
molecular movements, and molecular exchanges between membranes
within and between the physiological systems and the organs of an
animal.
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Chemical reaction rates vary with temperature and generally increase
as the temperature is increased. The solubility of gases in water
varies with temperature. Dissolved oxygen is decreased by the decay
or decomposition of dissolved organic substances and the decay rate
increases as the temperature of the water increases reaching a
maximum at about 30°C (86°F) . The temperature of stream water, even
during summer, is below the optimum for pollution-associated
bacteria. Increasing the water temperature increases the bacterial
multiplication rate when the environment is favorable and the food
supply is abundant.
Reproduction cycles may be changed significantly by increased
temperature because this function takes place under restricted
temperature ranges. Spawning may not occur at all because
temperatures are too high. Thus, a fish population may exist in a
heated area only by continued immigration. Disregarding the
decreased reproductive potential, water temperatures need not reach
lethal levels to decimate a species. Temperatures that favor
competitors, predators, parasites, and disease can destroy a species
at levels far below those that are lethal.
Fish food organisms are altered severely when temperatures approach
or exceed 90°F. Predominant algal species change, primary
production is decreased, and bottom associated organisms may be
depleted or altered drastically in numbers and distribution.
Increased water temperatures may cause aquatic plant nuisances when
other environmental factors are favorable.
Synergistic actions of pollutants are more severe at higher water
temperatures. Given amounts of domestic sewage, refinery wastes,
oils, tars, insecticides, detergents, and fertilizers more rapidly
deplete oxygen in water at higher temperatures, and the respective
toxicities are likewise increased.
When water temperatures increase, the predominant algal species may
change from diatoms to green algae, and finally at high temperatures
to blue-green algae, because of species temperature preferentials.
Blue-green algae can cause serious odor problems. The number and
distribution of benthic organisms decreases as water temperatures
increase above 90°F, which is close to the tolerance limit for the
population. This could seriously affect certain fish that depend on
benthic organisms as a food source.
The cost of fish being attracted to heated water in winter months
may be considerable, due to fish mortalities that may result when
the fish return to the cooler water.
Rising temperatures stimulate the decomposition of sludge, formation
of sludge gas, multiplication of saprophytic bacteria and fungi
(particularly in the presence of organic wastes), and the
consumption of oxygen by putrefactive processes, thus affecting the
esthetic value of a water course.
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In general, marine water temperatures do not change as rapidly or
range as widely as those of freshwaters. Marine and estuarine
fishes, therefore, are less tolerant of temperature variation.
Although this limited tolerance is greater in estuarine than in open
water marine species, temperature changes are more important to
those fishes in estuaries and bays than to those in open marine
areas, because of the nursery and replenishment functions of the
estuary that can be adversely affected by extreme temperature
changes.
The significant increases in water temperatures result from cullet
quenching and the heating of rinse waters used in some finishing
steps. Typical temperature increases for cullet quenching are 5.6°C
(1C°F) to 8.4°C (15°F). The absolute temperatures of etching and
alkali washing waste waters range from 33°C (91°F) to 57°C (135°F).
The temperature measurements were taken directly from the process
and are much greater than at the end of the pipe before the
receiving stream. Natural cooling in the sewer and dilution with
non-contact cooling water tend to reduce temperatures to about 5.6°C
(10°F) over ambient. An acceptable temperature discharge limit must
be based upon the volume and the water quality criteria of the
receiving stream. For this reason, no attempt has been made to
propose standards to limit effluent temperatures.
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SECTION VII
CONTROL AND TREATMENT TECHNOLOGY
As concluded in Section VI, the primary pollutants from the pressed
and blown glass industry are oil, fluoride, ammonia, lead, and sus-
pended solids. Oil is contributed to the waste water from all
subcategories except hand pressed and blown glass manufacturing.
Fluoride and lead are added by the finishing steps for television
picture tube envelopes and hand pressed and blown glass. Fluoride
and ammonia are carried over into the waste water following frosting
of incandescent lamp envelopes. Suspended solids are a result of
grinding, acid treatment, and cullet quenching.
The industry is currently treating its waste waters to reduce or
eliminate most of the pollutants. Oil is reduced by using gravity
separators such as belt skimmers and API separators. Treating for
fluoride and lead involves adding lime, rapid mixing, flocculation,
and sedimentation of the resulting reaction products. Several glass
container plants recycle non-contact cooling and cullet quench
water. Treatment for ammonia removal is presently not practiced in
the industry.
This chapter is divided into two sections. The first section is a
general description of the applicable treatment technologies that
will reduce or eliminate the pollutants from pressed and blown glass
manufacturing waste waters. The next section gives a detailed
description of treatment schemes that may be used to meet the
proposed effluent limitations guidelines. The transfer of treatment
technologies from other industries is necessary in some cases.
APPLICABLE TREATMENT TECHNOLOGY
Oil Removal
Oil is usually removed in two steps. In the primary treatment step,
floatable or free oils are removed by gravity separation. The
second step involves breaking any oil-water emulsions and separating
the remaining oil.
Primary Treatment-
Primary treatment makes use of the difference in specific gravity of
oil and water. The oily waste water is retained in a holding basin,
the oil and water being allowed to separate; the separated oil is
skimmed from the waste water surface. The efficiency of the gravity
separators depends upon both the proper holding basin hydraulic
design and the retention time in the basin. Typically, 60 to 90
percent of the influent free oil can be removed with gravity
separation units.
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Secondary Treatment-
Oil emulsions can be broken by either chemical or physical methods.
Physical methods include high rate filtration through sand and
gravel filters, high rate filtration with coagulant, and diatoma-
ceous earth filtration. High rate filter pilot plant studies in the
oil industry using an influent emulsified oil concentration of 230
mg/1 indicated that an effluent concentration of 15 mg/1 can be
achieved with filtration, and a 10 mg/1 effluent level can be
achieved using coagulant-assisted filtration.
Oil-adsorptive diatomaceous earth filtration can be used to reduce
oil and suspended solids effluent concentrations to 5 mg/1. The
diatomaceous earth filtration system consists of the filter, precoat
tank, and a slurry tank for continuous feeding of the diatomaceous
earth. About 0.9 kg (2 Ib) of diatomaceous earth is required per
0.45 kg (1 Ib) of oil removed, and the filtration rates range from
20.4 to 40.7 1/min/sq m (0.5 to 1 gpm/sq ft). Dry discharge
diatomaceous earth filters require no backwashing, and the sludge
requires no dewatering. Diatomaceous earth filtration is being used
to treat the blowdown from at least one cullet quench recycle system
at a glass container plant. Treatment results are similar to those
mentioned above.
Chemical treatment is a primary method used to break oil emulsions
by destabilizing the dispersed oil droplets or destroying the
emulsifying agents. The treatment may consist of chemical addition,
rapid mixing, flocculation, and settling or flotation.
Air flotation can be used to separate the oil and water. This
process consists of adding dissolved oxygen undet high pressure to
part of the waste water. The pressure is suddenly released, forming
thousands of microscopic air bubbles that attach to the oil droplets
and float them to the water surface for skimming and disposal.
Adding coagulants both with and without organic polyelectrolytes
considerably improves the efficiency of the method. Typical
effluent oil concentrations range from 10 to 15 mg/1.
Chemical coagulation and sedimentation can also be used to remove
the oil. In this process, the oil is adsorbed onto the coagulant
floe. Removal efficiencies are similar to those for chemical-
assisted air flotation; however less area is required for the air
flotation equipment. Oil in television picture tube abrasive waste
water is removed in this manner.
Fluoride Removal
The waste waters from pressed and blown glass plants are con-
taminated with fluoride by carry-over into the rinse waters
following hydrofluoric acid treatment. The fluoride is either in
the form of hydrogen fluoride (HF) or fluoride ion (F-), depending
on the pH of the waste water. The high fluoride concentrations in
the waste waters from television picture tube envelope
manufacturing, incandescent lamp envelope frosting, and hydrofluoric
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acid polishing and etching of hand pressed and blown glass must be
reduced to an acceptable level to prevent the toxic action of the
fluoride on aquatic life in the receiving body of water. There are
two methods to treat these waste waters, which may be classified as
the additive and the adsorptive methods.
Additive Methods-
In the additive methods, chemicals are added to the waste water and
the fluoride either forms a precipitate or is adsorbed onto a
precipitate. The fluoride removal efficiencies depend upon the
detention time in, as well as the effectiveness of, the
clarification unit used to separate the precipitate. The chemicals
used include lime and aluminum sulfate, but lime treatment is the
only practical method for treatment of waste waters with high
concentrations of fluoride. The lime is added to the waste water as
slurry, is rapidly mixed, and reacts with the fluoride during floc-
culation to form calcium fluoride. The calcium fluoride precipitate
is then settled out in a clarification unit. Suspended solids are
also removed by the lime treatment process.
Calcium fluoride has a maximum theoretical solubility of about 8
mg/1 as fluoride at a pH of 11 and concentrations above this
theoretical solubility limit form a precipitate. Therefore, the
effluent concentrations can be lowered by adding calcium ion
concentrations in excess of the stoichiometric requirements and also
by maintaining the pH during treatment at a value greater than 11.
Typical treated effluent fluoride concentrations range from 10 mg/1
to 30 mg/1.
The calcium fluoride precipitate formed during reaction with lime
has a very small particle size, and the flocculation and clarifica-
tion steps must therefore be optimized to remove the maximum amount
of fluoride. Factors to be considered include the flocculation
time, clarifier type and detention time, and post-sedimentation
filtration. Longer flocculation periods allow greater agglomeration
of the precipitate particles. Improved separation of the calcium
fluoride precipitate from the water can be accomplished by increas-
ing the clarifier detention time, using a solids contact clarifier,
or recirculating sludge. In a solids contact clarifier, the treated
waste water flows down through a center skirt in the clarifier and
up through a sludge blanket formed at the bottom of the clarifier.
Filtering the clarifier effluent can reduce fluoride concentrations
to about 10 mg/1 by removing additional calcium fluoride particles.
Sand or graded media filters similar to those used in water treat-
ment plants can be used.
High concentrations of aluminum sulfate have also been used to
reduce low fluoride concentrations in soft waters, but this method
is considered both technically and economically unfeasible for the
primary or secondary treatment of high fluoride wastes.
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Adsorptive Methods-
Treatment of fluorides by the adsorptive methods involves passing
the waste water through a contact bed, the fluoride being removed by
general or specific ion-exchange or chemical reaction with a solid-
bed matrix. Adsorptive methods may be used for treating low level
fluoride wastes and polishing the effluent from the lime process.
The requirement for frequent bed regeneration makes the adsorptive
methods economically infeasible for treating high fluoride
concentration wastes. Activated alumina, hydroxylapatite, and ion
exchange resins have been used as the adsorptive media, but
activated alumina has been determined to be the least expensive and
the most suitable for the pressed and blown glass segment.
Activated alumina has been used since the 1950's in municipal water
treatment plants to reduce the fluoride content of ground waters
from 8 mg/1 to 1 mg/1. In laboratory studies, the effluent from a
lime precipitation system treating a high fluoride content waste
(1000-3000 mg/1) was reduced from 30 mg/1 to 2 mg/1, using activated
alumina adsorption. A pH in the alkaline range was found not to
affect the ion exchange operation. The influent waste water should
be filtered before activated alumina adsorption to prevent premature
fouling of the exchange resin and to prevent shortened periods
between regeneration cycles.
An activated alumina filter can be either gravity or pressure oper-
ated. The gravity filter is similar to those used in municipal
water treatment plants, and consists of the activated alumina media,
underdrains, wash troughs, and a regenerant distributor. The pres-
surized column is similar to those used in conventional ion exchange
treatment systems.
Regenerating the activated alumina can be accomplished with a
caustic solution, sulfuric acid, or alum. Caustic regeneration is
being practiced at most water treatment plants. Water and dilute
acid rinses are used to remove residual caustic from the bed
following regeneration. The residual spent caustic regenerant can
be bled into the lime precipitation system to help maintain pH
control.
Ammonia Removal
Ammonia removal methods include air and steam stripping, biological
nitrificationdenitrification, breakpoint chlorination, and selec-
tive ion exchange. Air and steam stripping appear to be the most
viable methods for the incandescent lamp envelope manufacturing sub-
category. A discussion of these treatment techniques follows.
Ammonia Strjpping-
Ammonia exists in solution in two forms, as the ammonium ion, and as
dissolved ammonia gas. The equilibrium may be explained by the
following equation:
-------
NH4 + = H+ + NH3(g)
The reation is pH-dependent with only ammonium ions present at pH 7,
while only dissolved ammonia exists at pH 12; as the temperature
rises the reaction proceeds toward the production of ammonia gas.
At a pH approaching 12, ammonia gas can be removed from solution by
heating the solution and using an inert gas such as air or steam as
a stripping medium.
Steam Stripping-
Many oil refineries, petrochemical plants, and the nitrogen ferti-
lizer industry use steam stripping for ammonia removal. There are
many different stripping designs in existence, but most involve the
downward flow of waste water through a packed or trayed column
countercurrent to an ascending flow of steam. Other stripping media
such as flue or fuel gases are also employed.
Steam stripping is used in the petroleum industry to remove ammonia
from sour water. In columns ranging in size from 1.07 to 1.52 m
(3.5 to 5 ft) in diameter and 5.18 to 9.14 m (17 to 30 ft) in
height, and at temperatures ranging from 110 to 127°C (230 to
260°F), ammonia removal efficiencies range from 86 to 96.4 percent.
Various designs are used including trayed columns with from 6 to 13
plates or packed columns containing 3.66 vertical meters (12
vertical feet) of Raschig-rings. Ammonia concentrations in sour
water range from 1000 to 9800 mg/1 at a pH ranging from 8.0 to 9.25.
It should be noted that sour water strippers are designed for
removing hydrogen sulfide rather than ammonia. The optimum pH range
of ammonia removal is within the range of 10.8 to 11.5 which is
considerably higher than the ranges described above. The removal
efficiencies will greatly increase as the pH is adjusted to within
the optimum range.
Steam stripping in the nitrogen fertilizer manufacturing industry is
used to remove ammonia from process condensate. Packed columns have
yielded effluent ammonia concentrations in the 20 to 30 mg/1 range
at feed rates varying from 7.6 to 10.7 I/sec (120 to 170 gpm). A
typical column might be 0.914 m (3 ft) in diameter and 12.2 m (40
ft) high. stainless steel Pall rings have been used as packing
material. Another system uses a trayed stripping column 1.37 m (4.5
ft) in diameter, and 12.2 m (40 ft) high. The unit will handle 44
I/sec (700 gpm) of feed and produces an ammonia effluent
concentration of less than 5 mg/1.
Air Strippinq-
The ammonia stripping (air) tower is an economical, simple, and
easy-to-control system. The process involves raising the pH of the
waste water stream to within the range of 10.8 to 11.5, the forma-
tion and reformation of water droplets in a packed stripping tower,
and providing maximum air-to-water contact by circulating air
through the tower. Two serious limitations have been encountered
with air strippers: operational problems can occur at ambient air
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temperatures below O°C (32°F), calcium carbonate scaling has
developed, which can cause a loss in treatment efficiency due to a
reduction in the amount of air circulated. The temperature limita-
tion is not a drawback in warm climates. The scaling problem may be
controlled or eliminated through preventive design. Some forms of
scale can be avoided by installing water sprays to wash them away.
Complete accessibility to the tower packing will permit mechanically
scraping the packing. A dilute acid rinse can be used to remove
calcium carbonate scale.
Most research and development of the various air stripping systems
has involved treating raw domestic waste waters. At air-to-liquid
loadings of 3.74 cu m/1 (500 cu ft/gal) and at a pH of 11, one study
reports ammonia removals of 92 percent (from domestic sewage) in a
2.13 m (7 ft) tower packed with 1.27 cm (0.5 in.) Raschig rings
loaded at a rate of 12.2 1/min/sq m (0.3 gpm/sq ft). In a 7.6 m (25
ft) high, 1.83 m (6 ft) wide, and 1.22 m (4 ft) deep tower packed
with redwood slats, ammonia removals of 95 percent (from domestic
sewage) were achieved at a pH of 11.5 and an air-to-liquid loading
of 3.0 cu m/1 (400 cu ft/gal).
A full-scale ammonia stripping tower has been built at South Tahoe
to remove ammonia from domestic sewage. This tower is of cross-flow
design and is equipped with a two-speed reversible 7.32 m (24 ft)
diameter horizontal fan and packed with treated hemlock slats. Its
overall dimensions are 9.75 m (32 ft) by 19.5 m (64 ft) by 14.3 m
(47 ft) high, and the tower is designed to treat 14,200 cu m/day
(3.75 mgd) of water. Treatment efficiencies have been reported to
closely parallel that of the pilot scale tower from which it was
designed, but problems have limited winter-time operation. Ammonia
removal efficiencies on the order of 90 to 95 percent are being
consistently achieved in warm weather operation.
