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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Blowing—The 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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Pressing—Much 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  Spray—In  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.

Drawing—Glass 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
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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.

Casting—Television 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
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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 envelopes—Television 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
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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  envelopes—An  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 blown—The 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.
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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
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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   finishing—Numerous  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.
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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.
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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.
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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
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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

-------
                           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

-------
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

-------
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

-------
 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

-------
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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                                                    50

-------
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
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                      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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 (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

-------
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                   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

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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

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      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

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                             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

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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

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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

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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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of 8 to 10.  Temperature increases are  insignificant  except  where
heated  rinse  waters  are used.  Dissolved solids are not reported,
but significant  concentrations  may  be  anticipated  in  the  acid
polishing  and  etching  waste waters.  Nitrates are discharged as a
result of the rinsing steps following etching.  Insufficient data is
available to define the levels of discharge.

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
                                73

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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
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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
nitrification—denitrification,  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:

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                 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
                                 91

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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
                                 93

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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.
                                 94

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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

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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

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                               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

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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

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                            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

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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

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                             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

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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

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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

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                             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

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                             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

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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

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                              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

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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

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                             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

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                               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

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    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.


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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.
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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
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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

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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
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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
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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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