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XXlll
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may or may not operate their own laundry and dry cleaning ser-
vices.
Most industrial launderers offer their customers a variety of
textile maintenance services, but approximately 88% of the re-
ceipts are derived from the activities defined above. Although
there is some overlap in the work done by industrial launderers
and linen suppliers, industrial launderers can generally be dis-
tinguished because they rent personalized garments fitted and
labeled for the individual, while linen suppliers provide rental
garments by size.
Car Washes
Car wash trade associations have estimated that the total number
of car washes is about 40,000. Approximately 40% of these are
rollovers, 40% are wands, and 20% are tunnels. The industry
continues to grow at a rate of 3% to 4% a year, although the dif-
ferent types are growing at different rates. The number of new
tunnel facilities built each year is fairly constant. Rollovers
are primarily found at service stations where oil companies have
often used them as promotional devices. Sales are therefore de-
pendent on such things as the availability of gas.
The largest increases in sales have been for the self-service
wand-type car washes. The resurgence in sales is partly due to a
general upgrading of merchandise and facilities. Furthermore,
wand washes offer the best return for the least investment. The
number of bays sold for a location is generally tuned to what the
market requires, and the tendency is to begin with four bays.
Laundry and Garment Services Not Elsewhere Classified
This subcategory, Laundry and Garment Services NEC, is defined as
those establishments primarily engaged in furnishing other laundry
services, including both repairing, altering, and storing clothes
for individuals and the operation of hand laundries. Additional
services provided by these firms include garment cleaning, re-
pairing, and storage; glove mending; hoisery repair; pillow
cleaning and renovating; and tailoring. There are approximately
2,700 establishments in this category, most of which are very
small. No data on discharges are available because this subcate-
gory was not studied, and it will not be considered further.
II.2.1.3 Wastewater Flow Characterization [2-2,3]
The volume of wastewater produced by plants in this industry
range from 0.9 to 1,400 m3/d (240 to 360,000 gpd). This excludes
two subcategories: (1) Carpet and Upholstery Cleaning, for which
figures are not available, and (2) Dry Cleaning, which uses a
negligible amount of water (30 to 200 cm3/kg [0.004 to 0.023
Date: 9/25/81 II.2-7
-------
gal/lb] of material washed). Table 2-3 indicates water discharge
rates of those subcategories for which data are available.
TABLE 2-3.
PROCESS WASTEWATER DISCHARGE RATES BY SUBCATEGORY
[2-2,3]
cu.m/kq (qal/lbl
cu.m/dav (qpd)
Subcateaory
Industrial laundries
Linen suppl ies
Power laundries
Diaper services
Coin-operated laundries
Car washes
Minimum! a)
0.008
(0.9)
0.011
(1.7)
0.018
(2.2)
0.006
(0.7)
0.007
(0.8)
35(b)
Maximumla)
0.080
(9.6)
0.086
(10.3)
0.01(3
(5.1)
0.045
(5.14)
0.092
(II. 0)
80(b)
Averaqe
0.038
(H.6)
0.030
(3.6)
0.028
(3.5)
0.029
(3.5)
0.032
(3.8)
Minimum(a)
32
(8,600)
14
(3,600)
6.8
(1,800)
12
(3, 100)
0.9
(2UO)
1. 1
300(b)
Max i mural a I
1, 100
(290,000)
1,1(00
(360,000)
1, 100
(290,000)
680
( 180,000)
76
(20,000)
180
l(8,000(b)
Average
260
(68,000)
1(20
( 1 10,000)
230
(61,000)
160
(1(1,000)
|l(
(3,600)
Blanks indicate data not available.
(a(Minimum and maximum values apply only to the laundries
necessarily reflect absolute minima and maxima for the
(b)GalIons per car
surveyed and do not
industry as a whole.
II.2.2 WASTEWATER CHARACTERIZATION [2-2,3]
The physical and chemical characteristics of laundry wastewaters
are influenced by three primary factors: the general type of
cleansing process employed (i.e., water versus solvent wash), the
types and quantity of soil present on the textiles being laun-
dered, and the composition of the various chemical additives used
in the process. Water wash effluents contain all of the soil and
lint removed from the textiles, as well as the laundry chemicals
employed in the process. On the other hand, wastewaters from dry
cleaning processes tend to contain water-soluble materials; lint,
grit, and insoluble organic and inorganic compounds are largely
removed by the solvent filter or confined to the still bottoms.
However, dry cleaning effluents also contain appreciable quan-
tities of solvent, which are not normally present in water-wash
effluents.
Table 2-4 presents the minimum detection limits for toxic pol-
lutants in this industry. Tables 2-5 and 2-6 present subcategory
wastewater descriptions for classical and toxic pollutants found
in this industry.