A study of air stripping of ammonia from petroleum refinery waste
waters in the 100 mg/1 range reported ammonia removal efficiencies
of greater than 95 percent at all pH values above 9.0 in a closely
packed aeration tower with an air-to-liquid ratio of 3.59 cu m/1
(480 cu ft/gal) .
Ammonia treatment efficiencies have been reported as being con-
sistently good when the temperature of the waste water being treated
is maintained above 20°C (67°F). However, the colder air and water
temperatures in winter have been observed to have a pronounced
effect on the ammonia stripping efficiency. It was determined that
during winter operating conditions, at an air-to-liquid ratio of
3.59 cu m/1 (480 cu ft/gal) and a loading rate of 81.5 1/min sq m
(2.0 gpm/sq ft), temperature drops of from 8 to 10°C (14-18°F)
occurred when waste water influent was introduced at temperatures in
the 13 to 20°C (55-67°F) range.
All the reported cold air operational problems should be noted as
having been associated with the stripping of ammonia from the
effluent from a domestic sewage treatment plant. This effluent
would be relatively cold during winter operating conditions. The
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effluent from an incandescent lamp envelope manufacturing plant,
however, is at an approximate temperature of 38°C (100°F), even
during winter operating conditions.
It is unclear whether air stripping of ammonia is practicable
technology during winter operating conditions for the incandescent
lamp envelope manufacturing subcategory. Theoretically, the rate at
which ammonia strips is a function of the difference in partial
pressures of the ammonia dissolved in the liquid phase and that of
the gaseous phase. Therefore, at the high ammonia concentrations
experienced in the incandescent lamp envelope manufacturing segment
(approaching 650 mg/1), it is not clear whether the driving force
for ammonia stripping will be sufficiently hindered during cold
weather to render this technology impractical. The ammonia
concentrations experienced in the domestic treatment field are in
the range of 12 to 30 mg/1, and the driving force for stripping is
considerably lower at these concentrations. Whether the 38°C
(100°F) effluent temperatures will be sufficient to overcome the low
air temperatures experienced in northern climates during winter
operations is indeterminable at this time. There is sufficient
justification for further research of the application of this
technique to industrial waste waters. This technology could lead to
an economical and easily operated procedure of ammonia removal.
Selective Ion Exchange-
In recent years, a considerable amount of experimental work has been
done with clinoptilolite, a naturally occurring zeolite that is
selective for the ammonium ion in the presence of calcium and
magnesium. The experimental work has been done primarily with
domestic sewage where typical ammonia removals ranging from 93 to 97
percent were achieved for influent ammonia nitrogen concentrations
of 10 to 20 mg/1. The secondary treated sewage was filtered through
a multimedia filter before ammonia removal to prevent plugging of
the exchange media.
The clinoptilolite can be regenerated by a lime slurry or by an
electrolytic method. A mixture of Nad and Cacl2 in a solution
adjusted to a pH of about 11 with lime is used to regenerate the
clinoptilolite. The spent regenerant can then be air stripped to
remove the ammonia. Scaling can occur in the exchange columns with
the lime slurry regeneration method. The electrolytic method uses a
mixture of calcium, sodium, magnesium, and potassium chlorides for
eluting the ammonia from the beds. The regenerant is then
introduced into an electrolytic cell in which chlorine is produced
and reacts with the ammonia to produce nitrogen gas. The
electrolytic renovation of spent regenerant is economically
competitive with air stripping and does not require atmospheric
disposal of the ammonia.
A high frequency of regeneration and resultant disposal of con-
centrated regenerant will be required at the high ammonia levels
present in the incandescent lamp envelope frosting waste waters.
Further research is required to determine if selective ion exchange
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and regenerant recovery can be feasible as a secondary method for
treating frosting waste waters following primary removal by
stripping.
Nitrification and Denitrification-
Nitrification and denitrification are the most commonly used methods
to remove nitrogen compounds from domestic sewage. In the
nitrification step, aerobic bacteria convert the ammonia nitrogen to
nitrates. The nitrification step is carried out in an aeration
chamber with a longer retention time and lower loading than a
conventional activated sludge unit. The following equations
describe the reactions which occur during the nitrification step:
2NH3 + 302 = 2N02- + 2H+ + 2H20
2ND 2- + 02~ = 2ND 3
The denitrification step converts nitrate to nitrogen gas. Denitri-
fication is an anaerobic process in which anaerobic micro-organisms
break down the nitrates and available carbon into nitrogen gas and
carbon dioxide. An organic source must be added to the second step
to force the denitrification reaction to take place. Methanol has
been found to be the most effective source because it is inex-
pensive, reacts rapidly, and provides for a minimal growth of new
organisms. Typically, about 3 mg of methanol to 1 mg of nitrate
must be added to the waste water. Then, the following reaction
takes place:
6N03- + 5CH30H = 3N2 + 5C02 + 7H20 + 60H-
The above reaction occurs in an enclosed or covered chamber under
anaerobic conditions.
The nitrification and denitrification method of nitrogen removal has
been used primarily to treat municipal waste waters. Pilot plant
work using frosting waste water must be conducted to determine the
feasibility of the method in treating the frosting wastes. Such
factors as the high ammonia levels (650 mg/1), shock loads,
biological upsets, and supplemental chemical addition might preclude
the nitrification-denitrification method as a viable method for
treating frosting waste waters.
Breakpoint Ch 1 or i na t i on-
When chlorine is added to waste water containing ammonia nitrogen,
the ammonia reacts with the chlorine to produce chloramines. The
further addition of chlorine up to a breakpoint results in con-
verting the chloramines to nitrogen oxide which is released as a gas
to the atmosphere. Ammonia nitrogen in domestic sewage can be
reduced to a level of 0.1 mg/1 if adequate mixing, dosing, and pH
control are maintained. The following
-------
NH3 + HOCl = NH2C1 (monochloramine) + H20
NH3 » 2HOC1 = NHC12(dichloramine) + H20~~
NH2C1 + NHC12 + HOCl" = N20 + UHCl
Approximately eight to ten parts of chlorine to one part of ammonia-
N are required to reach the chlorine breakpoint. The high chlorine
dosage results in excessive chemical costs at high ammonia levels in
the waste water. Additional adverse effects of breakpoint
chlorination include high chlorine residuals and mineralization in
the form of chlorides. The high chlorine residuals can be reduced
by carbon contactors before discharge to the receiving body of
water. Breakpoint chlorination, however, will probably not prove
viable for treating frosting wastes because of excessive chemical
costs.
Lead Removal
Lead is contributed by the waste waters from the television picture
tube envelope and hand pressed and blown glass subcategories. The
lead is primarily in the form of particulates removed during
grinding and polishing of lead crystal and the funnel section of
television picture tube envelopes, and soluble lead resulting from
hydrofluoric acid polishing of leaded glass. The primary methods
used to remove lead from waste waters include plain sedimentation,
lime precipitation and sedimentation, and filtration. Suspended
solids are also removed in the lead treatment processes.
Plain sedimentation is relatively effective in removing particulate
lead but not dissolved lead. Improved settling is obtained by pH
adjustment to a neutral pH and by lengthened detention time in the
clarification unit.
The lime precipitation process is the most common method used to
treat dissolved lead wastes. In the lead precipitation process,
lead is precipitated as the carbonate (PbCOS) or the hydroxide
(Pb(OH)2). Conflicting values are given for the optimum pH for
precipitating the lead hydroxide: the suggested pH values range
from 6.0 to 10.0. Improved removal efficiencies can be obtained by
adding ferrous sulfate to the lime precipitation process. Treatment
efficiencies exceeding 95 percent have been achieved with lime
precipitation plus sedimentation both in full scale and pilot plant
operations.
In pilot plant work and in full scale studies at a municipal water
treatment plant, filtering through a dual media filter was shown to
further reduce the lead content following lime precipitation and
sedimentation. Effluent levels were reduced almost an order of
magnitude by sedimentation and filtration rather than by sedi-
mentation only. The additional removals are obtained by removing
poorly settling lead hydroxide particles that are carried over from
the clarification units.
The lead wastes from the pressed and blown glass segment are treated
in conjunction with the fluoride waste waters. The point of
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application of the lead waste varies; at one picture tube envelope
plant the lead wastes are treated by coagulation and then allowed to
settle with the lime treated wastes. At another picture tube plant,
the lime treated fluoride wastes are settled in a primary clarifier
and the lead abrasive wastes are added to the treated fluoride
wastes and settled again. The effluent from the two-stage system
contains about 1 mg/1 of lead. The lead wastes settle readily
because the lead is in the particulate form.
SUGGESTED TREATMENT TECHNOLOGY
As was indicated in the previous section, several treatment tech-
nologies are usually available to reduce a given pollutant para-
meter. This section discusses the application of specific methods
of treatment which may be employed for each subcategory to achieve
the effluent limitations and new source performance standards
recommended in Sections IX, X, and XI. These technologies are not
to be construed as the only means for achieving the stated effluent
levels, but are considered to be feasible methods of treatment based
on available information. The cost estimates developed in Section
VIII are based on these technologies.
Glass Container Manufacturing
As was stated in Section V, waste water results from forming and
cullet quenching in the manufacture of glass containers. In most
plants, these waste waters are combined with non-contact cooling
water prior to discharge, and in some cases a portion of the cooling
water is used for cullet quenching. Oil and suspended solids are
the only significant parameters contained in this waste water. The
quantity of pollutants discharged may be reduced by recycling the
cullet quench water and treating the blowdown using dissolved air
flotation followed by diatomaceous earth filtration as illustrated
in Figure 11.
Existing Treatment and Control (Alternative Aj_-
Both in-plant techniques and end*-of-pipe methods have been employed
to reduce pollutant discharge. Many plants have achieved low
effluent levels with only in-plant methods, and the presence of end-
of-pipe treatment systems has not necessarily assured a high quality
effluent. A number of plants without end-of-pipe treatment are
achieving low discharge levels while several plants with treatment
are discharging at rather high levels.
The typical combined cooling and cullet quench water flow for a
glass container plant is 2920 I/metric ton (700 gal/ton) with 53
percent of the total flow being process water. Suspended solids
discharges of 70 g/metric ton (0.1M Ib/ton) and oil discharges of 30
g/metric ton (0.06 Ib/ton) are presently being achieved by 70
percent of the UO plants for which data are available. These values
correspond to 24 mg/1 for suspended solids and 10 mg/1 for oil at
the typical flow.
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GULLET
WATER-
GULLET QUENCH
GULLET
RETURN TO
GULLET QUENCH
GRAVITY OIL SEPARATOR
SLOWDOWN
DISSOLVED AIR FLOTATION
1
"SLUDGE TO
LAND DISPOSAL
DIATOMACEOUS
EARTH FILTER
-----^SOLIDS TO
LAND DISPOSAL
SURFACE DISCHARGE
FIGURE 11
WASTE WATER TREATMENT
GLASS CONTAINER MANUFACTURING
MACHINE PRESSED AND BLOWN GLASS MANUFACTURING
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These effluent levels should be readily achievable by all plants
with a minimum of in-plant modification or end-of-pipe treatment.
In-plant modifications to reduce pollutant discharge include shear
spray collection of forming machine shop oil, or modified cleanup
procedures. Many plants collect and recycle shear spray. Pans are
placed around the shears to collect as much of the excess spray as
possible. The collected material is filtered and returned to the
shear spray make-up tank. Approximately 70 percent of the shear
spray can be recovered in this manner. In some plants, troughs are
built around the forming machines to collect the oily runoff
resulting from excess lubrication and leaks. The oily waste flows
by gravity to a storage tank and is periodically hauled away for
reclamation or disposal.
It is the practice of many plants to periodically hose down the area
around the forming machines. It may be possible to use a dry
removal method for at least part of the cleanup. One of the oil
adsorptive sweeping compounds might be used and disposed of as solid
waste, thereby eliminating some of the oil discharged into the waste
water system.
End~of-pipe treatment might involve some type of sedimentation
system with oil removal capability. This will serve to reduce
suspended solids and free oil but will not significantly reduce
emulsified oil. Although end-of-pipe treatment systems are
presently being used by some plants, it would appear that in-plant
techniques will be more effective and less expensive to achieve the
suggested effluent levels.
Recycle with Dissolved Air Flotation of Slowdown (Alternative B)-
Effluent levels can be further reduced by segregating the cullet
quench water from the cooling water system, recycling the cullet
quench water through a gravity separator and treating the blowdown
using dissolved air flotation. Suspended solids and oil will build
up in the recirculation system, but the dissolved solids
concentration will probably be limiting. A conservative value of 5
percent blowdown is assumed, based on the operating dissolved solids
level of approximately 1700 mg/1 in an existing recycle system.
Dissolved solids levels of 4000-5000 mg/1 are probably acceptable,
but supportive data are not presently available. A cooling tower is
not considered necessary. Existing recycle systems use only a tank
that serves as the recycling pump wet well and from which oil is
removed using a belt skimmer.
Segregation of the non-contact cooling water and recycle with a 5
percent blowdown will reduce the typical contact water discharge
flow to 77 I/metric ton (18.5 gal/ton). Blowdown from the recycle
system can be treated to 2 g/metric ton (0.004 Ib/ton) using
dissolved air flotation. COD is expected to be reduced in
proportion to the oil removed. The sludge production is
approximately 1900 I/day (500 gal/day) at 3 percent solids
concentration.
96
-------
Several glass container plants are presently recycling cullet quench
water to conserve water, but none are treating the blowdown using
dissolved air flotation. This technology is practiced in the flat
glass industry and should be readily transferable to the pressed and
blown glass industry.
At least one plant has recently begun treating a portion of the
recycling quench water using diatomaceous earth filtration. Long-
term operating data for this system are not available. It is
possible that diatomaceous earth filtration will not be effective
for the high oil concentrations in a recycling system or that
excessive diatomaceous earth usage will be required. For this
reason, the proposed model system includes dissolved air flotation.
Diatomaceous Earth Filtration {Alternative C) -
Diatomaceous earth filtration may be employed to further reduce the
oil and suspended solids in the dissolved air flotation discharge
stream to less than 5 mg/1 or 0.4 g/metric ton (0.0008 Ib/ton) .
Approximately 50 I/day (13 gal/day) of 15 percent solids sludge is
produced. This technology has been commonly employed for steam
condensate treatment and should be readily transferable to the
pressed and blown glass industry. As stated above, at least one
plant is presently employing the diatomaceous earth filtration
technology.
Rather than treat to such a low effluent level, it may be feasible
for a plant to consider complete recycle or discharge of the blow-
down into the batch. Several container manufacturers are investi-
gating this possibility and a number of plants have achieved nearly
complete recycle. More data than was available for this study will
be necessary to evaluate the feasibility of zero discharge through
application of this technique.
Machine Pressed and Blown Glass Manufacturing
Owing to similar manufacturing techniques, waste water resulting
from machine pressing and blowing of glass is similar to glass con-
tainer manufacturing waste water. Oil and suspended solids are the
significant pollutant parameters and their discharge may be reduced
by recycling the cullet quench water and then treating the blowdown
using dissolved air flotation followed by diatomaceous earth
filtration as illustrated in Figure 11.
Existing Treatment and Control ^Alternative A^-
The in-plant and end-of-pipe pollution control methods employed in
the glass container industry are also used for machine pressed and
blown glass manufacturing. The typical combined cooling and cullet
quench waste water flow is 5630 I/metric ton (1350 gal/ton) with 52
precent of the total flow being process water. Suspended solids
discharges of 140 g/metric ton (0.28 Ib/ton), equivalent to 25 mg/1
at the typical flow, are presently being achieved by three of the
nine plants for which data are available. Oil discharges of 60
97
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g/metric ton (0.12 lb/ton) are being achieved by four of six plants.
This corresponds to a concentration of 10 mg/1 at the typical flow.
These effluent levels should be readily achievable by all plants
with a minimum of in-plant modification or end-of-pipe treatment.
Possible methods of treatment are described earlier in the glass
container manufacturing subsection.
Recycle with Dissolved Air Flotation of Slowdown (Alternative BJ_-
Effluent levels can be further reduced by segregating the cullet
quench water from the cooling water system, recycling the cullet
quench water through a gravity separator, and treating the blowdown
using dissolved air flotation. Suspended solids and oil
concentrations will increase in the recirculation system, but the
dissolved solids level will again be limiting. No machine pressed
and blown glass plants are presently recycling cullet quench water,
but the same technology used for container plants should apply.
Using a maximum dissolved solids level of 1700 mg/1, only eight
cycles of concentration are possible as compared to 20 cycles for
container manufacturing. The decrease in allowable cycles results
from the higher dissolved solids increase reported per cycle in the
data with regard to the machine pressed and blown glass
manufacturing subcategory. Eight cycles correspond to a blowdown
rate of 370 I/metric ton (88 gal/ton). Further study by the
industry will probably indicate that substantially higher dissolved
solids levels are acceptable, thereby substantially reducing
blowdown requirements. Effluent concentrations of 25 mg/1 for both
oil and suspended solids can be achieved. This is equivalent to 9
g/metric ton (0.018 lb/ton) at the typical blowdown. Approximately
720 I/day (190 gal/day) of 3 percent sludge is produced.
Diatomaceous Earth Filtration (Alternative C]_-
Diatomaceous earth filtration may be employed to further reduce the
oil and suspended solids in the dissolved air flotation discharge to
less than 5 mg/1. This is equivalent to 1.8 g/metric ton (0.0036
lb/ton). Sludge production is approximately 50 I/day (13 gal/day)
at 15 percent solids. Diatomaceous earth filtration technology is
discussed in more detail earlier in this section.
Glass Tubing Manufacturing
Process waste water in the glass tubing manufacturing subcategory
results from cullet quenching during periods when normal production
has been interrupted. In most plants, cullet quench water is
combined with non-contact cooling water prior to discharge.
Suspended solids is the only significant pollutant in the quench
water along with small quantities of tramp oil. Recycle with
treatment of the blowdown, as illustrated in Figure 12, is a
feasible method of treatment.
98
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GULLET
WATER-
GULLET QUENCH
tGULLET
A
RETURN TO
GULLET QUENCH
\
COOLING TOWER
SLOWDOWN
DIATOMACEOUS
EARTH FILTER
TO
LAND DISPOSAL
SURFACE DISCHARGE
FIGURE 12
WASTE WATER TREATMENT
GLASS TUBING MANUFACTURING
99
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Existing Treatment and Control (Alternative A)-
Owing to the high quality and erratic discharge of cullet quench
water, no plants presently treat this source of waste water. All
four of the plants for which data are available presently achieve a
discharge of less than 225 g/metric ton (0.45 Ib/ton) of suspended
solids, and 85 g/metric ton (0.17 Ib/ton) of oil. This corresponds
to 27 mg/1 of suspended solids and 10 mg/1 of oil at the typical
combined cullet quench water and non-contact cooling water flow of
8340 I/metric ton (2000 gal/ton).
Recycle with Diatomaceous Earth Filtration of Slowdown (Alternative
Bl-
Because cullet quench water accounts for only five percent of the
combined flow, it is possible to further reduce the oil and
suspended solids levels by segregating the cullet quench water from
the non-contact cooling water, recycling the quench water through a
cooling tower, and treating the blowdown using diatomaceous earth
filtration. A flow over the cooling tower of 12.6 I/second (200
gpm) for the typical plant is assumed. Assuming a five percent
blowdown, the discharge will be 21 I/metric ton (5 gal/ton). The
minimum allowable blowdown is unknown because this technology is not
presently employed in the glass tubing industry, but five percent is
considered a conservative estimate. Suspended solids will probably
be limiting because only negligible dissolved solids increases were
noted in the available data. It is anticipated that at least a
portion of the suspended solids can be removed in a glass trap
associated with the collection sump.
It may be possible to use a tank rather than a cooling tower
provided sufficient water can be stored to sufficiently dissipate
the heat in the glass to be quenched. Information to calculate the
required storage volume is not available and, therefore, a cooling
tower is assumed.
Blowdown from the recycling system can be treated at a constant rate
using diatomaceous earth filtration. Approximately 15 I/day (4
gal/day) of 15 percent solids sludge will be produced. Diatomaceous
earth filtration is used to treat boiler condensate and is readily
transferable to the glass tubing manufacturing subcategory. Refer
to earlier portions of this section for more detailed information.
Disposal of the blowdown in the batch is an alternative to treatment
and will allow zero waste water discharge. The typical blowdown is
approximately 1.5 percent by weight of the furnace fill, well within
the range of the three percent of water added when batch wetting is
used.
Television Picture Tube Envelope Manufacturing
Waste waters are produced during both the forming and finishing of
television picture tube envelopes. Cullet quench water contains low
concentrations of oil and suspended solids and does not require
further treatment. Finishing waste water produced by acid and
abrasive polishing of television tube screens and funnels, contains
100
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high concentrations of suspended solids, fluoride, and lead. The
acid and abrasive wastes are presently treated using lime
precipitation, coagulation and sedimentation, but effluent levels
can be further reduced by sand filtration followed by activated
alumina adsorption. These treatments are illustrated in Figure 13.
Existing Treatment and control ^Alternative A).-
Television tube envelope manufacturing plants employ in-plant
methods of water conservation and end-of-pipe treatment for
fluoride, lead, and suspended solids removal. Because many of the
plants have been built within the last 10 years and all within the
last 25 years, relatively good water conservation is practiced.
Abrasive grinding slurries are recycled to recover usable abrasive
material and only the particles too small to be of further value are
discharged. Rinse waters are recycled where possible by using
countercurrent or overflow type rinse tanks. Some final rinses are
once through because a high quality water is required to prevent
spotting. It may be possible to recycle this water for less
critical uses. Spent acid solutions are either bled into the
treatment system at a slow rate or returned to the manufacturer for
recovery and recycling.
All of the plants, for which information was available, treat
abrasive and acid polishing waste waters by lime precipitation
followed by combined coagulation and sedimentation of the calcium
fluoride precipitate and abrasive waste suspended solids. The pH is
reduced where necessary and sulfuric acid is generally used. Vacuum
filtration is the most common method of dewatering, and the sludge
is disposed of as landfill. One plant reports sludge production of
20.9 metric tons/day (23 tons/day). The cullet quench waters are
combined with non-contact cooling water prior to discharge and are
not treated. The typical combined non-contact cooling and cullet
quench water flow is 8080 I/metric ton (1940 gal/ton) and suspended
solids and oil concentrations are below 5 mg/1. When combined with
the treatment plant effluent, the total typical flow is 12,500
I/metric ton (3000 gal/ton).
Effluent levels of 130 g/metric ton (0.25 Ib/ton) for suspended
solids and oil, 65 g/metric ton (0.13 Ib/ton) for fluoride, and 4.5
g/metric ton (0.009 Ib/ton) for lead can be achieved using existing
treatment methods and equipment. These values are equivalent to
concentrations in the treatment plant effluent of 15 mg/1 of
fluoride and 1 mg/1 of lead and concentrations in the combined
treated and cullet quench water streams of 10 mg/1 for oil and
suspended solids. The fluoride and lead concentrations in the
combined flow are 5.2 mg/1 and 0.35 mg/1, respectively. Of the four
television picture tube envelope manufacturing plants for which data
were available, three of the four presently achieve the above dis-
charge level for suspended solids, two of three for oil, three of
four for fluoride, and all meet the discharge level for lead. All
plants can achieve these levels by upgrading the operation of
existing treatment systems and improve housekeeping to minimize
pollutant discharge from the forming area.
101
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WATER
ACID
POLISHING
RETURN TO
PRECIPITATION
T
BACKWASH
WATER
SPENT
REGENERANT
WATER
~
ABRASIVE
POLISHING
WATER
LJ
PRECIPITATION
COAGULATION
SEDIMENTATION
SLUDGE
pH ADJUSTMENT
DEWATER
LAND
DISPOSAL
I
SAND FILTRATION
CAUSTIC REGENERANT
ACTIVATED ALUMINA
FILTRATION
GULLET
GULLET
QUENCH
CULLET
1
SURFACE DISCHARGE
FIGURE 13
WASTE WATER TREATMENT
TELEVISION PICTURE TUBE ENVELOPE MANUFACTURING
102
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Sand Filtration (Alternative B]_-
Fluoride and lead precipitates that are not removed during
sedimentation may be further reduced by filtering the lime treated
effluent using sand or graded media. The filter backwash can be
returned to the head of the lime treatment system and, therefore, no
additional sludge handling equipment is required. Filtration will
reduce the fluoride to 10 mg/1, the lead to 0.1 mg/1 and the
suspended solids to less than 5 mg/1. The total plant discharge,
including the treated effluent and the cullet quench water, will be
reduced to 60 g/metric ton (0.12 Ib/ton) for suspended solids, 45
g/metric ton (0.09 Ib/ton) for fluoride, and .45 g/metric ton
(0.0009 Ib/ton) for lead. The concentration of pollutants in the
total typical plant discharge for this level of treatment will be 5
mg/1 for suspended solids, 10 mg/1 for oil, 3.5 mg/1 for fluoride,
and 0.035 mg/1 for lead.
Filtration of waste water is not presently practiced in the pressed
and blown glass industry, but is a commonly employed treatment
method used in the water treatment industry following lime
softening.
Activated Alumina Filtration (Alternative cj_~
Reduction of fluoride to 2.0 mg/1 can be accomplished by passing the
effluent from the sand filter through a bed of activated alumina.
The activated alumina may be regenerated with sodium hydroxide;
rinsing with sulfuric acid may be necessary to reduce causticity.
The regenerants can be returned to the head of the lime treatment
system for removal of the fluoride. with this technology, the
fluoride discharge will be reduced to 9 g/metric ton (0.018 Ib/ton)
and the concentration of fluoride in the total typical plant
discharge will be 0.71 mg/1.
Activated alumina is not presently used in the pressed and blown
glass segment, but has been successfully used for many years at
several potable water treatment plants in the United States. Ex-
periments have indicated that the higher pH associated with lime
treatment will not adversely affect the fluoride removal capability.
All plants should be able to reduce the average effluent of fluoride
waste waters to 2.0 mg/1 using this technology.
Incandescent Lamp Envelope Manufacturing
Waste waters are produced during both forming and frosting in the
manufacture of incandescent lamp envelopes. Cullet quench waters
contain small quantities of oil and suspended solids, and frosting
waste waters contain moderate concentrations of suspended solids and
high concentrations of fluoride and ammonia. Frosting wastes are
presently treated for fluoride removal, but ammonia removal
techniques are currently not employed. Treatment methods that may
be employed to reduce the level of pollutants discharged by the
incandescent lamp glass industry are illustrated in Figure 14.
103
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WATER ^
RETURN TO
PREQPTTATION
BACKWASH
WATER
SPENT
1 REOENERANT
GULLET
ETCHINa PROCESS
(FROSTING)
1
PRECIPITATION
COAGULATION
SEDIMENTATION
.1 L
t
RECARBONATION
1
HEAT EXCHANGER
isTEAl
STEAM JIRIPPINO
i J"
SAND FILTRATION
»»__ k CUL
WATER p Qoe|
DEWATER *
MSFOSAL
1
1
1 CAUSTIC REOENERANT
ACTIVATED ALUMINA
FILTRATION
B V
1.
_3
L«T krvHiFT
«n r
r
-
'
DUTOMACEOM _^k SOLOS TO
EARTH FILTER ^TLAND DISPOSAL
SURFACE DISCHARGE
FIGURE 14
WASTE WATER TREATMENT
INCANDESCENT LAMP GLASS MANUFACTURING
104
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Existing Treatment and Control (Alternative A}-
Most of the treatment methods presently in use in the incandescent
lamp glass industry can be considered end^of-pipe methods. Gullet
quench waters are discharged untreated or at some plants belt type
oil skimmers are used to skim free oil from pump or discharge sumps.
Frosting waste waters are treated in all cases using lime
precipitation for fluoride and suspended solids removal; however,
this system is ineffective for ammonia removal. Some ammonia
discharge is eliminated by separate disposal of the concentrated
etching solution. At least one plant recovers the salts from this
solution by evaporating most of the water and then allowing the
sludge to air dry. Other plants truck the spent frosting solution
to permanent storage.
The percentage of lamps frosted varies from plant to plant, and
therefore, the cullet quench and frosting waste waters from this
subcategory must be categorized separately. Pollutants discharged
in the cullet quench water as a result of forming will be expressed
in terms of metric tons (tons) pulled from the furnace while the
pollutant parameters contributed by frosting will be expressed in
terms of the metric tons (tons) pulled for the frosting line. This
value is calculated by multiplying the tons pulled by the percent of
the plant output that is frosted. A plant frosting 85 percent of
its production has been assumed for cost estimating purposes and is
presented in Section VIII.
Little information is available on the quality of quench water, but
it is apparent that all plants can achieve a level of 115 g/metric
ton (0.23 Ib/ton) suspended solids and oil. This is equivalent to
25 mg/1 at the typical cullet quench water flow of 4500 I/metric ton
(1080 gal/ton). Plants not presently achieving these levels can
apply many of the methods for improved housekeeping described for
the glass container manufacturing subcategory. Much of the oil and
suspended solids originates in the ribbon machine area. Careful
attention to coolant spray and lubrication techniques should
eliminate excessive oil discharges. It might be necessary, in some
cases, to collect the highly contaminated waste waters that occur
during clean-up for separate disposal or treatment in the lime
treatment system.
Frosting waste waters are treated using lime to precipitate calcium
fluoride, followed by flocculation and sedimentation. The effluent
pH is lowered to at least 9.0 at most plants and neutralization is
considered typical. It is possible, using existing equipment to
treat frosting waste waters to levels of 85 g/metric ton frosted
(0,17 Ib/ton frosted) for suspended solids and 68 g/metric ton
frosted (0.14 Ib/ton frosted) for fluoride. These levels are
equivalent to 25 mg/1, and 20 mg/1, respectively, at the typical
flow of 3420 I/metric ton frosted (820 gal/ton frosted). The
typical concentration of 20 mg/1 is higher than can be achieved with
equivalent treatment technology in the television and handmade
subcategories because of apparent interference by one or more
constituents of the frosting solution. The data indicate con-
105
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sistently higher effluents from incandescent lamp envelope plants
than are obtained in television picture tube envelope plants.
A typical plant that frosts 85 percent of its production would have
a total effluent concentration of 25 mg/1 for suspended solids, 15
mg/1 for oil, 7.8 mg/1 for fluoride, and 260 mg/1 for ammonia. When
the combined forming and frosting waste waters are considered, one
of the five plants for which data are available is presently
achieving the recommended level for suspended solids and oil, two
are achieving the recommended level for fluoride, and no plant
significantly reduces ammonia.
Plants that are not achieving these effluent levels can upgrade
their treatment systems using the methods discussed earlier in the
treatment technology section. It is likely that, in many cases,
excessive fluoride discharge is associated with poor suspended
solids removal. Improvements to optimize suspended solids removal
such as careful control of flocculation, addition of polyelec-
trolytes or other coagulant aids, sludge recycle, and reduced weir
overflow rates may be employed in an existing waste water treatment
plant with a minimum of modification.
Ammonia Removal (Alternative BJ_-
The ammonia in the frosting waste water can be reduced to a more
acceptable level by steam stripping. This and other ammonia removal
technologies are discussed in detail in the treatment technology
section. One possible configuration is recarbonation, followed by a
heat exchanger, and then the stripping column.
Recarbonation will stabilize the excess calcium in the lime
treatment discharge and control pH. Further experimentation will be
required to determine the optimum location of the recarbonation
step. Ammonia removal efficiency increases as the pH increases, but
the calcium may precipitate in the stripping column and heat
exchanger and form calcium carbonate scale. It is probable that a
trade-off exists between ammonia removal efficiency and scaling. It
is possible that recarbonation will be more advantageous subsequent
to steam stripping. Purchased CO.2 is assumed in the cost estimate,
but the melting furnace stack gas is rich in CO2 and should be
considered as a possible source. The heat exchanger will preheat
the water entering the stripper while cooling the water being
discharged, thus minimizing fuel requirements.
A packed or tray type column can be used. It is estimated that one
pound of steam will be required for each gallon of water treated.
Additional plant boiler capacity to meet this requirement is assumed
to be a necessary expense. The waste heat discharged up the melting
tank stack may be a potential source of heat, but this possibility
can only be hypothesized pending further investigation by the
industry. The stripped ammonia vapor discharge may be above the
threshold of odor, in which case it should be vented to the
atmosphere through the melting tank stacks. Refer to Section VIII
for a more detailed discussion of this subject.
106
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Frosting waste water ammonia levels can be reduced from 2.2
kg/metric ton frosted (4.4 Ib/ton frosted) to 0.100 kg/metric ton
frosted (0.20 Ib/ton frosted) using this technology. This
corresponds to an effluent concentration of 30 mg/1 at the typical
flow.
The alternative methods of ammonia removal discussed earlier in this
section should also be carefully investigated before an ammonia
removal system is chosen. Air stripping has been employed with some
success in several domestic sewage treatment plants and may have
potential in the glass industry. Ion-exchange appears to have
potential as a polishing step following air or steam stripping, but
is still in the experimental stage and, therefore, has not been
recommended. Steam stripping is a demonstrated technology and is
presently being successfully used for ammonia removal in both the
petroleum and fertilizer industries.