II.2.2.1 Industrial Laundries
In comparison to domestic sewage, industrial laundry wastewaters
typically contain high concentrations of BODS, COD, TOC, sus-
pended solids, and oil and grease. BOD5 concentrations as low as
91 mg/L and as high as 7,800 mg/L were observed, which attests to
Date: 8/31/32 P. Change 1 II. 2-8
-------
TABLE 2-4. MINIMUM DETECTION LIMITS FOR TOXIC POLLUTANTS(a) [2-2,3]
Concentration
Compounds yg/L
Hetals
Arsenic
Antimony
Beryllium
Cadmium
Chromium
Copper
Lead
Nickel
Mercury
Selenium
Silver
Thallium
Zinc
Acids
2-Chlorophenol
Phenol
2 , 4-Dichlorophenol
2-Nitrophenol
p-Chloro-m-cresol
2,4, 6-Trichlorophenol
2 , 4-Dimethy Iphenol
2 ,4-Dinitrophenol
4,6-Dinitro-o-cresol
4-Nitrophenol
Pentachlorophenol
Volatiles
Chlorome thane
Dichlorodifluorome thane
Bromome thane
Vinyl chloride
Chloroe thane
Methylene chloride
Trichlorofluorome thane
1 , 1-Dichloroethylene
1 , 1-Dichloroe thane
Trans- 1 ,2-dichloroethylene
Chloroform
1,2-Dichloroethane
1 , 1 , 1-Trichloroethane
Carbon tetrachloride
Bromodichlorome thane
Bis-chloromethyl ether
1 ,2-Dichloropropane
Trans-1 ,3-dichloropropene
Trichloroethylene
Oibromochlorome thane
Cis- 1 , 3-dichloropropene
1,1, 2-Trichloroe thane
Benzene
2-Chloroethylvinyl ether
Bromoform
1,1,2, 2-Tetrachloroethane
Toluene
Chlorobenzene
Ethylbenzene
1
10
0.04
2
4
4
22
36
0.5
1
5
50
1
0.09
0.07
0.1
0.4
0.1
0.2
0.1
2.0
40
0.9
0.4
0.2
0.2
0.2
0.4
0.5
0.4
2.0
2.0
3.0
2.0
5.0
2.0
2.0
4.0
0.9
1.0
0.7
0.4
0.5
0.3
0.5
0.7
0.2
1.0
0.6
0.9
0.1
0.2
0.2
, Concentration,
Compounds U9/L
Base neutrals
1 ,3-Dichlorobenzene
1 ,4-Dichlorobenzene
Hexachloroe thane
1 , 2-Dichlorobenzene
Bis-2-chloroisopropyl ether
Hexachlorobutadiene
1,2, 4-Trichlorobenzene
Naphthalene
Bis-2-chloroethyl ether
Hexachlorocyclopentadiene
Nitrobenzene
Bis-2-chloroethoxy methane
2 - Chloronap thalene
Acenaphthylene
Acenapthene
Isophorone
Fluorene
2 ,6-Dinitrotoluene
1 , 2-Diphenylhydrazine
2 , 4-Dinitrotoluene
N-nitrosodiphenylamine
Hexachlorobenzene
4-Bromophenyl phenyl ether
Phenanthrene
Anthracene
Dimethyl phthalate
Diethyl phthalate
Fluoranthene
Pyrene
Di-n-butyl phthalate
Benzidine
Butyl benzyl phthalate
Chrysene
Bis ( 2-e thylhexyl )phthalate
Benzo ( a ) anthracene
Benzo (b ) f luoranthene
Benzo ( k ) f luoranthene
Benzo(a)pyrene
Indeno (l,2,3-cd)pyrene
Dibenzo(a.h) anthracene
Benzo (g,h,i)perylene
N-nitrosodimethylamine
N-nitrosodi-n-propylamine
4-Chlorophenyl phenyl ether
3 , 3-Dichlorobenzidine
Di-n-octyl phthalate
Pesticides
0.02
0.04
0.1
0.05
0.06
0.08
0.09
0.007
0.07
0.2
0.08
0.06
0.02
0.02
0.04
0.06
0.02
0.2
0.02
0.02
0.07
0.05
0.1
0.01
0.01
0.03
0.03
0.02
0.01
0.02
0.02
0.03
0.02
0.04
0.02
0.02
0.02
0.02
0.02
0.02
0.01
0.8
0.2
0.03
1.0
0.89
1.0
(a) The minimum detection limit for all toxic pollutants in the car wash sub-
category is 10 ug/L.
Date: 8/31/82 R Change 1 II.2-9
-------
ti-
ro
TABLE 2-5. WASTEWATER CHARACTERIZATION OF CLASSICAL POLLUTANTS
IN AUTO AND OTHER LAUNDRIES, SCREENING DATA [2-2,3]
00
U)
M
\
00
n
tr
I
I-1
o
Po 1 1 utant. mq/L
BOD5
COD
TOC
TSS
Total phosphorus
Tota 1 pheno 1 s
Oil and grease
pH, pH units
Number of
samp les
51
60
24
69
12
19
66
62
Maximum
Industria 1
7,800
7,000
6,800
6, 100
42
1.5
7,900
12
Med fan
laundries
920
3,800
1,200
700
9. 1
0. 18
730
10
Mean
1,300
5,000
1,400
1,000
12
0.32
1, 100
10
Number of
samp les
50
26
28
59
5
7
52
58
Power laundries
BOD5
COD
TOC
TSS
Tota 1 phosphorus
Total phenols
Oil and grease
pH, pH units
BOD5
COD
TOC
TSS
Total phosphorus
Tota 1 pheno 1 s
Oil and grease
pH, pH units
8
1 1
4
1 1
6
5
9
14
31
18
1
28
2
3
13
29
940
1,400
240
410
24
0.97
370
1 1 .0
Coin-operated
500
930
68
630
18
0.30
74
9.2
210
580
160
230
4.0
0.07
52
9.6
1 aund r ies
120
270
85
<0.002
23
8.0
340
660
150
220
7.3
0.31
1 10
9.4
140
340
140
9.8
0. 10
26
7.9
5
8
2
8
2
3
7
9
Dry cleaning plants
BOD5
COD
TOC
TSS
Tota 1 phosphorus
Tota 1 pheno 1 s
Oil and grease
pH, pH units
2
<2
8
2
3
0.2
<0.005
<2
7.2
<0.003
7
7
6
7
7
Maximum Median
Linen
1,500
4,000
1,200
1,200
48
0.26
910
12
Diaper
560
1, 100
400
280
30
0.08
330
1 1 .0
Carpet c
99
280
46
100
29
19
7. 1
Car
220
520
0.024
5,400
8.4
laundries
610
1,500
300
360
14
0. 12
300
10
laundries
240
520
130
0.04
85
10.4
leaning plant
washes
42
64
<0.002
21
7.2
Mean
620
1,600
400
400
19
0. 12
330
10
320
580
390
150
23
0.04
120
9.9
68
180
<0.006
81
7. 1
Analytic method: V.7.3.1, Data set I
Blanks indicate data not available.