Sand and Activated Alumina Filtration ^(Alternative C) -
Fluoride in the frosting waste water may be further reduced using
sand filtration followed by activated alumina filtration. It may be
possible for the activated alumina to serve the dual function of
filtering suspended solids and adsorbing fluoride, but this is
doubtful at the anticipated suspended solids loading. Both the
filter backwash and activated alumina regenerants can be returned to
the head of the lime precipitation system for treatment and
disposal. Suspended solids can be reduced to 17 g/metric ton
frosted (0.034 Ib/ton frosted) and fluoride to 7 g/metric ton
frosted (0.014 Ib/ton frosted) using this technology. These
loadings are equivalent to 5 mg/1 and 2 mg/1, respectively, at the
typical frosting waste water flow rate.
This technology is not presently employed in the pressed and blown
glass industry, but has been used for many years for potable water
treatment.
Diatcmaceous Earth Filtration J[Alternative D]_-
The oil and suspended solids in the cullet quench water can be
reduced using diatomaceous earth filtration. The cullet quench
water troughs can be intercepted and the water filtered through an
oil adsorptive diatomaceous earth media. A dry discharge type
filter will produce a sludge cake suitable for landfill. Ap-
proximately 0.54 cu m/day (0.7 cu yd/day) of 15 percent solids
sludge will be produced. With this technology, the oil and
suspended solids concentrations can be reduced to 5 mg/1 or 23
g/metric ton (0.045 Ib/ton). A similar technology is presently
practiced in at least one glass container plant.
Hand Pressed and Blown Glass Manufacturing
Significant sources of waste water in the hand pressed and blown
glass manufacturing subcategory result from finishing operations.
At least six waste water producing processes are presently used in
107
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the industry. These have been classified as crack-off and
hydrofluoric acid polishing, grinding and polishing, machine
cutting, alkali washing, hydrofluoric acid polishing, and
hydrofluoric acid etching. Some plants employ all of the finishing
steps, while others use only one or two, but grinding and polishing
is probably the most frequently used. Owing to the variation in
finishing steps, it is impossible to generalize the industry in
terms of a typical plant.
The waste water constituents requiring treatment are suspended
solids, fluoride, and lead, but all of these are not contained in
each type of waste water. High and low pH values have also been
observed, and neutralization may be required in some cases. Figure
15 illustrates the sequence of treatments that might be employed for
a waste water containing all of these constituents. This type of
treatment system would apply to those plants which employ
hydrofluoric acid finishing techniques to leaded or unleaded glass.
Figure 16 illustrates the sequence of treatments that might be
employed to a waste containing only suspended solids. This system
would be applicable to those plants which produce leaded or unleaded
glass and do not employ hydrofluoric acid finishing techniques.
Very limited data were available from the hand pressed and blown
industry; therefore, the information presented in this subsection is
almost entirely the result of plant visits and field sampling done
as part of this study. Owing to the small size of the companies
within the industry, the low waste water volumes, the lack of
significant quantities of cooling water that could be used for
dilution, and the very limited data available, achievable effluent
levels in the hand pressed and blown glass manufacturing subcategory
are expressed in terms of milligrams per liter (mg/1).
Tables 14 and 15 present a summary of the current operating
practices of the hand pressed and blown glass manufacturing
subcategory. Forty-two plants were contacted with regard to
treatment practices, type of glass produced, and finishing
techniques employed. It should be noted that the majority (69%) of
the plants either discharge to municipal systems or do not dischrage
process waste water. Treatment practices for the remaining 31% of
the subcategory vary from no treatment to sedimentation to batch
lime precipitation.
Plants which employ hydrofluoric acid finishing techniques would
have potential problems with regard to fluoride, suspended solids,
and, in the case of leaded glass production, lead. Plants which do
not employ hydrofluoric acid finishing techniques would have
potential problems with regard to suspended solids. A treatment
system for the removal of lead and fluoride from waste water would
include batch lime precipitation, sand filtration, and ion exchange,
while for removal of suspended solids would include coagulation,
sedimentation, and sand filtration. For this reason, two treatment
schemes are discussed; the first is applicable to those plants which
employ acid finishing techniques to leaded or unleaded glass, while
108
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WATER
FINISHING OPERATIONS
PRECIPITATION
COAGULATION
SEDIMENTATION
SLUDGE
DEBATER
RETURN TO
PRECIPITATION
t
BACKWASH
WATER
SPENT
REGENERANT
RECARBONATION
LAND
DISPOSAL
WATER
SAND FILTRATION
CAUSTIC REGENERANT
ACTIVATED ALUMINA
FILTRATION
\
SURFACE DISCHARGE
FIGURE 15
WASTE WATER TREATMENT
HAND PRESSED AND BLOWN GLASS MANUFACTURING
109
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WATER
RETURN TO
COAGULATION
SEDIMENTATION
BACKWASH
WATER
FINISHING OPERATIONS
f
I
COAGULATION
SEDIMENTATION
WATER
SAND FILTRATION
LAND
DISPOSAL
FIGURE 16
WASTE WATER TREATMENT
HAND PRESSED AND BLOWN GLASS MANUFACTURING
no
-------
TABLE 14
Current Treatment Practices Within the Hand Pressed
and Blown Glass Manufacturing Subcategory
Treatment Practice No. of Plants Percen ta ge of Sybcategory
No Discharge 6 14.3
Treatment with Surface
Discharge 7 16.7
No Treatment with Surface
Discharge 6 14.3
Municipal Discharge 23 54.7
Total in Survey 42 100.0
TABLE 15
Current Operating Practices Within the Hand Pressed
and Blown Glass Manufacturing Subcategory
Type of Glass Produced Finishing Techniques
No. Percentage No. Percentage
Leaded Glass 4 9.5 Employ HF 19 45.3
Non-Leaded Do Not
Glass 38 90.5 Employ HF 23 54.7
42 100.0 ~42TOO
111
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the second is applicable to those plants which do not employ acid
finishing techniques.
Treatment System Applicable to Plants which Employ Hydrofluoric Acid
Finishing Techniques
Treatment and Control jAlternative AJ_-
Very few hand pressed and blown glass plants are presently treating
waste waters; however, a few plants have lime precipitation systems
for fluoride and lead removal. In most cases, flows are low, less
than 38 cu m/day (10,000 gpd) . Significant quantities of pollutants
may be discharged, however, and could have a detrimental effect on a
small receiving stream.
Batch Precipitation and Recarbonation J Alternative B}_-
Fluoride, lead, and suspended solids concentrations can be sig-
nificantly reduced using batch lime precipitation followed by
coagulation, sedimentation, and recarbonation for pH reduction and
calcium stabilization. Using this system, the daily flow of waste
water might be collected in a tank equipped with a stirring
mechanism. At the end of the day, lime and polyelectrolyte would be
added to precipitate fluoride or lead where removal of these
constituents was required. The tank would be slowly stirred for a
sufficient time to allow optimum flocculation and then allowed to
settle overnight^ The following day the supernatant would be
transferred to a second tank for recarbonation and additional
sedimentation, and the sludge would be transferred to a holding tank
where additional thickening would take place before the sludge was
disposed of as landfill or to permanent storage. Acid could be used
in place of recarbonation for pH reduction, but dissolved solids
levels would be increased rather than decreased. The achievable
percent solids in the sludge would depend on the type of material
treated and coagulant used. It is estimated that 10 to 15 percent
solids can be achieved in a lime precipitation system. Effluent
levels of 25 mg/1 for suspended solids, 15 mg/1 for fluoride, and
1.0 mg/1 for lead are achievable using a batch system. At least one
handmade plant is presently using batch lime precipitation, but is
not neutralizing the effluent pH.
Sand Filtration (Alternative CJ.-
Precipitates and other particulates not removed by gravity
separation can be further reduced by sand or graded media fil-
tration. Additional suspended solids, fluoride, and lead can be
removed using this technology. Effluent levels can be reduced to 10
mg/1 for fluoride, 5 mg/1 for suspended solids, and 0.1 mg/1 for
lead. Backwash waters can be returned to the batch treatment system
for further treatment. No hand pressed and blown plants presently
practice this technology, but filtration is widely used in the water
treatment industry.
112
-------
Activated Alumina Filtration (Alternative D)-
Activated alumina filtration is an available technology for further
reducing fluoride concentrations. Following sand filtration, the
waste water may be passed through a bed of activated alumina to
reduce the fluoride concentration to 2 mg/1. Sodium hydroxide may
be used for regeneration and can be returned to the lime
precipitation system for fluoride removal. This technology is not
presently employed in the hand pressed and blown glass industry, but
can be transferred from the water treatment industry.
Treatment System Applicable to Plants Which Do Not Employ
Hydrofluoric Acid Finishing Techniques
Existing Treatment and Control (Alternative A}_ -
Many plants, where grinding and abrasive polishing are done, collect
finishing waste water in trenches with small traps which catch the
gross solids. These are periodically cleaned and disposed of as a
solid waste. In most cases flows are low, less than 11.4 cu m/day
(3000 gpd). The typical flow is 1.89 cu m/day (500 gpd).
Batch Coagulation and S ed intent at ion (Alternative B]_ -
Suspended solids concentrations can be significantly reduced using
batch coagulation and sedimentation. Using this sytem, the daily
flow of waste water might be collected in a tank equipped with a
stirring mechanism. Alum or some other coagulant would be added and
the tank stirred slowly for a sufficient time to allow solids to
settle. The following day the supernatant would be discharged and
the sludge transferred to a holding tank where additional thickening
would take place prior to sludge disposal. An effluent level of 25
mg/1 for suspended solids is achievable using a batch coagulation
and sedimentation system. Many handmade glass plants employ
sedimentation systems for solids control.
Sand Filtration (Alternative CJ_ -
Particulates not removed by gravity separation can be further
reduced by sand or graded media filtration. Additional suspended
solids can be removed to an effluent level of 5 mg/1. Backwash
waters can be returned to the batch treatment system for further
treatment.
113
-------
-------
SECTION VIII
COST, ENERGY, AND NONWATER QUALITY ASPECTS
COST AND REDUCTION BENEFITS OF ALTERNATIVE TREATMENT AND CONTROL
TECHNOLOGIES
Investment and operating costs for the alternative waste water
treatment and control technologies described in Section VII are
presented here.
The cost data include the traditional expenditures for equipment
purchase, installation, and operation and where necessary, solid
waste disposal. No significant production losses due to the in-
stallation of water pollution control equipment are anticipated.
The costs are based on a typical plant for all subcategories except
for hand pressed and blown glass manufacturing, where two
hypothetical plants are presented. It is assumed that one is a
producer of leaded glass to which many finishing steps are applied
including hydrofluoric acid finishing; this represents a maximum raw
waste load discharge and the model treatment system is
representative of any hand pressed and blown glass plant which
employs hydrofluoric acid finishing techniques. The other
hypothetical plant is representative of any hand pressed and blown
glass plant which does not employ hydrofluoric acid finishing
techniques. Owing to wide variations in production methods and
waste water characteristics, it is impossible to define a typical
plant for the handmade industry.
Investment costs include all the equipment, excavations, founda-
tions, buildings, etc., necessary for the pollution control system.
Land costs are not included because the small additional area
required is readily available at existing plants.
Costs have been expressed as August, 1971, dollars and have been
adjusted using the national average Water Quality Office - Sewage
Treatment Plant Cost Index. The cost of capital was assumed to be 8
percent and is based on information collected from several sources
including the Federal Reserve Bank. Depreciation is assumed to be
20 year straight-line or 5 percent of the investment cost.
Operating costs include labor, material, maintenance, etc.,
exclusive of power costs. Energy and power costs are listed sepa-
rately. Six subcategories have been defined in the development
document and costs for a typical plant(s) in each subcategory will
be covered separately.
Container Manufacturing
The typical glass container manufacturing plant may be located in
any part of the country and may be 50 or more years old. The daily
production is approximately 454 metric tons (500 tons). Gullet
quenching and non-contact cooling water are not segregated. Costs
115
-------
and effluent quality for the three treatment alternatives are sum-
marized in Table 16.
Alternative A - Existing Treatment and Control-
Alternative A involves no additional treatment. These effluent
levels are readily achievable by all plants within this subcategory
through normal maintenance and clean-up operations within the plant
and represent the raw waste loadings expected from a glass container
plant. Improved housekeeping techniques may be required at some
plants to achieve the typical effluent levels, while others may
elect to provide end-of-pipe treatment in the form of some type of
sedimentation system with oil removal capabilities. It is felt
however, that in-plant techniques will be a more effective and a
less expensive means of achieving effluent levels.
Costs. No additional cost.
Reduction Benefits. Upgrading of all effluent discharges to
this level.
Alternative B - Recycle with Dissolved Air Flotation of Slowdown-
Alternative B involves segregation of non-contact cooling water from
cullet quench water. The cullet quench water is recycled back to
the cullet quench process through a gravity oil separator, and
blowdown is treated using dissolved air flotation. The blowdown is
5 percent of the total cullet quench water flow.
Costs. Incremental investment costs are $285,000 and total
annual costs are $56,100 over Alternative A.
Reduction Benefits. The incremental reductions of oil and
suspended solids compared to Alternative A are 93 percent and 97
percent, respectively.
Alternative C - Diatomaceous Earth Filtration-
Alternative C provides further treatment of the effluent from
Alternative B by diatomaceous earth filtration.
Costs. Incremental investment costs are $27,000 and total
annual costs are $10,800 over Alternative B.
Reduction Benefits. The incremental reductions of oil and
suspended solids compared to Alternative B are 80 percent.
Total reductions of oil and suspended solids are 98.7 and 99. U
percent, respectively.
Machine Pressed and Blown Glass Manufacturing
The typical machine pressd and blown glass manufacturing plant may
be located in any part of the country and may be 50 or more years
116
-------
TABLE 16
WATER EFFLUENT TREATMENT COSTS
GLASS CONTAINER MANUFACTURING
Alternative Treatment or Control
Investment
Annual Costs :
Capital Costs
Depreciation
Operating and Maintenance Costs
(excluding energy and power costs)
Energy and Pover Costs
Total Annual Cost
Effluent Quality:
Raw
₯aste
Effluent Constituents Load
Flow (l/metric ton) 2920
Oil (g/metric ton) 30
Suspended Solids
Cg/metric ton ) 70
Flow (I/sec) 15.3
Oil (rng/l) 10
Suspended Solids (mg/l) 2H
C$1000)
ABC
0 285 . 312 .
0 22.8 25.
0 lH.3 15. T
0 17-2 23.
0 1.8 3.2
0 56.1 66.9
Resulting Effluent
Levels
2920 77 77
30 2 O.H
70 2 Q.h
15.3 .Hi .H:
10 25 5
2H 25 5
117
-------
old. The daily production is 90.9 metric tons (100 tons). Gullet
quenching and non-contact cooling waters are not segregated. Costs
and effluent quality for three treatment alternatives are summarized
in Table 17.
Alternative A - Existing Treatment and Control-
Alternative A involves no additional treatment. These effluent
levels are readily achievable by all plants within this subcategory
through normal maintenance and clean-up operations within the plant
and represent the raw waste loadings expected from a typical machine
pressed or blown ware plant. Improved housekeeping may be required
at some plants to achieve the typical effluent levels, while others
may elect to provide end-of-pipe treatment in the form of some type
of sedimentation system with oil removal capabilities. It is felt
however, that in-plant techniques will be a more effective and a
less expensive means of achieving these effluent levels.
Costs. No additional cost.
Reduction Benefits. Upgrading of all effluent discharges to
this level.
Alternative B - Recycle with Dissolved Air Flotation of the
Blowdown
Alternative B involves the segregation of non-contact cooling water
from cullet quench water, recirculation of the cullet quench water
following gravity oil separation, and treatment of the 13 percent
cullet quench system blowdown by dissolved air flotation.
Costs. Incremental investment costs are $187,000 and total
annual costs are $41,800 over Alternative A.
Reduction Benefits. The incremental reductions of oil and
suspended solids over Alternative A are 84 percent and 94
percent, respectively.
Alternative C - Diatomaceous Earth Filtration-
Alternative c involves the treatment of the effluent from the
dissolved air flotation unit by employing diatomaceous earth
filtration.
Costs. Incremental investment costs are $27,000 and total
annual costs are $11,400 over Alternative B.
Reduction Benefits. The incremental reduction of oil and
suspended solids compared to Alternative B is 80 percent. Total
reductions are 97 and 98.7 percent, respectively.
118
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TABLE 17
WATER EFFLUENT TREATMENT COSTS
MACHINE PRESSED AND BLOW GLASS MANUFACTURING
Alternative Treatment or Control
Technologies:
Investment
Annual Costs:
Capital Costs
Depreciation
Operating and Maintenance Costs
(excluding energy and power costs)
Energy and Power Costs
Total Annual Cost
C$1000)
A
0
0
0
0
0
0
B
187.
15.
9.U
16.2
1.2
Ul.8
c
^.
17.2
10.8
22.6
2.6
53.2
Effluent Quality:
Effluent Constituents
Flow (l/metric ton)
Oil (g/metric ton)
Suspended Solids
(g/metric ton )
Flow (l/sec)
Oil (mg/1)
Suspended Solids (mg/1)
Raw
Waste
Load
5630
56
iko
5.9
10
25
Resulting Effluent
Levels
5630
56
lUo
5-9
10
25
370
9
9
.39
25
25
370
1.8
1.8
.39
5
5
119
-------
Glass Tubing Manufacturing
The typical glass tubing manufacturing plant may be located in any
part of the country and is at least 10 years old. The daily
production at the plant is approximately 90.9 metric tons (100
tons). Costs and effluent quality for the two treatment
alternatives are summarized in Table 18.
Alternative A - Existing Treatment and Control-
Alternative A involves no additional treatment. There are no plants
at present which treat cullet quench water and all plants for which
data are available achieve these effluent levels.
Costs. No additional costs.
Reduction Benefits. None.
Alternative B - Recycle with Diatomaceous Earth Filtration of
Blowdown-
Alternative B involves the recirculation of the cullet quench water
stream through a cooling tower. The cooling tower blowdown is
treated by diatomaceous earth filtration.
Costs. Incremental investment costs are $97,600 and total
annual costs are $22,700 over Alternative A.
Reduction Benefits. Almost complete oil and suspended solids
removal is obtained.
Television Picture Tube Envelope Manufacturing
The typical television picture tube envelope manufacturing plant can
be located in any part of the country and is at least 10 years old.
The daily production of the plant is 227 metric tons (250 tons).
Costs and effluent quality for the three treatment alternatives are
summarized in Table 19. The effluent values are for the combined
cullet quench and finishing waste water streams.
Alternative A - Existing Treatment and Control-
Alternative A involves no additional treatment. Lime addition,
precipitation, coagulation, sedimentation, and pH adjustment are
presently used throughout the industry for removal of fluoride,
lead, and suspended solids from finishing wastes. Cullet quench
water is not treated.
Costs. No additional cost.
Reduction Benefits. Total reductions of suspended solids,
fluoride, and lead are 97, 96, and 99 percent, respectively.
The waste water pH is adjusted to neutrality.
120
-------
TABLE 18
WATER EFFLUENT TREATMENT COSTS
GLASS TUBING MANUFACTURING
Alternative Treatment or Control
Technologies :
Investment
Annual Costs :
Capital Costs
Depreciation
Operating and Maintenance Costs
(excluding energy and power costs)
Energy and Power Costs
Total Annual Cost
Effluent Quality:
Effluent Constituents
Flow (l/metric ton)
Oil (g/metric ton)
Suspended Solids
(g/metric ton)
Flow (l/sec)
Oil (mg/1)
Suspended Solids (mg/l)
Raw
Waste
Load
83^0
80
230
8.8
10
27
($1000)
A B
0 97-6
0 7.8
0 4.9
0 9-7
0 0.3
0 22.7
Resulting Effluent
Levels
83^0 21
80 0.1
230 0.1
8.8 .022
10 5
27 5
121
-------
TABLE 19
₯ATER EFFLUENT TREATMENT COSTS
TELEVISION PICTURE TUBE ENVELOPE MANUFACTURING
Alternative Treatment or Control
Technologies:
Investment
Annual Costs:
Capital Costs
Depreciation
Operating and Maintenance Costs
(excluding energy and power costs]
Energy and Power Costs
Total Annual Cost
Effluent Quality:
($1000)
B
6T.O
231
0 5-^
0 3.4
0 8.7
0 0.9
0 15.4
18. 5
11.6
37
1
68.1
Effluent Constituents
Flow (l/metric ton )
Oil (g/metric ton)
Suspended Solids
(g/metric ton)
Fluoride (g/metric ton)
Lead (g/metric ton)
Flow (l/sec)
Oil (mg/1)
Suspended Solids (mg/l)
Fluoride (mg/l)
Lead (mg/l )
Raw
₯aste
Load
12,500
130
1+200
1800
390
33
10
335
143
30
Resulting Effluent
Levels
12,500
130
130
65
4.5
33
10
10
5.2
0.35
12,500 12
130
60
45
0.45
33
10
5
3.5
.035
,500
130
60
9
0.45
33
10
5
0.71
.035
122
-------
Alternative B - Sand Filtration-
Alternative B includes sand filtration of the effluent from the lime
precipitation system of Alternative A. Filter backwash water is
recycled back to the lime precipitation system.
Costs. Incremental investment costs are
annual costs are $15,400 over Alternative A.
$67,000 and total
Reduction Benefits. The incremental reductions of suspended
solids, fluoride, and lead over Alternative A are 54, 31, and 90
percent, respectively. Total reductions of suspended solids,
fluoride, and lead are 98.6, 97.5, and 99.9 percent,
respectively.
Alternative C - Activated Alumina Filtration-
Alternative C involves the activated alumina filtration of the
effluent from Alternative B. Spent caustic regenerant is recycled
back to the lime precipitation system.
Costs. Incremental investment costs are $164,000 and total
annual costs are $52,700 over Alternative B.
Reduction Benefits. The incremental reduction of fluoride over
Alternative B is 80 percent. Total reductions of suspended
solids, fluoride, and lead are 98.6, 99.5, and 99.9 percent,
respectively.
Incandescent Lamp Glass Manufacturing
The typical incandescent lamp glass manufacturing plant may be
located in any part of the country and is at least 50 years old.
Daily production is 159 metric tons (175 tons). Frosted envelopes
account for eighty-five percent of the plant production, and clear
envelopes make up the remainder of the plant production. Cost and
effluent quality for the four treatment alternatives are summarized
in Table 20. Effluent characteristics are given for the combined
cullet quench and frosting waste water flows.
Alternative A - Existing Treatment and Control-
Alternative A involves no additional treatment. Lime addition,
coagulation, precipitation, and sedimentation are presently used
throughout the industry for removal of fluoride and suspended solids
from frosting wastes. Oil skimmers are employed for oil removal
from cullet quench water. Some plants may have to improve
housekeeping techniques to meet these effluent levels.
Costs. No additional costs.
Reduction Benefits. Total reductions of suspended solids and
fluoride are 56 and 99.3 percent, respectively.
123
-------
TABLE 20
WATER EFFLUENT TREATMENT COSTS
INCANDESCENT LAMP ENVELOPE MANUFACTURING
Alternative Treatment or Control
Technologies:
Investment
Annual Cost:
Capital Costs
Depreciation
Operating & Maintenance Costs
(excluding energy & power costs)
Energy & Power Costs
Total Annual Costs
Effluent Quality:
Effluent Constituents
Flow(l /metric ton formed)
(1 /metric ton frosted)
Oil (g/metric ton formed)
Suspended Solids
(g/metric ton formed)
(g/metric ton frosted)
Fluoride (g/metric ton)
Ammonia (g/metric ton)
Flow (I/sec)
Oil (mg/1)
Suspended Solids (mg/1)
Fluoride (mg/1)
Ammonia (mg/1)
Raw
Waste
Load
4500
3420
115
115
340
9600
2200
13.7
15
54
mo
260
A
0
0
0
0
0
0
B
470
37.
23.
63
116
240
($1000)
C
624
6 49.9
5 31.2
81.6
116.5
279
D
697
55.
34.
90.
118.
300
7
8
9
4
Resulting Effluent
Levels
4500
3420
115
115
85
68
2200
13.7
15
25
8
260
4500
3420
115
115
85
68
100
13.7
15
25
8
12
4500
3420
115
115
17
7
100
13.7
15
17
1
12
4500
3420
23
23
17
7
100
13.7
3
5
1
12
124
-------
Alternative B - Ammonia Removal-
Alternative B involves ammonia removal by steam stripping of the
effluent from Alternative A. This alternative also includes
recarbonation and a heat exchanger. Recarbonation may be required
for pH adjustment and also to prevent scaling in the stripping unit.
A heat exchanger is used in conjunction with the steam stripping
unit to maximize the efficiency of stripping and to reduce the dis-
charge temperature of the treated waste water.
Costs. Incremental investment costs are $470,000 and total
annual costs are $240,000 over Alternative A.
Reduction Benefits. The incremental reduction of ammonia
compared to Alternative A is 95 percent. The treated waste
water pH is adjusted to 9.0. Oil, suspended solids, and
fluoride remain at the levels achieved in Alternative A.
Alternative C - Sand and Activated Alumina Filtration-
This alternative includes sand filtration of the effluent from
Alternative B. Following sand filtration, the waste water is passed
through a bed of activated alumina to reduce the remaining fluoride
in the waste water.
Costs. Incremental investment costs are $154,000 and total
annual costs are $39,000 over Alternative B.
Reduction Benefits. Incremental reductions are 90 percent for
fluoride and 34 percent for suspended solids. Total reductions
of fluoride and suspended solids are 99.9 and 71 percent,
respectively.
Alternative D - Diatomaceous Earth Filtration-
Alternative D employs diatomaceous earth filtration of the cullet
quench water. The frosting waste waters are not treated above the
level of Alternative C.
Costs. Incremental investment costs are $73,000 and total
annual costs are $21,000 over Alternative C.
Reduction Benefits. Incremental reductions are 70 percent for
suspended solids and 80 percent for oil. Total reductions of
oil, suspended solids, fluoride, and ammonia are 80, 91, 99.9,
and 95 percent, respectively.
Hand Pressed and Blown Glass Manufacturing
No typical plant can be developed for the hand pressed and blown
glass manufacturing subcategory because of the wide variation in
finishing steps applied to the handmade glass. The hypothetical
plants assumed for cost estimating purposes may be located in any
part of the country and are at least 50 years old. The first plant
is one of the largest in the country and has a daily finished
product output of 5.9 metric tons (6.5 tons). The plant employs all
125
-------
the finishing steps available at handmade glass plants and is
representative of those plants which produce leaded or unleaded
glass and employ hydrofluoric acid finishing techniques. The second
hypothetical plant is representative of those handmade glass plants
which produce leaded or unleaded glass and do not employ
hydrofluoric acid finishing techniques. The cost and effluent
quality for the treatment alternatives applicable to each
hypothetical plant are listed in Tables 21 and 22.
Treatment System Applicable to Plants Which EmpJ.oy, Hydrofluoric Acid
Finishing Techniques
Alternative A - Existing Treatment and Control-
Alternative A is no waste water treatment or control. Many plants
do not need waste water treatment or control because of the absence
of waste-producing finishing steps or because of the low volume of
discharge. Some plants have lime precipitation treatment facilities
for the reduction of fluoride from hydrofluoric acid polishing and
acid etching wastes. It is felt that for any plant discharging less
than 0.19 cu m/day (50 gallons/day) of waste water, treatment is
impractical as other means of disposal are considerably less
expensive (i.e., land retention or dust suppression).
Costs. None.
Reduction Benefits. None.
Alternative B - Batch Precipitation and Recarbonation-
This alternative includes a batch lime precipitation system for
reduction of suspended solids, fluoride, and lead from finishing
waste waters. The lime precipitation system effluent is recar-
bonated with carbon dioxide gas to adjust the treated waste water to
a neutral pH from the alkaline pH of the lime treatment process.
Costs. Incremental investment costs are $284,000 and total
annual costs are $55,100 over Alternative A.
Reduction Benefits. Total reductions of suspended solids,
fluoride, and lead are 95, 96, and 91 percent, respectively.
The pH of the acidic waste is raised to an alkaline pH of 11-12
during lime treatment and then is lowered to a pH of 9 by
recarbonation.
Alternative C - Sand Filtration-
Alternative C involves the sand filtration of the effluent from
Alternative B. The sand filtration system is similar to those
employed at municipal water treatment works.
Costs. Incremental investment costs are $41,000 and total
annual costs are $8400 over Alternative B.
126
-------
TABLE 21
WATER EFFLUENT TREATMENT COSTS
HAND PRESSED AND BLOWN GLASS MANUFACTURING
Alternative Treatment or Control
Technologies:
A
B
($1000)
C
Investment
Annual Costs:
Capital Costs
Depreciation
Operating and Maintenance Costs
(excluding energy and power costs) 0
Energy and Pover Costs
Total Annual Cost
Effluent Quality:
281*
325
D
371
0
0
0
0
0
22.7
lU.2
15-6
2.6
55-1
26.0
16.2
18.6
2.7
63.5
29-7
18.5
21. U
2.7
72.3
Effluent Constituents
Flow (l/sec)
pH (mg/l)
Suspended Solids (mg/l)
Fluoride (mg/l)
Lead (mg/l)
Raw
Waste
Load
0.6l 0.6l
2 2
51*1* 5l*l*
1*22 1*22
11.1* 11.1*
Resulting Effluent
Levels
0.6l
9
25
15
1
0.6l
9
5
10
0.1
0.61
9
5
2
0.1
127
-------
TABLE 22
WATER EFFLUENT TREATMENT COSTS
HAND PRESSED AND BLOWN GLASS MANUFACTURING
SUSPENDED SOLIDS REMOVAL
Alternative Treatment or Control
Investment
Annual Costs:
Capital Costs
Depreciation
Operating & Maintenance Costs
(excluding energy & power costs)
Energy and Power Costs
TOTAL ANNUAL COST
Effluent Quality:
Effluent Raw Waste
Constituents Load
Flow ~ cu m/day 1 .89
Suspended Solids(mg/l) 9600
A
0
0
0
0
0
0
1.89
9600
($1000)
B
48.7
3.9
2.4
5.3
0.3
11.9
Resulting Effluent
Levels
1.89
25
C
54.3
4.3
2.7
8.0
0.3
15.3
1.89
5
128
-------
Reduction Benefits. Incremental reductions over Alternative B
for suspended solids, fluoride, and lead are 80, 33, and 90
percent, respectively. Total reductions are 99.1 percent for
suspended solids and lead, and 98 percent for fluoride. The
waste water pH is adjusted to 9.
Alternative D - Activated Alumina Filtration-
This alternative includes activated alumina filtration of the
effluent from Alternative C. Activated alumina filtration is
employed for further reduction of the effluent fluoride concen-
tration.
Costs. Incremental investment costs are $46,000 and total
annual costs are $8800 over Alternative C.
Reduction Benefits. The incremental reduction of fluoride is 80
percent over Alternative C. Total reductions of suspended
solids, fluoride, and lead are 99.1, 99.5, and 99.1 percent,
respectively.
Treatment System Applicable to Plants Which Do Not Employ
Hydrofluoric Acid Finishing Techniques
Alternative A - Existing Treatment and Control -
Alternative A involves no waste water treatment or control. Many
plants do not need waste water treatment or control because of the
absence of waste-producing finishing steps or because of the low
volume of discharge. Many plants employ some type of sedimentation
system for solids control. It is felt that for any plant
discharging less than 0.19 cu m/day (50 gallons/day) of waste water,
treatment is impractical as other means of disposal are considerably
less expensive (i.e., land retention or dust suppression).
The raw waste water suspended solids expressed in terms of grams
(pounds) per production unit or concentration is impossible to
typify, owing to the wide range of production methods employed in
the subcategory. Approximately 9600 mg/1 was assumed for
calculating sludge production, but the influent suspended solids
concentration is not directly related to treatment costs. The
typical flow is 1.89 cu m/day (500 gpd).
Costs. None.
Reduction Benefits. None.
Alternative B - Batch Coagulation and Sedimentation -
The daily waste water discharge is collected in one of two mixing
tanks (one tank is treated and discharged while the other is
filling). At the end of the day coagulants are added, and the
mixture is flocculated. The treated waste water is discharged
129
-------
following overnight sedimentation. Sludge is collected in a holding
tank and eventually discharged as landfill.
Costs. Incremental investment costs are $48,700 and total
annual costs are $11,900 over Alternative A.
Reduction Benefits. Suspended solids reduced to 25 mg/1.
Alternative C - Sand Filtration -
Discharge from Alternative B is passed through sand filters for
additional suspended solids reduction. Filter backwash is returned
to the head of the system.
Costs. Incremental investment costs are $5600 and total annual
costs are $3400 over Alternative B.
Reduction Benefits. Suspendes solids reduced to 5 mg/1.
BASIS OF TOTAL INDUSTRY COST ESTIMATES
The effluent limitations guidelines presented in this document
pertain to surface dischargers and therefore, only surface
dischargers are considered impacted by the recommended guidelines.
There are: (a) 55 known glass container, (b) 23 known machine
pressed and blown glass, (c) 9 known glass tubing, (d) 4 known
television picture tube envelope, (e) 3 known incandescent lamp
envelope, and (f) 13 known hand pressed and blown glass
manufacturing surface dischargers. This estimate is based on RAPP
applications, industry supplied data, and a survey of the pressed
and blown glass segment. Tables 23 through 28 list the known
surface dischargers for each subcategory of the pressed and blown
glass segment of the glass manufacturing category.