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TABLE 2-6. CONCENTRATION OF TOXIC POLLUTANTS FOUND IN RAW WASTEWATER FROM
AUTO AND OTHER LAUNDRIES, SCREENING DATA [2-2,3]
NJ
I
Industrial Laundry
Number of detections/ Range of
Toxic pollutant. uq/L Number of samples detections
Metals and inorganics
Ant imony
Arson i c
Be ry 1 1 i urn
Cadm i urn
Chrom i urn
Copper
Cyan i de
Lead
Mercury
Nickel
Se 1 en i urn
Si Iver
Tha 1 1 ium
Z i nc
Phtha lates
Bis (2-ethylhexyl )
phtha late
Butyl benzyl
phtha 1 ate
Di-n-butyl phthalate
Diethyl phthalate
Di-n-octyl phthalate
Nitroq_en compounds
N-n i t rosod i pheny lami ne
Pheno 1 s
2, 1-Di methyl phenol
Phenol
p-Ch 1 oro-m-creso 1
Benzene
D i ch 1 o robenzenes
Ethy 1 benzene
To 1 uene
Polycyclic aromatic hydrocarbons
Anthracene/phenanthrene
2-Ch loronaptha lene
Naptha lene
Halogenated alphatics
Chloroform
D i ch 1 o rob romome thane
Methylene chloride
Tet rach lo roe thy lene
1 , 1 , 1 -Tri ch 1 o roe thane
Trich lo roe thy 1 ene
T r i ch 1 o ro f 1 uo ro-
methane
Pesticides
1 sophorone
21/22
23/23
8/8
36/36
35/35
36/36
25/27
36/36
22/22
35/36
13/13
11/11
9/9
36/36
16/19
3/16
8/17
1/11
1/16
1/2
2/15
6/18
1/3
1 1/15
1/2
8/17
17/17
1/17
1/2
9/1 1
11/16
1/11
8/16
13/17
6/15
8/11
1/2
I/I
BDL
1
1
BDL
10
70
10
BDL
0.5
BDL
-------
o
pj
rt
(D
00
\
OJ
TABLE 2-6. CONCENTRATION OF TOXIC POLLUTANTS FOUND IN RAW WASTEWATER FROM AUTO AND OTHER
LAUNDRIES (continued)
CO
to
O
tr
0)
(0
H
to
I
to
Power Laundry
Number of detections/ Range of
Pollutant. UQ./L Number of samples detections
Heta 1 s and inorganics
Antimony
Arsen ic
Be ry 1 1 i urn
Cadm i urn
Chromi urn
Copper
Cyan ide
Lead
Mercury
Nickel
Selenium
S i 1 ve r
Tha 1 1 [urn
Z inc
Phthalates
Bis(2-ethylhexyl )
phtha late
Butyl benzyl
phtha late
Di-n-butyl phtha late
Diethyl phtha late
Di-n-octyl phtha late
Pheno 1 s
2-Chl oropheno 1
2,i»-Dichlorophenol
2, U-D i me thy 1 pheno 1
Pentachlorophenol
Phenol
Dichl orobenzenes
Polycyclic aromatic hydrocarbons
Anthracene/phenan-
threne
Flucranthene
Naptha 1 ene
Pyrene
Haloqenated aliphatics
Ch lo reform
Methylene chloride
Tetrach 1 oroethy lene
1, 1, l-Trichloroethane
Trichl oroethy lene
5/5
V»
2/2
14/t
6/6
6/6
'i/i|
6/6
6/6
6/6
3/3
6/6
2/2
5/5
3/3
3/3
3/3
1/2
2/3
2/3
I/I
2/3
I/I
2/3
1/2
2/3
I/I
2/3
I/I
2/3
2/3
3/U
I/I
1/2
BDL
10
0.2
<2
7
55
<20
22
BDL
BDL
-------
resulting floe to the surface of the contained effluent where it
can be skimmed off.
In EC pilot tests, chemical addition was required prior to elec-
trolysis to achieve removal of pollutants. Alum, sulfuric acid,
and polymer were added to the laundry effluent. Test results of
laundry wastewater treatment using chemical addition and elec-
trolysis are given in Table 2-34.
TABLE 2-34. RESULTS OF LAUNDRY WASTEWATER TREATMENT
USING A PILOT ELECTROCOAGULATION SYSTEM
(a) [2-2]
Pol lutant
Oil and grease, mg/L
BOD(5), mg/L
TSS, mg/L
Copper, (ig/L
Lead, |ig/L
Zinc, ug/L
Number
or data
points
it
it
4
14
1
>t
Concentration
Influent
Median
530
770
290
200
6140
Range
380 - 690
660 - 960
250 - 330
200 - 300
1, 100
1(60 - 760
Effluent
Median
79
270
140
100
350
Ranae
7M - 150
|i|0 - 600
120 - 170
100 - 200
20
300 - M40
Percent
Median
80
70
50
50
no
remova 1
Ranae
75 - 89
9-82
148 - 51
33 - 50
98
35 - 53
Analytic methods: V.7.3.1, Data set I.
(a)System incorporates chemical addition with alum, sulfuric acid, and polymer at
average dosage rates of 1,100 mg/L, 850 mg/L, and l| mg/L, respectively.
Other technologies have been tested on laundry wastewaters with
varying degrees of success. In general, these techniques are not
applicable to the pollutants present or are not considered eco-
nomically competitive. They include reverse osmosis, foam sepa-
ration, distillation, and carbon adsorption.
Date: 8/31/82 R Change 1 II.2-41
-------
-------
ft
CD
oo
\
U)
CO
to
n
(D
TABLE 3-3. WASTEWATER CHARACTERIZATION OF TOXIC AND CLASSICAL POLLUTANTS
DETECTED IN THE ALKALINE DRAINAGE MINES SUBCATEGORY,
SCREENING AND VERIFICATION DATA [2-5]
Raw Wastewater
Pollutant
Number
of
samples
Number
of
detect Ions
Range
of
detect ions
Mean
of
detect ions
Med ian