ENERGY REQUIREMENTS OF TREATMENT AND CONTROL TECHNOLOGIES
Large quantities of energy are used in the pressed and blown glass
industry to produce the high temperatures required for glass melting
and annealing. Approximately 1,670,000 kilogram-calories/metric ton
(6,000,000 BTU/ton) are required to melt the raw materials for the
manufacture of glass containers. This energy requirement is
considered typical for the pressed and blown glass industry. The
additional energy required to implement the treatment technologies
is less than 1 percent of the process requirements for each of the
subcategories with the exception of the incandescent lamp envelope
manufacturing subcategory. The treatment alternatives requiring
relatively little additional energy include: cullet quench recycle
systems, the lime precipitation process, and sand or activated
alumina filtration. The energy requirements for these systems range
from 124,000 to 537,000 kilogram-calories/day (492,000 to 2,130,000
BTU/day).
130
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TABLE 23
KNOWN SURFACE DISCHARGERS
GLASS CONTAINER MANUFACTURING SUBCATEGORY
Company No. of Plants
Anchor Hocking Corporation 7
Ball Corporation 1
Brockway Glass Company, Inc. 11
Chattanooga Glass Company 3
Diamond Glass Company 1
Foster-Forbes Glass Company 1
Gayner Glass Works 1
Glass Containers Corporation 7
Glenshaw Glass Company 2
Indian Head, Inc. 2
Kerr Glass Manufacturing Corporation 2
Laurens Glass Company 1
Maryland Glass Corporation 1
Midland Glass Company 1
Obear-Nester Glass Company 1
Owens-Illinois 8
Puerto Rico Glass Corporation 1
Star City Glass Company 1
Thatcher Glass Manufacturing Company 2
Universal Glass Products Company 1
TOTAL 55
131
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TABLE 24
KNOWN SURFACE DISCHARGERS
MACHINE PRESSED AND BLOWN GLASS MANUFACTURING
SUBCATEGORY
Company
Anchor Hocking Corporation
Corning Glass Works
Federal Glass Company
General Electri c-Mahoning
Mid-Atlantic Glass Company
Owens-Illinois
L.E. Smith Glass Company
No. of Plants
3
14
1
1
1
2
1
TOTAL
23
TABLE 25
KNOWN SURFACE DISCHARGERS
GLASS TUBING MANUFACTURING SUBCATEGORY
Company
Corning Glass Works
General Electric Company
GTE - Sylvania, Inc.
RCA
Westinghouse Electric Corporation
No. of Plants
2
4
1
1
1
TOTAL
TABLE 26
KNOWN SURFACE DISCHARGERS
TELEVISION PICTURE TUBE ENVELOPE MANUFACTURING SUBCATEGORY
Company
Corning Glass Works
Owens-Illinois
TOTAL
No. of Plants
2
2
4
132
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TABLE 27
KNOWN SURFACE DISCHARGERS
INCANDESCENT LAMP ENVELOPE MANUFACTURING
SUBCATEGORY
Company No. of Plants
Corning Glass Works 2
General Electric Company 1
TOTAL 3
TABLE 28
KNOWN SURFACE DISCHARGERS
HAND PRESSED AND BLOWN GLASS MANUFACTURING
SUBCATEGORY
Company No. of Plants
Blenko Glass Company 1
Colonial Glass Company 1
Davis-Lynch Glass Company 1
Fenton Art Glass Company 1
Fostoria Gla-ss Company 1
Gil lender Brothers, Incorporated 1
Imperial Glass Corporation 1
Kanahwa Glass Company 1
Lewis County Glass Company 1
Pennsboro Glass Company 1
Pilgrim Glass Corporation 1
Wheaton Industries 1
West Virginia Glass Specialty Company 1
TOTAL 13
133
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Steam stripping of incandescent lamp envelope frosting waste waters
for ammonia removal will require the greatest energy requirement of
the proposed treatment alternatives. Steam stripping of the typical
flow will require approximately 46,600,000 kilogram-calories/day
(185,000,000 BTU/day) and is equivalent to 7870 liters/day (2080
gallons/day) of No. 2 fuel oil. This energy requirement is about 8
percent of that required for the total manufacturing process.
Industry supplied data indicate that approximately 605,000,000
kilogram-calories/day (2,400,000,000 BTU/day) of energy per plant
are required in the total incandescent lamp envelope manufacturing
process. The energy requirement for steam stripping is not
excessive, when compared to the total energy consumed in the
manufacturing process. It may be feasible to use melting tank stack
gas as a source of heat, thereby eliminating the necessity for
additional fuel, but further investigation is necessary to determine
the practicability of such a system.
NON-WATER QUALITY ASPECTS OF TREATMENT AND CONTROL TECHNOLOGIES
Air Pollution
The incandescent lamp envelope manufacturing subcategory is the only
subcategory that may pose an air pollution problem. Ammonia removal
by steam stripping is recommended for control of high ammonia
discharges from the frosting waste stream. It is possible that the
steam and ammonia gas from the stripping unit could be vented to the
atmosphere through the furnace exhaust stack. The ammonia
concentration of the combined stack discharge is not expected to
exceed 35 mg/cu m (46 ppmv), which is the threshold odor limit for
ammonia. Because the ammonia concentration will be below the
threshold odor level, steam stripping should not cause a significant
air pollution problem.
There are no significant air or noise pollution problems directly
associated with the treatment and control technologies of the other
subcategories. The waste waters and sludges are odorless and no
nuisance conditions result from their treatment or handling.
Solid Waste Disposal
Three types of waste solids are produced by the treatment systems
developed for the pressed and blown glass industry. These are: (1)
gravity oil separator and dissolved air flotation skimmings, (2)
spent diatomaceous earth, and (3) lime precipitation sludges
associated with fluoride waste water treatment.
The skimmings and spent diatomaceous earth result from the treatment
of cullet quench waste waters. The skimmings have a three percent
solids content and the production of skimmings ranges from 21.4 to
49.1 kg/day (47 to 108 Ib/day) or 720 to 1630 I/day (190 to 430
gal/day). The oily skimmings can be disposed of by an oil
reclamation firm, used as road oil, or can be incinerated.
134
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Spent diatomaceous earth has an estimated moisture content of 85
percent, but does not flow. This material is stable and should be
suitable for landfill. Estimated production of diatomaceous earth
waste ranges from 0.042 to 0.53 cu m/day (1.5 to 19 cu ft/day). The
lower figure results from the treatment of the blowdown for the
cullet quench system and the higher figure is the result of treating
the entire cullet quench waste water stream at an incandescent lamp
envelope plant.
The lime precipitation process for fluoride removal produces the
largest volume and most difficult sludge to handle. Vacuum
filtration is used at almost all plants to reduce the sludge volume.
The volume of sludge production ranges from 277 kg/day (610 Ibs/day)
for a handmade glass plant to 20.9 metric ton/day (23 tons/day) at a
television picture tube envelope manufacturing plant. The
television picture tube envelope manufacturing plant is treating a
combination of abrasive grinding wastes and fluoride containing
rinse waters.
Most lime precipitation sludge is currently disposed of as landfill.
Several attempts have been made to convert the sludge into a salable
material, but no markets have been found for these products.
Currently, further research is being conducted to develop a saleable
by-product from the sludge.
135
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SECTION IX
EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION OF
THE BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE
EFFLUENT LIMITATIONS GUIDELINES
INTRODUCTION
The effluent limitations that must be achieved by July 1, 1977, are
to specify the degree of effluent reduction attainable through the
application of the best practicable control technology currently
available. Best practicable control technology currently available
is generally based upon the average of the best existing performance
by plants of various sizes, ages, and unit processes within the
industrial category or subcategory.
Consideration must also be given to:
a. The total cost of application of technology in relation
to the effluent reduction benefits to be achieved from
such application;
b. the size and age of equipment and facilities involved;
c. the processes employed;
d. the engineering aspects of the application of various
types of control techniques;
e. process changes;
f. non-water quality environmental impact (including energy
requirements).
Also, best practicable control technology currently available
emphasizes treatment facilities at the end of a manufacturing
process, but also includes the control technologies within the
process itself when the latter are considered to be normal practice
within the industry.
A further consideration is the degree of economic and engineering
reliability that must be established for the technology to be "cur-
rently available". As a result of demonstration projects, pilot
plants, and general use, there must exist a high degree of con-
fidence in the engineering and economic practicability of the
technology at the time of commencement of construction or instal-
lation of the control facilities.
IDENTIFICATION OF THE BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
AVAILABLE
Current treatment practices as well as additional end-of-pipe treat-
ment techniques constitute the best practicable control technology
currently available. The best practicable control technology cur-
rently available for the subcategories of the pressed and blown
glass segment is summarized below. Recommended effluent limitations
are summarized in Table 29. These limitations are monthly averages
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TABLE 29
RECOMMENDED MONTHLY AVERAGE EFFLUENT LIMITATIONS USING
BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE
Suspended
Solids Oil Fluoride Lead Ammonia pH
Glass Containers
g/metric ton 70 30 - - - 6-9
(Ib/ton) 0.14 0.06 - - -
Machine Pressed and
Blown Glass
g/metric ton 140 56 - - - 6-9
(Ib/ton) 0.28 0.112 -
Glass Tubing
g/metric ton 230 85 - - 6-9
(Ib/ton) 0.46 0.17 - - -
Television Picture
Tube Envelope
g/metric ton 130 130 65 4.5 - 6-9
(Ib/ton) 0.25 0.25 0.13 0.009
Incandescent Lamp.
Envelopes
Forming
g/metric ton 115 115 - - 6-9
(Ib/ton) 0.23 0.23 - - -
Frosting
g/metric ton frosted 85 - 68 - 100 6-9
(Ib/ton) 0.17 - 0.14 - 0.20
Hand Pressed and Blown
Leaded & Hydrofluoric
Acid Finishing
mg/1 25 - 15 1.0 - 6-9
Non-Leaded &
Hydrofluoric Acid
Finishing
mg/1 25 - 15 - 6-9
Non-Hydrofluoric
Acid Finishing
mg/1 25 - - 6-9
138
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based on any 30 consecutive calendar days. Maximum daily averages
are two times the monthly average.
Glass Container Manufacturing
No additional control technology is proposed for the glass container
manufacturing subcategory. Oil skimmers are presently employed at
some plants, but many plants do not require treatment. Improved
housekeeping techniques may be required at some plants to meet the
limitations. Effluent limitations for suspended solids are 70
g/metric ton (0.14 Ib/ton) ; for oil, 30 g/metric ton (0.06 Ib/ton) ;
and pH of between 6.0 and 9.0.
Machine Pressed and Blown Glass Manufacturing
No additional control technology is proposed for the machine pressed
and blown glass subcategory. Oil skimmers are presently employed at
some plants, but many plants do not provide treatment. Improved
housekeeping may be required at some plants to meet the limitations.
Effluent limitations for suspended solids are 140 g/metric ton (0.28
Ib/ton); for oil, 56 g/metric ton (0.112 Ib/ton); and pH of between
6.0 and 9.0.
Glass Tubing Manufacturing
No additional control technology is proposed for the glass tubing
subcategory. Most plants presently do not provide treatment because
the raw waste water pollutant concentrations are already at low
levels. Improved housekeeping may be required at some plants to
meet the limitations. Effluent limitations for suspended solids are
230 g/metric ton (0.46 Ib/ton); for oil, 85 g/metric ton (0.17
Ib/ton); and pH of between 6.0 and 9.0.
Television Picture Tube Envelope Manufacturing
The control technology on which the recommended limitations are
based involves lime addition, coagulation, sedimentation, and pH
adjustment. This technology is currently practiced throughout the
industry for the treatment of finishing waste waters. Effluent
limitations for suspended solids and oil are 130 c ^metric ton (0.26
Ib/ton); for fluoride, 65 g/metric ton (0.13 Ib/t ,R) ; for lead, 4,5
g/metric ton (0.009 Ib/ton); and pH of between 6.0 and 9.0.
Incandescent Lamp Envelope Manufacturing
The control technology on which the recommended limitations are
based involves ammonia removal by steam stripping used in
conjunction with the lime precipitation system for fluoride and
suspended solids removal. The lime precipitation treatment is
practiced throughout the industry for frosting waste water treat-
ment. Recarbonation is also included in the control technology for
adjustment of the treated waste water pH to a range of 6 to 9.
Effluent limitations are listed separately for forming and frosting
because there is a wide variation in the percentage of envelopes
139
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that are frosted. The forming limitations are based on furnace pull
production and the frosting limitations are based on the portion of
the furnace pull production that is frosted. Effluent limitations
for the waste waters resulting from forming are 115 g/metric ton
(0.23 Ib/ton) for both suspended solids and oil. Frosting waste
water effluent limitations for suspended solids are 85 g/metric ton
(0.17 Ib/ton); for fluoride, 68 g/metric ton (0.14 Ib/ton); for
ammonia, 100 g/metric ton (0.20 Ib/ton); and pH of between 6.0 and
9.0.
Hand Pressed and Blown Glass Manufacturing
The control technology on which the limitations are based involves:
(1) in the case of leaded or non-leaded glass to which is applied
hydrofluoric acid finishing techniques, a batch lime precipitation
system for reduction of suspended solids, fluoride, and, where
applicable, lead; and (2) in the case of leaded or non-leaded glass
to which no hydrofluoric acid finishing techniques are applied, a
batch coagulation and sedimentation system. The lime precipitation
system effluent is recarbonated with carbon dioxide gas to reduce
the pH of the treated waste water to neutrality. Because of the
limited data base, effluent limitations are given as mg/1
concentrations. Effluent limitations for suspended solids,
fluoride, and lead are 25, 15, and 1.0 mg/1 respectively; only those
parameters which are applicable to a particular sector of this
subcategory are to be applied. The pH of the effluent waste water
must be in the range from 6-9.
EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION OF BEST
PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE
Based on the information contained in Sections III through VIII of
this document, a determination has been made of the degree of
effluent reduction attainable through the application of the best
practicable control technology currently available for the pressed
and blown glass segment of the glass manufacturing category. The
effluent reductions are summarized here.
Fluoride
Fluoride is a principal pollutant constituent in waste waters
resulting from the manufacture of television picture tube envelopes,
frosted incandescent lamp envelopes, and hydrofluoric acid polished
and etched handmade glass. Application of this technology will
reduce fluoride by 96 percent for television picture tube envelope
manufacturing and 99.3 percent for incandescent lamp envelope
manufacturing. Effluent fluoride concentrations for handmade glass
plants which employ hydrofluoric acid finishing techniques will be
reduced to 15 mg/1 with this technology.
Ammonia
A primary constituent of the raw waste water from the frosting of
incandescent lamp envelopes is ammonia. Ammonia levels will be
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reduced 95 percent in the incandescent lamp envelope manufacturing
subcategory waste waters using this control technology.
Lead
Lead is contributed to television picture tube envelope plant and
handmade glass plant waste waters by finishing steps applied to the
picture tube envelope and leaded handmade glassware. Application of
this control technology will reduce lead levels in television
picture tube envelope manufacturing waste waters by 99 percent.
Lead levels in waste waters from handmade glass plants which employ
hydrofluoric acid finishing techniques to leaded glass will be
reduced to 1.0 mg/1 with the application of this technology.
Oil
Oil is a constituent of the waste waters from all subcategories
except the hand pressed and blown glass manufacturing. Belt oil
skimmers and baffled skimming basins are employed at some plants,
but many plants do not provide treatment. Analysis of the data
indicates no discernible difference between the effluent oil con-
centration of plants employing oil skimming and plants without
treatment. No additional waste water treatment or control is
proposed because of the low oil concentrations in the raw waste
water. Some plants may need to improve housekeeping techniques to
meet the proposed effluent levels. .
Oxygen Demanding Materials
Oxygen demand in the pressed and blown glass segment is related to
the oil content of the waste water. Since no additional waste water
treatment or control for oil removal is proposed, the BOD and COD
will not be reduced. The BOD and COD are already low by
conventional standards.
Waste waters resulting from acid treatment of glassware have a pH of
2 to 3. The acidic wastes are treated to remove fluoride and other
pollutants by lime addition to a pH of 11-12. At some waste water
treatment plants, the alkaline treated waste waters are adjusted to
a neutral pH. This control technology will be applied to the
television picture tube envelope, incandescent lamp envelope, and
handmade pressed and blown glass manufacturing subcategories to
achieve an effluent pH of 6 to 9.
Suspended Solids
Suspended solids are contributed to the process waste waters from
all subcategories. Application of this technology will reduce
suspended solids levels for television picture tube envelope manu-
facturing and incandescent lamp envelope manufacturing by 97 and 56
percent respectively. This technology will lower the suspended
solids concentrations of handmade glass plant waste waters to a
141
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concentration of 25 mg/1. The cullet quench water stream is not
treated for the incandescent lamp envelope subcategory and there-
fore, lower removal percentages are obtained. Suspended solids
remain at the present levels for glass container manufacturing,
machine pressed and blown glass manufacturing, and glass tubing
manufacturing.
Dissolved Solids
Dissolved solids are contributed to the waste waters from the
pressed and blown glass segment by acid treatment of glass and
frosting of incandescent lamp envelopes. The proposed control tech-
nologies do not reduce dissolved solids.
Temperature
Process waste waters from all subcategories may show some tempera-
ture increase because of cullet quenching, acid polishing, and
frosting of incandescent lamp envelopes. Application of this
control technology will not result in significant temperature
reduction.
RATIONALE FOR THE SELECTION OF BEST PRACTICABLE CONTROL TECHNOLOGY
CURRENTLY AVAILABLE
Engineering Aspects of Application
In all cases, this control technology has been applied in the
pressed and blown glass segment or in another industry where the
characteristics of the water treated are sufficiently similar to
provide a high degree of confidence that the technology can be
transferred to the pressed and blown glass industry. The derivation
and rationale for selection of the control technologies are
described in detail in Sections V and VII. These may be briefly
summarized as follows:
Glass Container Manufacturing
No additional waste water treatment or control will be required at
the majority of glass container plants to achieve this level. Some
plants presently employ oil skimmers, but many plants do not provide
treatment. In analysis of the data, no discernible difference could
be established between plants with oil skimming treatment and plants
without treatment. Collection of I.S. machine oil leakage, control
of shear spray oil drippage, and other housekeeping techniques may
be required at some plants to meet the effluent limitations.
Machine Pressed and Blown Glass Manufacturing
Machine pressed and blown glass manufacturing waste waters are
presently of such quality that the waste waters do not require
additional treatment. The majority of plants are achieving the
effluent limitations guidelines. As in the glass container
142
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subcategory, some plants may need to improve housekeeping controls
to meet the effluent limitations.
Glass Tubing Manufacturing
Most plants presently do not provide waste water treatment and are
meeting the proposed effluent limitations. It might be necessary
for some plants to improve housekeeping techniques to achieve the
effluent limitations.
Television Picture Tube Envelope Manufacturing
Lime precipitation, coagulation, sedimentation, and pH adjustment
are currently practiced throughout the industry to treat waste
waters from the finishing of television picture tube envelopes. The
majority of plants meet the effluent limitations, but those that do
not may be required to upgrade waste water treatment practices and
in-plant housekeeping controls to meet the effluent limitations.
Incandescent Lamp Envelope Manufacturing
Lime precipitation, coagulation, and sedimentation are currently
practiced throughout the industry for removal of fluoride and
suspended solids from frosting waste waters. Gullet quench waste
waters are also treated at most plants. None of the plants provide
treatment for ammonia removal. To achieve the effluent limitations,
the majority of the plants must upgrade present treatment facilities
and add facilities for ammonia removal.
At least two plants are meeting the fluoride effluent limitations.
By implementation of improvements in the treatment facilities such
as increased flocculation, longer retention time in the clarifica-
tion unit, and improved clarifier design, the remaining plants
should be able to meet the fluoride and suspended solids limitations
levels.
Ammonia is presently removed from fertilizer plant effluent
discharge streams at approximately the same concentrations and flow
rates as those experienced in the incandescent lamp envelope
subcategory by steam stripping. The technology can be transferred
to the incandescent lamp envelope manufacturing subcategory with
similar resultant effluent levels.
Water pH adjustment by recarbonation has been practiced for many
years in conventional water treatment plants. This method can also
be applied for pH adjustment of treated frosting waste waters.
Hand Pressed and Blown Glass Manufacturing
At least one hand pressed and blown glass plant is employing the
batch lime precipitation method to remove suspended solids,
fluoride, and lead from finishing waste waters. The plant is also
achieving all of the effluent limitations with the exception of the
pH limitation. Recarbonation of the treated waste waters will
143
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adjust the pH into the acceptable range from 6 to 9. Most plants
presently do not provide treatment other than sedimentation basins;
those with waste water producing finishing steps will have to employ
treatment to meet the effluent limitations levels.
Total cost of Application
Based on the information presented in Section VIII of this document
the industry, as a whole, would have to invest approximately
$2,670,000 to achieve the effluent limitations prescribed herein.
The increased annual costs of applying this control technology are
approximately $966,000 for the industry segment.
Size and j^ge of Equipment
The size of plants within the same subcategory does not vary enough
to substantiate differences in control technology based on size.
Most pressed and blown glass plants have actively developed and
implemented new production methods so that the age of equipment and
facilities does not provide a basis for differentiation in the
application of this control technology.
Processes Employed
All plants in a given subcategory use very similar manufacturing
processes and produce similar waste water discharges. The control
technology for a given subcategory is compatible with all of the
manufacturing processes presently used in that subcategory.
Process Changes
No process changes are required to implement this control
technology, and major changes in the production processes are not
anticipated. Therefore, the waste water volume and characteristics
should remain the same for the foreseeable future.
Non-Water Quality Enyironrnental Impact
With the exception of ammonia removal, required for the incandescent
lamp envelope subcategory, there is no evidence that application of
this control technology will result in any unusual air pollution or
solid waste disposal problems. The ammonia stripped from incandes-
cent lamp envelope waste waters will be discharged to the atmosphere
but methods are available to reduce the concentration below the
threshold of odor. The control technologies which represent the
best practicable control technology currently available are
currently used in either the pressed and blown glass industry or
other industries without adverse environmental effects. The pressed
and blown glass industry consumes enormous amounts of energy for
melting raw materials and annealing. The energy required to apply
this control technology represents only a small increment of the
present total energy requirements of the industry.
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SECTION X
EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION OF
THE BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
EFFLUENT LIMITATIONS GUIDELINES
INTRODUCTION
The effluent, limitations that must be achieved July 1, 1983, are to
specify the degree of effluent reduction attainable through the
application of the best available technology economically achiev-
able. This control technology is not based upon an average of the
best performance within an industrial category, but is determined by
identifying the very best control and treatment technology employed
by a specific plant within the industrial category or subcategory,
or where it is readily transferable from one industry process to
another.
Consideration must also be given to:
a. The total cost of application of this control tech-
nology in relation to the effluent reduction benefits
to be achieved from such application;
b. the size and age of equipment and facilities involved;
c. the processes employed;
d. the engineering aspects of the application of this
control technology;
e. process changes;
f. non-water quality environmental impact (including
energy requirements).
Best available technology economically achievable also considers the
availability of in-process controls as well as control or additional
end-of-pipe treatment techniques. This control technology is the
highest degree that has been achieved or has been demonstrated to be
capable of being designed for plant scale operation up to and
including "no discharge" of pollutants.
Although economic factors are considered in this development, the
costs for this level of control are intended to be the top-of-the-
line of current technology subject to limitations imposed by
economic and engineering feasibility. However, this control
technology may be characterized by some technical risk with respect
to performance and with respect to certainty of costs. Therefore,
this control technology may necessitate some industrially sponsored
development work prior to its application.
IDENTIFICATION OF BEST AVAILABLE CONTROL TECHNOLOGY ECONOMICALLY
ACHIEVABLE
In-plant control measures as well as end-of-pipe treatment tech-
niques contribute to the best available technology economically
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achievable. Water recycle and reuse will tend to reduce the cost of
end-of-pipe treatment facilities.
The best available technology economically achievable for the sub-
categories of the pressed and blown glass industry is summarized
below. Recommended effluent limitations are summarized in Table 30.
These limitations are monthly averages based on any 30 consecutive
days. The maximum daily average is two times the monthly average.
Glass Container Manufacturing
The control technology includes segregation of non-contact cooling
water from the cullet quench water. The cullet quench water is
recycled back to the cullet quench process through a gravity oil
separator. Cullet quench system blowdown is treated by dissolved
air flotation followed by diatomaceous earth filtration. The
blowdown is 5 percent of the total cullet quench water flow.
Effluent limitations for suspended solids and oil are 0.4 g/metric
ton (0.0008 Ib/ton).
Machine Pressed and Blown Glass Manufacturing
The control technology is the same as for the glass container manu-
facturing subcategory. The non-contact cooling water is segregated
from the cullet quench water and the cullet quench water is recycled
back to the cullet quench process through a gravity oil separator.
Blowdown from the quench system is treated by dissolved air flota-
tion followed by.diatomaceous earth filtration. The blowdown is
estimated at 13 percent of the total cullet quench water flow.
Effluent limitations for suspended solids and oil are 1.8 g/metric
ton (0.0036 Ib/ton).
Glass Tubing Manufacturing
The control technology involves the recirculation of the cullet
quench water through a cooling tower. The cooling tower blowdown is
treated by diatomaceous earth filtration. The blowdown is estimated
at 5 percent of the total cullet quench water flow. Effluent
limitations for suspended solids and oil are 0.1 g/metric ton
(0.0002 Ib/ton).
Television Picture Tube Envelope Manufacturing
The control technology specified includes lime precipitation,
sedimentation, and pH adjustment of all finishing waste waters, as
described in Section IX, followed by sand filtration and activated
alumina filtration. Cullet quench water is not treated. Effluent
limitations for suspended solids are 60 g/metric ton (0.12 Ib/ton);
for oil, 130 g/metric ton (0.26 Ib/ton); for fluoride, 9 g/metric
ton (0.018 Ib/ton); for lead, 0.45 g/metric ton (0.0009 Ib/ton); and
pH of between 6.0 and 9.0.
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TABLE 30
RECOMMENDED MONTHLY AVERAGE EFFLUENT LIMITATIONS USING
BEST AVAILABLE CONTROL TECHNOLOGY ECONOMICALLY ACHIEVABLE
Suspended
Solids
Oil
Fluoride
Lead
Ammonia
Glass Containers
g/metric ton 0.4 0.4
(Ib/ton) 0.0008 0.0008
Machine Pressed and
Blown Glass
g/metric ton 1.8 1.8
(Ib/ton) 0.0036 0.0036
Glass Tubing
g/metric ton 0.1 0.1
(Ib/ton) 0.0002 0.0002
Television Picture
Tube Envelope
g/metric ton 60 130
(Ib/ton) 0.12 0.26
Incandescent Lamp
Envelopes
Forming
g/metric ton 23 23
(Ib/ton) 0.045 0.045
Frosting
g/metric ton frosted 17
(Ib/ton) 0.034
Hand Pressed and Blown
Leaded & Hydrofluoric
Acid Finishing
mg/1 5
Non-Leaded &
Hydrofluoric Acid
Finishing
mg/1
Non-Hydrofluoric
Acid Finishing
mg/1
9
0.018
7
0.014
0.45
0.0009
6-9
6-9
6-9
6-9
100
0.20
6-9
6-9
0.1
6-9
6-9
6-9
147
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Incandescent Lamp Envelope Manufacturing
The control technology involves lime precipitation, sedimentation,
recarbonation, and ammonia removal by steam stripping of frosting
waste waters, as described in Section IX, followed by sand
filtration and activated alumina filtration. In addition to this
control technology, diatomaceous earth filtration is used to treat
the cullet quench waste waters. Effluent limitations for waste
waters resulting from the forming of incandescent lamp envelopes are
23 g/metric ton (0.045 Ib/ton) for suspended solids and oil.
Frosting waste water effluent limitations for suspended solids are
17 g/metric ton (0.03U Ib/ton); for fluoride, 7 g/metric ton (0.014
Ib/ton); for ammonia, 100 g/metric ton (0.2 Ib/ton); and pH of
between 6.0 and 9.0.
Hand Pressed and Blown Glass Manufacturing
The control technology specified includes batch lime precipitation,
sedimentation, and recarbonation, as described in Section IX,
followed by sand filtration and activated alumina filtration.
Effluent limitations for suspended solids, fluoride, and lead are 5,
2r and 0.1 mg/1, respectively. The pH of the effluent waste water
must be adjusted to the range between 6.0 and 9.0.
EFFLUENT REDUCTION ATTAINABLE THROUGH THE APPLICATION OF BEST
AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
Based on the information contained in Sections III through VIII of
this document, a determination has been made of the degree of
effluent reduction attainable through the application of the best
available technology economically achievable. Recycle of cullet
quench water is attainable for the glass container, machine pressed
and blown glass, and glass tubing manufacturing subcategories. The
effluent reductions attainable through application of the specified
control and treatment technologies are summarized here.
Fluoride
This technology reduces fluoride discharges from television picture
tube envelope manufacturing by 99.5 percent, and from incandescent
lamp envelope manufacturing by 99.9 percent. The effluent fluoride
concentration for handmade glass plants which employ hydrofluoric
acid finishing techniques is reduced to 2 mg/1 by application of
this technology. The incremental increase over the levels achieved
using the best practicable control technology currently available
for television picture tube envelope manufacturing and incandescent
lamp envelope manufacturing are 86 and 90 percent, respectively.
Ammonia
Ammonia is reduced by 95 percent for the incandescent lamp envelope
manufacturing subcategory with this technology. There is no incre-
mental increase over the application of the best practicable control
148
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technology currently available as the
technologies remain the same for both levels.
Lead
proposed treatment
With this technology, the lead discharged as a result of television
picture tube envelope manufacturing is reduced by 99.9 percent and
the incremental increase in removal over the level achieved using
the best practicable control technology currently available is 90
percent. The lead concentration for handmade glass plants which
employ hydrofluoric acid finishing techniques is reduced to a
concentration of 0.1 mg/1 using this technology.
Oil
With this technology, oil in glass container manufacturing waste
waters is reduced by 98.7 percent, from machine pressed and blown
glass manufacturing waste waters by 97 percent, from glass tubing
manufacturing waste waters by approximately 100 percent, and from
incandescent lamp envelope manufacturing waste waters by 80 percent.
The incremental reductions over the best practicable control
technology currently available are equal to the total reductions
listed above. The lower reduction achieved for the incandescent
lamp envelope manufacturing subcategory is due to a larger discharge
volume because the waste water is not recirculated as proposed in
the other three subcategories.
Oxygen Demanding Materials
Oxygen demand is related to the waste water oil concentration in the
pressed and blown glass industry; and, therefore, the reductions in
oxygen demand will be in proportion to the oil removals listed
above.
ES
Waste waters
pressed and
resulting from glass container manufacturing, machine
blown glass manufacturing, and glass tubing
manufacturing are presently in the pH range of 6-9. This technology
includes the adjustment of pH in the television picture tube,
incandescent lamp envelope, and hand pressed and blown glass
manufacturing subcategories to a range from 6-9.
Suspended Solids
This technology reduces suspended solids for glass container manu-
facturing, machine pressed and blown glass manufacturing, glass
tubing manufacturing, television picture tube envelope manufactur-
ing, and incandescent lamp envelope manufacturing by 99.4, 98.7,
99.9, 98.6, and 91 percent, respectively. Incremental increases in
removal over the level achieved using the best practicable control
technology currently available is 54 percent for television picture
tube envelope manufacturing and 80 percent for incandescent lamp
envelope manufacturing. The lower incremental reduction achieved
149
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for television picture tube envelope manufacturing is due to the low
suspended solids in the treated waste water. Suspended solids are
reduced to a concentration of 5 mg/1 in the hand pressed and blown
glass manufacturing subcategory by application of this technology.
Pollutant Constituents
Temperature and dissolved solids are not significantly reduced by
application of this technology.
RATIONALE FOR THE SELECTION OF BEST AVAILABLE TECHNOLOGY
ECONOMICALLY ACHIEVABLE
Cost of Application
Based upon the information contained in Section VIII of this docu~
ment, the industry as a whole is estimated to have to invest an
additional $27,700,000 to achieve the effluent limitations
prescribed herein. The increased annual costs to the industry will
be approximately $5,620,000.
Size and Age of Equipment and Facilities
As discussed in Section IX, differences in size and age of equipment
and facilities do not play a significant role in the application of
this control technology.
Process Employed.
The manufacturing processes employed within each subcategory of the
industry are similar and will not influence the applicability of
this control technology.
Engineering Aspects of Application
This level of technology is presently being achieved by several
glass container plants and can be readily applied to the machine
pressed and blown glass manufacturing and glass tubing manufacturing
subcategories. The specified waste water treatment and control
systems are now employed in other industries and this technology is
readily transferrable to the pressed and blown glass segment. The
derivation and rationale for selection of the control technology are
described in detail in Section VII. These may be briefly summarized
as follows:
.ass Container Manufacturinq-
Cullet quench water recycle systems are presently employed at a
number of glass container plants. The recycle systems have been in
operation for several years without major operational difficulties.
The technologies for treating the blowdown are presently used by at
least one glass container plant and also used in the flat glass
industry. This technology is readily transferrable to the remainder
of the segment.
150
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Machine Pr egged and Blown Glass Manufacturinq-
Cullet quenching as practiced at machine pressed and blown glass
manufacturing plants is similar to quenching at glass container
plants. The recycle system technology developed in the glass
container manufacturing subcategory can be transferred without
difficulty to the machine pressed and blown glass industry.
Glass Tubing Manufacturing-
Recycle of cullet quench water is feasible because the pollutant
concentrations are at low levels in the quench water. Non-contact
cooling water is already recycled at a number of plants within the
industry.