of
detect ions
Toxic pollutants, (ig/L
Meta 1 s and
Ant imony
Arsen ic
Asbestos,
Be ry 1 1 i urn
Cadmium
Chromi urn
Copper
Cyanide
Lead
Mercury
Nickel
Se 1 en i urn
Si 1 ver
Tha 1 1 ium
Zinc
Phtha lates
inorganics
f ibers/L
Diethyl phthalate
Di-n-butyl phthalate
Bis(2-ethylhexyl)phthalate
Butyl benzyl phthalate
Nitrogen compounds
3,3 -Dichlorobenzi d i ne
Pheno I s
Phenol
PentachlorophenoI
2,4-Din itrophenol
4,6-Din i tro-o-cresol
Aromat ics
Benzene
1,4-D i chIorobenzene
Ethyl benzene
Toluene
44
44
7
44
44
44
44
28
44
44
44
44
44
44
44
21
21
21
21
21
21
21
21
21
20
21
20
20
14
16
7
4
6
23
24
3
15
20
13
I I
8
7
35
2
0
0
0
BDL - 27 BDL
BDL - 72 II
3.3 x IOE6 - 4.I x IOE9 I.I x IOE9
BDL - BDL BDL
BDL - 21 14
BDL - I 10 43
BDL - 42 13
BDL - BDL BDL
BDL - 94 33
BDL - 13 BDL
30 - 360 98
BDL - 160 23
10-22 14
BDL - 23 BDL
BDL - I,100 91
BDL - BDL BDL
BDL - BDL BDL
BDL - 14 BDL
BDL
BDL - BDL BDL
BDL - 73 26
BDL
I I
I I - 40 26
BDL
BDL
I x IOE8
BDL
15
39
10
BDL
15
BDL
62
20
13
BDL
50
BDL
BDL
BDL
26
-------
D
0)
ft
(D
oo
\
U)
00
to
O
tr
0)
3
iQ
(D
H
•
I
TABLE 3-3. WASTEWATER CHARACTERIZATION OF TOXIC AND CLASSICAL POLLUTANTS DETECTED
IN ALKALINE DRAINAGE MINES (continued)
Raw Wastewater
Number
of
samples
Polynuclear aromatic hydrocarbons
lndeno( 1 ,2, 3-cd Jpyrene
Dibenzo(a, hjanthracene 21
Benzo(ghi )perylene 21
Anthracene/phenanthrene 20
Fluoranthene 21
Naphthalene 21
Pyrene
Halogenated hydrocarbons
Methylane chloride
Chloroform
1 ,2-Dichloroethane
1 , 1 , l-Trich loroethane
T r i ch 1 o rof 1 uo romethane
Tr ich loroethylene
1 , I-D ich loroethylene
1 , 2- trans-D ich loroethylene
Tetrach loroethylene
Pesticides
Alpha-BHC
Beta-BHC
Gamma-BHC
Aldrin
Heptachlor
Heptachlor epoxide
Classical pollutants, mg/L
TSS
1 ron
Manganese
COD
Di sso 1 ved so 1 ids
Total organic carbon
Total volatile solids
Volatile suspended solids
Phenols
pH, pH units
20
20
20
20
20
20
20
20
20
21
21
21
20
21
21
40
44
43
28
16
27
20
15
27
25
Number
of ,
detect ions
1
1
1
0
1
19
12
0
2
0
0
3
0
0
1
1
2
0
0
0
HO
43
35
26
16
22
19
10
6
25
Range
of
detections
BDL
BDL
BDL
1 1
BDL - 9,000
BDL
BDL
BDL
BDL
0.5
0.01
0.003
0.4
85
5
10
1
2
2.5
- 470
- BDL
- BDL
BDL
BDL
- BDL
- 870
- 39
- 7
- 3,300
- 3,200
- 130
- 67,000
- 200
- 40
- 8.6
Mean
of
detections
1,200
75
BDL
BDL
BDL
81
1 .8
0.53
160
1,300
33
3,800
24
18
5.6
Med ian
of
detect ions
530
32
BDL
16
0.38
0. 14
170
880
1 1
140
2.6
16
5.9
-------
p.
rt
n>
TABLE 3-3. WASTEWATER CHARACTERIZATION OF TOXIC AND CLASSICAL POLLUTANTS DETECTED
IN THE ALKALINE DRAINAGE MINES SUBCATEGORY (continued)
CO
\
U)
00
to
O
tr
0)
3
-------
rt
(D
oo
U)
M
\
OO
n
n>
TABLE 3-3. WASTEWATER CHARACTERIZATION OF TOXIC AND CLASSICAL POLLUTANTS DETECTED
IN ALKALINE DRAINAGE MINES (continued)
u>
I
H
cn
Treated Effluent
Number
of
samples
Number Range
of of
detections detections
Mean
of
detect ions
Med ian
of
detect ions
Polynuclear aromatic hydrocarbons
lndeno( 1 ,2,3-cd)pyrene
Dibenzo(a, h) anthracene
Benzofgh i )perylene
Anthracene/phenanthrene
Fl uoranthene
Naphtha lene
Pyrene
Halogenated hydrocarbons
Methylene chloride
Chloroform
1 ,2-Dich lo roe thane
1, 1, 1 -Tr ichloroethane
Trich lorof 1 uorome thane
Trichloroethylene
1, l-Dichloroethylene
1,2-Trans-d ichlo roe thy lene
Tet rach 1 o roethy 1 ene
Pest ic ides
Alpha-BHC
Beta-BHC
Gamma-BHC
A 1 d r i n
Heptachlor
Heptachlor epoxide
Classical pollutants, mg/L
TSS
1 ron
Manganese
COD
D i sso 1 ved so 1 ids
TOC
TVS
VSS
Phenol s
pH, pH units
30
30
30
29
30
30
30
28
28
28
28
28
28
28
38
28
28
28
28
28
28
28
56
57
56
37
23
34
29
24
36
56
1
1
2
3
1
1
25
2
2
4
4
2
2
3
8
56
54
47
35
23
3
29
18
5
56
10
12
BDL - BDL
BDL - BDL
BDL
1 1
BDL
BDL - 71,000
BDL - 470
BDL - BDL
BDL - BDL
16-25
BDL - BDL
BDL - BDL
BDL - BDL
BDL - 81
BDL
BDL
BDL
BDL
BDL
BDL
0.032 - 450
0.021 - 5.1
0.01 1 - 2.8
0.04 - 3,300
86 - 3,600
1 - 65
44 - 67,000
1 - 200
0.002 - 0.04
3.2 - 9.4
BDL
BDL
5, 100
50
BDL
BDL
19
BDL
BDL
BDL
14
30
0.89
0.38
120
1,200
20
2,600
16
0.016
7.7
BDL
790
1 1
BDL
17
BDL
4
12
0.39
0. 17
22
860
9.4
140
4
0.009
7.8
Analytic methods: V.7.3.2, Data sets I, 2.
BDL, below detection limit.
-------
rt
(D
oo
\
U)
TABLE 3-5. WASTEWATER CHARACTERIZATION OF TOXIC AND CLASSICAL POLLUTANTS
DETECTED IN ASSOCIATED AREAS SUBCATEGORY, SCREENING AND VERIFICATION
DATA [2-5]
oo
to
o
(D
H
H
H
•
U)
I
Pol lutant
Toxic pollutants, ng/L
Metals and inorqanics
Antimony
Arsenic
Beryl 1 ium
Cadmium
Chromium
Copper
Lead
Me rcu ry
Nickel
Selenium
S i 1 ve r
Tha 1 1 i urn
Zinc
Phthalates
Di-n-butyl phthalate
Bis(2-ethylhexyl ) phthalate
Aromat ics
Benzene
Chlorobenzene
To 1 uene
Haloqenated hydrocarbons
Methyl chloride
Chloroform
T r i ch 1 o rof 1 uo rome thane
Pesticides
Beta-BHC
Delta-BHC
Classical pollutants, mg/L
TSS
COD
TOC
TVS
VSS
Dissolved sol ids
1 ron
Manganese
pH, pH units
Number
of
samples
9
9
9
9
9
9
9
9
9
9
9
9
9
4
4
4
4
<4
4
it
4
-------
D
0)
rt
(D
oo
\
U)
TABLE 3-5. WASTEWATER CHARACTERIZATION OF TOXIC AND CLASSICAL POLLUTANTS
DETECTED IN ASSOCIATED AREAS SUBCATEGORY (continued)
oo
N)
O
y
&
in
CD
U)
i
NJ
NJ
Treated Effluent
Pol lutant
Toxic pollutants, U9/L
Meta 1 s and inorganics
Antimony
Arsen ic
Be ry 1 1 i urn
Cadmium
Ch rom i urn
Copper
Lead
Mercury
Nickel
Se 1 en i urn
S i 1 ve r
Tha 1 1 i urn
Z i nc
Phtha lates
Di-n-buty! phthalate
Bis(2-ethylhexyl ) phthalate
Aroma tics
Benzene
' Chlorobenzene
Toluene
Haloqenated hydrocarbons
Methyl chloride
Ch 1 o ro f o rm
Trich lorofl uorome thane
Pesticides
Beta-BHC
Del ta-BHC
Classical pollutants, mg/L
TSS
COD
TOC
TVS
VSS
Dissolved sol ids
1 ron
Manganese
pH, pH units
Number
of
samples
8
8
8
8
8
8
8
8
8
8
8
8
8
3
3
3
3
3
3
3
3
3
3
6
3
3
3
2
3
8
8
6
Number
of
detections
2
3
0
2
5
5
1
3
3
3
3
0
6
2
3
1
0
2
3
3
1
1
1
6
3
2
3
2
3
8
7
6
Range
of
detect ions
BDL - BDL
BDL - BDL
15 - 17
li» - 49
BDL - 32
BDL
BDL - BDL
59 - 130
BDL - BDL
BDL - 31
19 - 150
BDL - 210
BDL - 6, 100
BDL
BDL - BDL
BDL - 66,000
BDL - >480
22
BDL
BDL
6-62
16-29
5.5 - 7.6
26 - 58
it. 8 - 20
1,600 - 1,900
0.2 - 9.5
0.027 - 6.3
7.2 - 9.7
Mean
of
detect ions
BDL
BDL
16
30
16
BDL
83
BDL
22
56
1 10
2,000
BDL
22,000
170
25
21
6.6
38
12
1,700
1 .8
1.8
8.0
Med ian
of
detect ions
BDL
27
1 1
BDL
59
BDL
17
38
BDL
550
1 1
18
17
31
1,600
0.62
0.35
7.6
Analytic methods: V.7.3.2, Data sets I, 2.
BDL, below detection limit.
-------
toxic metals were lower than typical values from active mine
drainage. On the other hand, post-mining discharges from under-
ground mines are very similar to wastewater generated during
active mining. This is because the mechanism for wastewater
generation is identical. Nevertheless, these discharges are
subcategorized separately from active mine drainage because these
discharges were not covered under BPT regulations.
Since abandoned underground mines and reclamation areas at sur-
face mines are not actively dewatered and receive their water
input naturally, there are no data available on the amounts of
wastewater discharged from these areas. Discharges from post-
mining underground mines are similar to wastewaters encountered
during active mining, therefore, the reader should refer to the
active mine drainage tables for characterization of post-mining
discharges from underground mines. Table 3-6 presents wastewater
data for areas under reclamation. These data are from self-mon-
itoring surveys and engineering site visits.
II.3.3 PLANT SPECIFIC DESCRIPTION [2-5]
Mine 198
Mine 198 is a surface mine with a 1977 production totalling
218,000 Mg (240,000 tons). The acid drainage at the mine site
consists of pit pumpage and seepage from old spoil piles. There
is also some runoff from new disturbed and reclaimed areas. All
runoff is treated in seven settling ponds dispersed throughout
the mine property. Chemical treatment involves addition of
hydrated lime and potassium permanganate to all ponds. Hydrated
lime is used mainly as a neutralizing agent and has a limited use
as a flocculating agent. Potassium permanganate is used to
oxidize manganese and precipitate it as MnO2. The effluents from
all ponds discharge to a creek. Table 3-7 lists toxic and clas-
sical pollutant verification data for acid surface mine 198.
Mine 21
Mine 21 is an underground mine with a 1976 production of 626,000
Mg (690,000 tons). Drainage from the mine sump is acid and
amounts to 4,360,000 L/d (1,150,000 gal/d). It is treated by a
process involving lime neutralization and sedimentation. The
acid mine drainage empties into an equalization pond. From there
it is pumped to a flash mix tank. A small amount of the pumped
stream is diverted to the slaker where quick lime (stored in a
silo above the slaker) is added by a star valve to form lime
slurry. The slurry is mixed with AMD in the flash mix tank.
From there it passes by a flume, where it received aeration, to a
settling pond. The pond is divided into three sections by two
transverse floating baffles. Sludge is pumped periodically to a
sludge lagoon. At the time of the screening visit, sludge was
pumped from the first section of the settling pond, and the
Date: 8/31/82 R Change 1 II.3-23
-------
TABLE 3-6. WASTEWATER CHARACTERIZATION OF TOXIC AND CLASSICAL POLLUTANTS
DETECTED IN AREAS UNDER RECLAMATION [2-5]
Raw Wastewater
Pol lutant
Toxic pollutants, ug/L
Metals and inorganics
Antimony
Arsenic
Beryl 1 ium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Si Ivor
Tha 1 1 i urn
Zinc
Classical pollutants, mg/L
TSS
1 ron
Manganese
pH, pH units
Toxic pollutants, ug/L
Metals and inorganics
Antimony
Arsenic
Be ry 1 1 i urn
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Se 1 en i urn
Si Ivor
Tha 1 1 1 urn
Zinc
Classical pollutants, mg/L
TSS
I ron
Manganese
pH, pH units
Number
of
samoles
15
15
15
15
15
15
15
15
15
15
15
15
15
16
16
15
16
14
14
14
14
14
14
14
14
14
14
14
14
14
15
15
14
15
Number
of
detections
13
4
8
6
12
14
4
1
8
2
4
3
15
16
16
15
16
1 1
2
5
3
8
1 1
0
0
3
2
4
3
14
15
15
14
15
Range
of
detections
66 - 240
66 • 890
BOL - 12
1 1 - 40
BOL - 120
BDL - 130
30 - 100
40
45 - 1,000
70 - 77
BDL - BDL
150 - 180
BDL - 13,000
12 - 1,900
0.24 - 66
0.094 - 12
5. 1 - 8.0
Treated
52 - 260
42 - 55
BOL - BDL
BDL - BDL
BDL - 24
BOL - 41
71 - ISO
42 - 77
BOL - BOL
12 - 140
BDL - 380
10-82
0.3 - II
0.077 - 6.9
5.5 - 8.0
Mean
of
detections
120
330
BDL
19
37
44
59
260
74
BDL
160
1,200
340
13
1 .4
7.3
Effluent
100
48
BOL
BOL
12
17
1 10
60
BDL
58
71
30
2. 1
0.83
7.4
Median
of
detections
100
79
BOL
16
17
19
37
85
BOL
150
71
72
2.4
0.39
7.5
78
BDL
BOL
BOL
15
82
BOL
23
32
22
0.81
0.24
7.5
Analytic method: V.7.3.2, Data set 3
BDL, below detection limit.