Television Picture Tube Manufacturinq-
Rapid sand filtration is a thoroughly proven technology that is used
extensively in the water treatment industry. Activated alumina
filtration has been employed since the 1950 's at municipal water
treatment plants to reduce high levels of fluoride in ground water
to potable water levels. This technology can be applied in the
television picture tube envelope, incandescent lamp envelope, and
hand pressed and blown glass manufacturing subcategories to further
reduce effluent suspended solids, fluoride, and lead concentrations.
Incandescent Lamp Envelope Manu f ac t ur in cj~
Steam stripping is currently being used in the petroleum refining,
petrochemical, and fertilizer industries. The ammonia waste water
stream concentrations and volumes are similar to those occurring in
the incandescent lamp envelope manufacturing subcategory. Effluent
concentrations equal to those necessary to achieve the effluent
limitations are being achieved in the fertilizer industry and,
therefore, can be anticipated when this technology is applied to the
treatment of frosting waste waters.
Both diatomaceous earth filtration and recarbonation are proven
water treatment methods and can be readily applied to the treatment
of waste waters resulting from incandescent lamp envelope
manufacturing.
Process Chanqeg
No process changes are required to implement this technology and
plant operations and production will not be significantly affected
during the installation of the treatment equipment.
Non-water Quality Environmental Aspects
The application of this control technology will not create any new
air or land pollution problems with the possible exception of the
ammonia discharge discussed in Chapter IX. Energy requirements will
not increase significantly above the levels of the best practicable
151
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control technology currently available because the additional energy
requirements are primarily for pumping within the treatment system.
152
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SECTION XI
NEW SOURCE PERFORMANCE STANDARDS
The term "new source" is defined to mean "any source, the con-
struction of which is commenced after the publication of the
proposed regulations prescribing a standard of performance". New
sources for all of the subcategories listed in this document should
achieve the effluent limitations prescribed as attainable through
the application of the best available technology economically
achievable.
This technology reduces the concentration of pollutant constituents
to trace levels for all parameters except ammonia, which is reduced
to 30 mg/1. Several technologies to further reduce ammonia are in
the development stage and can be implemented when their feasibility
is demonstrated. No other technology is indicated that will, by
virtue of new construction, further reduce the treatment levels
attainable using the best practicable technology economically
achievable.
153
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SECTION XII
ACKNOWLEDGEMENTS
The Environmental Protection Agency wishes to acknowledge the
contributions to the project by Sverdrup & Parcel and Associates,
Inc., St. Louis, Missouri. Dr. H. G. Schwartz, Project Executive,
Mr. Richard C. Vedder, Project Manager, and Mr. John Lauth, Project
Engineer, directed the project, conducted the detailed technical
study, and drafted the initial report on which this document is
based.
Appreciation is extended to the many people in the pressed and blown
glass industry who cooperated in providing information for this
study. Special mention is given to company representatives who were
particularly helpful ixi this effort:
Mr. Frank S. Meade of Anchor Hocking Corporation;
Mr. Joseph J. Kozlowski of Ball Corporation;
Mr. Timothy Keister of Brockway Glass Company, Inc.;
Mr. R. G. Watson of Chattanooga Glass Company;
Mr. Allen and Mr. Borchert of Colonial Glass Company;
Mr. J. W. LaFollette of Columbine Glass Company, Inc.;
Mr. Hugh H. Kline and Mr. Anthony J. Gallo of Corning Glass Works;
Mr. Kenneth W. Neidenthal and Mr. John C. Smith of Federal Glass
Company;
Mr. Tom Bobbitt of Fenton Art Glass Company;
Mr. George L. Thomas of Foster-Forbes Glass Company;
Mr. John M. Corliss and Mr. Art E. Williams of Fostoria Glass
Company;
Mr. Leonard M. Reitz and Mr. John Harrsen of General Electric
Company;
Mr. Joseph F. Gillender, Jr. and Mr. George A. Jones of Gillender
Brothers, Inc.;
Mr. D. I. Gandee of Gladding-Vitro-Agate Company;
Mr. George W. Keller of Glass Containers Corporation;
Mr. Robert F. staib of Indian Head;
Mr. James E. Vachris of Kaufman Glass Company;
Mr. Ray Gentry of Kerr Glass Manufacturing Corporation;
Mr. Walter Van Saum, Jr. of Latchford Glass Company;
Mr. Don K. Andrews of Liberty Glass Company;
Mr. Michael R. Sturm of Louie Glass Company, Inc.;
Mr. C. W. Starr and Mr. R. G. Watson of Maryland Glass Corporation;
Mr. W. L. Anderson of Metro Containers Company;
Mr. A. L. Bracken, Jr. and Mr. A. Richard Krivonyak of Minners
Glass Company;
Mr. Bradley E. Wiens, Mr. Chuck N. Frantz, and Mr. Fred D. Pinotti
of Owens-Illinois;
Mr. James E. Stamm of Pilgrim Glass Corporation;
Mr. Thomas H. Mike and Mr. Shawn McKinney of Thatcher Glass
Manufacturing Company;
Mr. J. H. Underwood and Mr. William Ripple of Underwood Glass
Company
Mr. Larry Barrickman and Mr. Paul Kilgore of Viking Glass Company;
155
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Mr. Sam Lipton and Mr. Ken Enos of Westinghouse Electric Corporation;
Mr. Garry Pertz and Mr. John Vankirk of West Virginia Glass Specialty
Company, Inc.
Acknowledgement is also given to Mr. John H. Abrahams, Jr., of the
Glass Containers Manufacturers Institute, and Mr. Joseph V. Saliga,
of the Air Pollution Committee of the West Virginia Society of
Ceramic Engineers, who were helpful in providing input to this study
and in soliciting the cooperation of their member companies.
Acknowledgement is also given to Mr. John Schmidt and his staff at
the Commonwealth of Pennsylvania, Department of Environmental
Resources, for their efforts in gathering information and providing
data related to those portions of the pressed and blown glass
segment located in the State of Pennsylvania.
Appreciation is expressed to those in the Environmental Protection
Agency who assisted in the performance of the project. Especially
deserving recognition are: Ernst Hall, John Riley, Arthur Mallon,
Calvin Smith, James Kamihachi, Ms. Jaye Swanson, and Ms. Barbara
Wortman.
156
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SECTION XIII
REFERENCES
1. American Water Works Association, Water Quality and Treatment,
McGraw-Hill Book Co., New York, 1971.
2. Barnes, Robert A., Atkins, Peter F., Jr., and Scherger, Dale A.,
"Ammonia Removal in a Physical-Chemical Wastewater Treat-
ment Process", prepared for Office of Research and
Monitoring, U.S. Environmental Protection Agency, November,
1972.
3. Battelle Memorial Institute, "Inorganic Fertilizer and Phosphate
Mining Industries - Water Pollution and Control", Environ-
mental Protection Agency Grant No. 12020FPD, September,
1971.
4. Battelle - Northwest and South Tahoe Public Utility District,
"Wastewater Ammonia Removal by Ion Exchange", Water
Pollution Control Research Series No. 17010EEZ, Environ-
mental Protection Agency, February, 1971.
5. Beychok, M. R., Aqueous Wastes from the Petroleum and
Petrochemical Plants, John Wiley and Sons, 1967.
6. Child, Frank S., "Aspects of Glassmaking, as an Engineer Views
It", American Glass Review, December, 1973, pp. 6-7.
7. Gulp, Gordon L., "Physical Chemical Techniques for Nitrogen
Removal", Environmental Protection Agency, Technology
Transfer Seminar, Kansas City, Missouri, January 15-17,
1974.
8. Culp, R. L. and Culp, G. L., Advanced Wastewater Treatment, Van
Nostrand Reinhold Company, New York, 1971.
9. Culp, R. L. and Gonzales, J. G., "New Developments in Ammonia
Stripping", Public Works, May - June, 1973.
10. Culp, Russell L. and Stoltenberg, Howard A., "Fluoride Reduction
at Lacrosse, Kansas", Journal of the American Water Works
Association, March, 1958, pp. 423-431.
11. Environmental Protection Agency, "Development Document for Basic
Fertilizer Chemicals", November, 1973.
12. Giegerich, W. and Trier, W., Glass Machines, Springer-Verlag,
Inc., New York, 1969.
157
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REFERENCES (CONTINUED)
13. Hodkin, F. W. and Cousen, A., A Textbook of Glass Technology,
Constable & Company, Ltd., London, 1925.
14. Hutchins, J. R., III and Harrington, R. V., Corning Glass Works,
"Glass", Encyclopedia of Chemical Technology, 2nd Edition,
Volume 10, John Wiley 6 Sons, Inc., 1966, pp. 533-604.
15. Jorgensen, Professor S. E., "A New Method for the Treatment of
Municipal Wastewater", Paper No. 2, Water Pollution
Control, 1972.
16. Ledbetter, Joe O., Air Pollution, Part Aj. Analysis, Marcel
Dekker, Inc., New York, 1972. ~~
17. McKee, J. E. and Wolf, H. W., "Water Quality Criteria", 2nd
Edition, Publication No. 3A, State Water Quality Control
Board, State of California, The Resources Agency, 1963.
18. McLaren, James R. and Farguhar, Grahame J., "Factors Affecting
Ammonia Removal by Clinoptilolite", Journal of the
Environmental Engineering Division. AS£E/ vol. 99, No. EE4,
August, 1973, pp. 429-446.
19. Maier, F. J., "Defluoridation of Municipal Water Supplies",
Journal of the American Water Works Association, August,
1953, pp. 879-887.
20. Mulbarger, M. C., "Nitrification and Denitrification in
Activated Sludge Systems", Journal of the Water Pollution
Control Federation, Vol. 43, No. 10, "October, 1971, pp.
2059-2070.
21. "Nitrification and Denitrification Facilities - Wastewater
Treatment", Environmental Protection Agency Technology
Transfer Seminar Publication, August, 1973.
22. "Nitrogen Removal From Wastewaters", Federal Water Quality
Administration, Division of Research and Development,
Advanced Waste Treatment Research Laboratory, Cincinnati,
Ohio, October, 1970.
23. O'Farrell, T. P., Franson, F. P., Cassel, A. F., and Bishop, D.
F., "Nitrogen Removal by Ammonia Stripping", Journal of the
Water Pollution control Federation, August, 1972, pp. 1527-
1535.
158
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REFERENCES (CONTINUED)
24. Office of Management and Budget, Standard Industrial
Classification Manual, U. S. Government Printing Office,
Washington, D. C., 1972.
25. Patterson, J. W., and Minear, R. A., Wastewater Treatment
Technology, 2nd Edition, Illinois Institute for Environ-
mental Quality, National Technical Information Service,
February, 1973.
26. "Public Health Service Drinking Water Standards", U. S.
Department of Health, Education, and Welfare, Public Health
Service, Washington, D. C., 1962.
27. "Pulling Effluents Into Line", Chemical Engineering, July 12,
1971, p. 40.
28. Reeves, T. G., "Nitrogen Removal: A Literature Review", Journal
of the Water Pollution Control Federation, Vol. 44, No. 10,
October, 1972, pp. 1895-1905.
29. Roesler, Joseph F., Smith, Robert, and Eilers, Richard G.,
"Simulation of Ammonia Stripping from Wastewater", Journal
of the Sanitary Engineering Division, ASCE, Vol. 97, No.
SA3, June, 1971.
30. Sanitary Engineering Research Laboratory, University of
California, Berkeley, "Optimization of Ammonia Removal by
Ion Exchange Using Clinoptilolite", Report for the
Environmental Protection Agency, Project No. 17080 DAR,
September, 1971.
31. Savinelli, Emilio A. and Black, A. P., "Defluoridation of Water
with Activated Alumina", Journal of the American Water
Works Association. January, 1958, pp. 33-44. ~~
32. Shand, E. B., Gla_ss Engineering Handbook, McGraw-Hill Book
Company, New York, 1958.
33. Smith, Robert, and McMichael, Walter F., "Cost and Performance
Estimates for Tertiary Wastewater Treating Processes", U.
S. Department of the Interior, June, 1969.
159
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REFERENCES (CONTINUED)
34. Snow, R. H., and Wnek, W. J., "Design of Cross-Flow Cooling
Towers and Ammonia Stripping Towers", Industrial
Engineering Chemical Process Design Development, Vol. 11,
No. 3, 1972, pp. 343-349.
35. Zabban, Walter, and Jewett, H. W., "The Treatment of Fluoride
Wastes", Proceedings of the 22nd Industrial Waste
Conference, Purdue University, 1967, pp. 706-716.
160
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SECTION XIV
GLOSSARY
Act
The Federal Water Pollution Control Act as amended.
Activated Alumina
An insoluble, granular media that adsorbs fluoride as the waste
water percolates through the media.
Annealing
Prevention or removal of objectionable stresses by controlled
cooling from a suitable temperature.
API Separator
A free oil separator based on the design recommendations of the
American Petroleum Institute.
The raw materials, properly proportioned and mixed, for delivery to
the furnace.
Slowdown
A discharge from a system, designed to prevent a buildup of some
material, as in a boiler to control dissolved solids.
Blowpipe
The pipe used by a glassmaker for gathering molten glass and blowing
the glass by mouth.
Casting
The forming method used to make television picture tube envelope
funnels. The funnel mold is spun and centrifugal force causes the
molten glass to form in the funnel shape.
Category and Subcategorv
Divisions of a particular industry which possess different traits
which affect water quality and treatability.
Cooling Water
Water used primarily for dissipation of process heat. Can be both
contact or non-contact, and is usually the latter.
161
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The process of severing a glass article by breaking, as by
scratching and then heating.
Gullet
Waste or broken glass, usually suitable as an addition to the raw
material batch.
Gullet Quench
The process of dissipating the heat from cullet by the addition of
water.
Diatomaceous Earth
The skeletal remains of tiny aquatic plants, commonly used as a
filter medium to remove suspended solids from fluids. Specially
treated diatomaceous earth can be obtained for the removal of
emulsified oil from water.
Envelope
The glass portion of a picture tube or light bulb that encloses the
electrical components of the assembled product.
Etching
The process of placing designs in high quality stemware by hydro-
fluoric acid attack of the glass.
Forehearth
A section of a melting tank, from which glass is taken for forming.
Frosting
The process used in the incandescent lamp envelope industry to give
the inside surface of an envelope a matted surface. This improves
the light diffusing property of the envelope.
Gob
A portion of hot glass delivered by a feeder, after being cut from
the molten glass stream by shear cutters.
I.S.. Machine
The individual section machine is the machine most commonly used to
form glass containers.
162
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Lehr
A long tunnel-shaped oven for annealing glass by continuous passage.
New Source
Any building, structure, facility, or installation from which there
is or may be a discharge of pollutants and whose construction is
commenced after the publication of the proposed regulations.
Process Water
Any water which comes into direct contact with the intermediate or
final product. Includes contact cooling, washing, grinding and
polishing, etc.
Ribbon Machine
The machine used to form incandescent lamp envelopes.
Surface Waters
Navigable waters. The waters of the United States including the
territorial seas.
Tons Frosted
Calculated by multiplying the tons pulled by the percentage of plant
production frosted.
Tons Pulled
Tons of glass drawn from the melting furnace.
Washer
A process device used for water cleaning of the product.
Waste Water
Process water or contact cooling water which has become contaminated
with process waste and is considered no longer usable.
163
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TABLE 31
CONVERSION TABLE
MULTIPLY (ENGLISH UNITS) by TO OBTAIN (METRIC UNITS)
ENGLISH UNIT ABBREVIATION CONVERSION ABBREVIATION METRIC UNIT
acre ac
acre - feet ac ft
British Thermal
Unit BTU
British Thermal
Unit/pound BTU/lb
cubic feet/minute cfm
cubic feet/second cfs
cubic feet cu ft
cubic feet cu ft
cubic inches cu in
degree Fahrenheit °F
feet ft
gallon gal
gallon/minute gpm
horsepower hp
inches in
inches of mercury in Hg
pounds Ib
million gallons/day mgd
mile mi
pound/square
inch (gauge) psig
square feet sq ft
square inches sq In
ton (short) ton
yard yd
0.405
1233.5
0.252
0.555
0.028
1.7
0.028
28.32
16.39
0.555(°F-32)*
0.3048
3.785
0.0631
0.7457
2.54
0.03342
0.454
3,785
1.609
(0.06805 psig +1)*
0.0929
6.452
0.907
0.9144
ha hectares
cu m cubic meters
kg cal kilogram - calories
kg cal/kg kilogram calories/kilogram
cu m/min cubic meters/minute
cu m/min cubic meters/minute
cu m cubic meters
1 1i ters
cu cm cubic centimeters
°C degree Centigrade
m meters
1 liters
I/sec liters/second
kw killowatts
cm centimeters '
atm atmospheres
kg kilograms
cu m/day cubic meters/day
km ki1ometer
atm atmospheres (absolute)
sq m square meters
sq cm square centimeters
kkg metric ton (1000 kilograms^
m meter
* Actual conversion, not a multiplier
164
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