Date: 8/31/82 R Change 1 II.3-24
-------
TABLE 3-7. PLANT SPECIFIC TOXIC AND CLASSICAL POLLUTANT DATA FOR ACID SURFACE MINES,
SUBCATEGORY, PLANT 198, VERIFICATION DATA [2-5]
Pol lutant
Toxic pollutants, M9/L
Metals and Inorganics
Antimony
Arsenic
Asbestos, fibers/L
Beryl 1 ium
Chromi urn
Copper
Lead
Mercury
Nickel
Selenium
Si Ivor
Thai 1 Ium
Zinc
Phthalates
Bis (2-ethylhexyl ) phthalate
Dl-n-butyl phthalate
Diethyl phthalate
Aromat ics
Benzene
Ethyl benzene
Toluene
Polvnuclear aromatic hydrocarbons
Naptha lene
Benzo( a (pyrene
Benzo ( k)f luoranthene
Di benzo( a, h (anthracene
lndeno( 1 , 2,3-c,d)pyrene
Haloqenated hydrocarbons
Methylene chloride
Dissolved metals, ug/L
Antimony
Copper
Nickel
Selenium
Si Iver
Thai 1 ium
Zinc
Aluminum
Tota 1 i ron
Manganese
Classical pollutants, mg/L
COD
Dissolved sol Ids
Settleable sol ids
Total organic carbon
Aluminum
Chloride
Manganese
Alka 1 inl ty (CaCo3)
pH , pH units
Phenol Ics (MAAP)
Sul rate
Ha rdness
1 ron
Raw
wastewater (a)
0.71
0.29
1,800,000
M.9
MO
190
58
0.29
230
3.3
5.3
2
380
1.6
<6.l
99
57
>99
>99
>99
>99
>99
52
NM
NM
>99
76
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
25
29
>99
17
NM
NM
NM
28
NM
NM
>99
>99
99
NM
l|0
NM
>99
NM
NM
>99
Analytic methods: V.7.3.2, Data set 2.
NA, not analyzed.
ND, not detected.
NM, not meaningful.
(a)Data are averages of 5~day sampling program.
Date: 8/31/82
Change 1 II. 3-25
-------
effluent from the pond was discharged to a creek. The lagoon did
not discharge. At the time of the verification visit, sludge was
pumped from the third section of the pond, and both the pond and
the lagoon were discharging. Aquifer drainage [150,000 L/d
(40,000 gal/d)] is pumped from'the airshaft to prevent flooding,
and is discharged without treatment. Table 3-8 lists toxic and
classical pollutant verification data for acid underground mine
21.
Mine 23
Mine 23 is an underground mine with a 1976 production of 980,000
Mg (1,080,000 tons). Acid mine drainage from the sump is pumped
to an equalization pond at the rate of 23,400,000 L/d (6,190,000
gal/d). From there it is pumped to a flow splitter which sends
the AMD to one of two parallel treatment systems. As the drainage
flows from the splitter to the aerator, lime slurry from the lime
mixer and sludge recycle are added to the stream. The mixture
then flows via a flume to a thickener. The lime slurry is formed
in the mixer by adding slaked lime from a storage container to
water pumped from the flume. The amount of water added to the
mixer is regulated by a level control box, and excess water is
returned to the flume. The overflow from the thickener passes to
a polishing pond which discharges to a creek at the rate of
15,800,000 L/d (4,180,000 gal/d). Sludge from the thickener is
pumped to an abandoned mine. Table 3-8 lists toxic and classical
pollutant verification data for acid underground mine 23.
Mine 188
Mine 188 is an acid mine drainage treatment plant. The source of
the acid mine drainage treated by the plant is the creek next to
which it is located. Upstream of the treatment plant acid mine
drainage discharges into the creek from active and abandoned
mines. Also, runoff from undisturbed areas and from refuse piles
empties into the stream. The treatment process is a complex
process involving primary settling, lime addition, aeration,
flocculant addition, clarifying, thickening, secondary settling
(2 polishing ponds) and sludge drying (2 non-discharging ponds).
Effluent from the second polishing pond discharges to the creek.
Normally the entire flow of the creek passes through the treat-
ment plant. During high flow periods, water is bypassed around
the plant and discharges into the first polishing pond. Lime is
hand-fed into the bypass stream to raise the pH to provide excess
alkalinity in the final discharge. During floods the excess
water is directed untreated back into the original stream channel
to be treated downstream. Table 3-8 lists toxic and classical
pollutant verification data for acid underground mine 188.
Date: 8/31/82 Change 1 II.3-26
-------
Mine 190
Mine 190 is an underground mine with a 1978 production of 315,000
Mg (347,000 tons). Two shafts are the sources of the acid mine
drainage. The drainage from the first shaft is fed into a reactor
mixing tank. This tank is used to mix hydrated lime with the
mine water. The effluent from the reactor tank flows directly to
a settling pond, a Dorr thickener, or is used as process water in
the preparation plant. The settling pond effluent and the prepa-
ration plant wastewater in turn flow to the Dorr thickener. The
thickener overflow is collected prior to discharging to the creek
at the rate of 64,300,000 L/d (17,000,000 gal/d). The untreated
drainage from the second shaft is discharged to the creek at the
rate of 53,000,000 L/d (14,000,000 gal/d). Table 3-8 lists toxic
and classical pollutant verification data for acid underground
mine 190.
Mine 9
Mine 9 is a surface mine with a 1976 production of 2,180,000 Mg
(2,400,000 tons). Pit water is the major source of the alkaline
drainage at the mine since the lignite seam is an aquifer. The
AMD is treated by a system of flocculation and sedimentation.
Prior to entering settling ponds, two types of flocculant are
metered into the drainage. One is a cationic flocculant which is
added at the rate of 94,000 L/d (24,800 gal/d), and the other is
an anionic flocculant which is added at the rate of 20,400 L/d
(5,400 gal/d). The effluent from the pond is discharged to
surface waters. Five ponds are nondischarging, and no flocculant
is added to these. Table 3-9 lists toxic and classical pollutant
verification data for alkaline surface mine 9.
Mine 10
Mine 10 is a surface mine with a 1977 production of 384,000 Mg
(423,000 tons). The alkaline mine drainage is the result of
surface runoff and pit water. Treatment is provided by settling
ponds, and the effluent is discharged to surface waters. There
is one baffled pond in use at the mine. The baffle system con-
sists of a fixed baffle at the influent end which causes consid-
erable siltation, and one located at the discharge stand pipe
which forms a flume extending across the pond. Effluent from
this pond is discharged to surface waters. Table 3-9 lists toxic
and classical pollutant verification data for alkaline surface
mine 10.
Mine 11
Mine 11 is a surface mine with a 1976 production of 204,000 Mg
(225,000 tons). Alkaline drainage [21,570,000 L/d (5,700,000
gal/d)] from the mine results from surface runoff and pit water.
Continual dewatering of the pit prevents acid formation, and the
Date: 8/31/82 Change 1 II. 3-27
-------
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TABLE 3-8. PLANT SPECIFIC TOXIC AND CLASSICAL POLLUTANT DATA FOR ACID UNDERGROUND MINES
SUBCATEGORY (MINES 21, 23, 188, 190), VERIFICATION DATA [2-5]
ro
oo
Pol lutant
Toxic pollutant, M9/L
Hetals and Inorganics
Antimony
Arsenic
Beryl 1 lum
Cadmium
Ch rom 1 urn
Coppe r
Cyanide
Lead
Mercury
Nickel
Se 1 en 1 urn
SI Iver
Zinc
Phtha lates
Bis(2-ethylhexyl ) phthalate
Butyl benzyl phthalate
Ol-n-butyl phthalate
Diethyl phthalate
Haloqenated allphatlcs
Ch lo reform
Methylene chloride
Pesticides and metabolites
Alpha-BHC
Beta-BHC
Delta-BHC
Gamma -BHC
Heptachlor
Classical pollutants, mg/L
Total volatile solids
COO
TSS
Settleable sol Ids
Total organic carbon
Aluminum
Boron
Ca 1 c 1 urn
Coba 1 t
Magnesium
Manganese
Molybdenum
pH, pH units
Sod f urn
Tin
Titanium
Total Iron
Vanadium
Yttrium
Raw
wastewater
2.1
31
9.3
NO
60
77
NO
27
0.17
1400
ND
8.3
900
ND
NO
<3.3
ND
<6.7
99
75
>99
>99
>99
>99
NM
>99
NM
98
NM
NM
>99
NM
NM
NM
NM
NM
>99
13
NM
71
99
6
97
0
NM
>99
65
11
95
15
88
NM
99
90
87
Raw
wastewater
31
18
9.3
10
80
13
ND
100
ND
1,000
0.67
ND
NO
ND
ND
99
>99
>99
75
>99
NM
>99
>99
NM
NM
NM
NM
77
93
61
>99
59
98
18
NM
>99
39
17
>99
NM
78
99
>99
>99
-------
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TABLE 3-8. PLANT SPECIFIC TOXIC AND CLASSICAL POLLUTANT DATA FOR ACID UNDERGROUND MINES
SUBCATEGORY (MINES 21, 23, 188, 190), VERIFICATION DATA [2-5] (CONTINUED)
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Mine
Raw
Pollutant wastewater
Toxic pollutant, M9/L
Metals and Inorganics
Arsenic
Beryl 1 lum
Chromium
Copper
Lead
Mercury
Nickel
Se 1 en i um
Si Iver
Tha 1 1 i um
Zinc
Phthalates
Bls(2-ethylhexyl ) phthalate
Di-n-butyl phthalate
Dl ethyl phthalate
Polycycllc aromatic hydrocarbons
Napthalene
Phenanthrene
Halogenated allphatlcs
Chloroform
Methyl ene chloride
Dissolved metals, |ig/L
Beryllium
Chromium
Coppe r
N 1 eke 1
Sliver
Zinc
A 1 um i num 2
Tota 1 i ron 9
Manganese 3
Classical pollutants, mg/L
COD
Dissolved sol Ids
TSS
Settleable sol Ids 0.
Total organic carbon
A 1 um i num
Chloride
Manganese
pH, pH units
Phenol Ics (4AAP)
Sulfate
Tota 1 i ron
Hardness
Acidity (CaCoJ)
Alkal inity (CaCo3)
NA
2.3
28
32
5
ND
60
ND
5
ND
550
< 1 1
ND
ND
ND
ND
ND
ND
2.3
170
48
55
4
530
,600
,600
,700
42
460
86
0005
0.6
3.3
0.9
3.9
3.6
ND
270
0. 12
210
41
NA
188. (a)
Treated
wastewater
NA
0.67
9
10
ND
ND
3.3
ND
2.2
ND
85
< 1 6
ND
ND
ND
ND
ND
ND
ND
17
7.3
ND
ND
54
480
30
66
ND
430
5.7
ND
0.6
0.63
1.5
0.3
7.2
2.3
260
0.073
260
NA
16
Percent
remova 1
71
68
69
>99
94
56
84
NM
>99
90
85
>99
>99
90
82
>99
98
>99
6
93
>99
0
81
NM
92
NM
4
39
NM
Raw
wastewater
ND
5
43
24
4.5
ND
64
ND
5.5
ND
1,200
40
12
21
NO
3
99
0
89
90
99
91
NM
18
NM
NM
8
NM
NM
70
20
46
NM
NM
Analytic methods:
NA, not analyzed
ND, not detected.
NM, not meaningful.
(a) Data are averages of 3-day sampling program.
-------
drainage is treated in settling ponds. Discharge is intermittent
depending upon rainfall. Table 3-9 lists toxic and classical
pollutant verification data for alkaline surface mine 11.
Mine 18
Mine 18 is an underground mine with a 1976 production of 544,000
Mg (600,000 tons). The alkaline drainage is pumped from the mine
at 927,000 L/d (245,000 gal/d), and is treated by a series of
three settling ponds to remove suspended solids. At the time of
the screening visit a flocculant (stored in a 55 gallon container)
was added to the drainage between pond one and pond two by drip-
ping through a spigot. At the time of the verification visit,
flocculation had been discontinued as new land had been made
available for larger settling ponds. The last settling pond
discharges to surface waters. Table 3-10 lists toxic and class-
ical pollutant verification data for alkaline underground mine
18.
II.3.4 POLLUTANT REMOVABILITY [2-5]
Full-scale treatment methods that have been cited in the litera-
ture, but for which no data were presented, include: neutraliza-
tion sometimes followed by aeration and oxidation of Fe (II) to
Fe (III), reverse osmosis, ion exchange, settling, ozonation,
mixed media filtration, and engineering design (planning) to
prevent acid formation (entailing oxygen, water, and contact time
exclusion).
Date: 8/31/82 Change 1 II. 3-30
-------
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TABLE 3-9. PLANT SPECIFIC TOXIC AND CLASSICAL POLLUTANT DATA FOR ALKALINE SURFACE
MINES SUBCATEGORY (MINES 9, 10, II), VERIFICATION DATA [2-5]
Pol lutant
Toxic pollutant, |ig/L
Metals and Inorganics
Ant i mor.y
Arsenic
Ch rom i urn
Copper
Lead
Mercury
Nickel
Se I en i urn
Si Iver
Thallium
Zinc
Phthalates
Bi s(2-ethylhexyl ) phthalate
Butyl benzyl phthalate
Dl-n-butyl phthalate
Dlethyl phthalate
Dimethyl phthalate
Dl-n-octyl phthatate
Nitrogen compounds
3 , 3 ' -0 1 ch 1 orobenz 1 d 1 ne
1 ,2-Diphenylhydrazlne
Pheno 1 s
2 , t-0 1 n i t ropheno 1
Pentach 1 oropheno 1
Pheno 1
1,6-Dlnl tro-o-cresol
Aromat ics
Benzene
1 ,2-Dichlorobenzene
1 -II-D ! ch 1 orobenzene
Ethyl benzene
Toluene
Polycvclic aromatic hydrocarbons
Benzo(ghi )perylene
Dibenz( ah) anthracene
Fluoranthene
F 1 uorene
lndeno( 1 ,2,3-cd)pyrene
Naptha lene
Pyrene
Raw
wastewater
12
3.2
55
9.5
ND
0.55
ND
2
ND
NO
ND
ND
ND
< 10
ND
ND
ND
ND
ND
ND
ND
ND
ND
120
ND
ND
5
28
ND
ND
ND
ND
ND
ND
ND
Mine 9 (a)
Treated
wastewater
12
3.6
63
0.89
ND
0.52
ND
1.2
ND
1.6
ND
NO
ND
99
>99
11
0
25
83
>99
>99
>99
NM
NM
NM
Raw
wastewater
ND
NO
100
ND
ND
ND
ND
ND
ND
ND
ND
< 1 0
< 10
<10
ND
ND
ND
ND
ND
ND
ND
< 10
ND
ND
< 10
-------
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TABLE 3-9. PLANT SPECIFIC TOXIC AND CLASSICAL POLLUTANT DATA FOR ALKALINE SURFACE
MINES SUBCATEGORY (MINES 9, 10, II), VERIFICATION DATA [2-5] (CONTINUED)
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Pol tutant
Haloaenated aliohatics
Ch (oroform
1 , 1 -Dichloroethylene
Hexach 1 o roe thane
Methylene chloride
Te t rach 1 o roe thy 1 ene
1, 1, l-Trichloroethane
Trichloroethylene
Pesticides and metabolites
Aldrin
B-BHC
Hep tach lor
Heptachlor epoxide
Classical pollutants, mg/L
COD
TVS
TSS
Settleable sol ids
Total organic carbon
Al umi num
Ba r i urn
Boron
Ca 1 c i um
Coba 1 t
Manganese
Magnes ium
Mo lybdenum
pH, pH units
Sod i um
Tin
T i tan ium
Total iron
Vanad turn
Yttrium
Raw
wastewater
60
73
NM
NM
88
56
NM
NM
NM
NM
NM
5
NM
55
7
96
52
NM
NM
18
NM
>99
23
NM
85
89
NM
Raw
wastewater
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
NO
15
110
86
0.0003
17
770
68
33
92
1.8
0.58
28
ND
7.8
18
ND
0.012
1.1
0.003
0.003
Mine 10 (a)
Treated
wastewater
99
61
16
28
NM
17
NM
33
67
Raw
wastewater
ND
NO
ND
NO
ND
ND
ND
ND
ND
ND
ND
21
210
7.9
ND
7.8
1
0.01
0.32
0.21
ND
1
100
NO
6.6
310
0.03
NO
6.3
ND
ND
M i ne II la)
Treated
wastewater
NO
ND
1.1
<1
<0.2
NO
<0. 17
ND
ND
ND
ND
17
260
58
0.00031
1
1.3
0.019
0.5
0.31
ND
0.31
71
ND
8.0
300
0.018
0.007
1 . 1
ND
ND
Percent
remova 1
NM
NM
NM
NM
29
NM
NM
NM
19
NM
NM
NM
NM
92
29
3
10
NM
83
Analytic methods: V.7.3,2, Data set 2.
NA, not analyzed.
ND, not detected.
NM, not meaningful,
(a) Data are averages of 3-day sampling program
-------
TABLE 3-10. PLANT SPECIFIC TOXIC AND CLASSICAL POLLUTANT DATA FOR ALKALINE
UNDERGROUND MINES SUBCATEGORY (MINE 18), VERIFICATION DATA [2-5]
Pol lutant
Toxic pollutants, ug/L
Metals and Inorganics
Cadmium
Chromium
Lead
Mercury
Nickel
Se 1 en { um
Phthalates
Bls(2-ethylhexyl ) phthalate
Butyl benzyl phthalate
Benzene
Haloqenated allphatlcs
Methylene chloride
Pesticides and metabolites
Alpha-BHC
Beta-BHC
Oelta-BHC
Classical pollutants, mg/L
COD
TVS
TSS
Total organic carbon
Barium
Boron
Ca 1 c lum
Coba 1 1
Manganese
Magnesium
Molybdenum
pH, pH units
Sod I um
Tin
Titanium
Tota 1 1 ron
Vanadium
Yttrium
Raw
wastewater
M
30
50
1.9
13
NO
NO
NO
NO
<3.3
0.37
0. 13
NO
13
16
2.6
5.5
0.03
1.3
70
0.007
6
32
0.007
7.5
160
O.OM
0.003
7.3
0.013
0.013
Mine 18 la)
Treated
wastewater
NO
9.7
NO
0.3
NO
1
<6.7
<3.3
<3.3
<3.3
0.03
0.26
0.07
l>4
71
3.8
5.3
0.0i»
1
65
NO
i»
31
NO
7.8
150
0.03
ND
"4.7
ND
ND
Percent
remova 1
>99
68
>99
84
>99
NM
NM
NM
NM
NM
92
NM
NM
NM
NM
NM
It
NM
23
7
>99
33
3
>99
6
25
>99
36
>99
>99
Analytic methods: V.7.3.2, Data set 2.
NA, not analyzed.
ND, not detected.
NM, not meaningful
(a) Data are averages of 3-day sampling program.
Date: 8/31/82
Change 1 II.3-33
-------
-------
Ammonium hydroxide. Ammonium hydroxide is predominantly
used as a chemical intermediary and reagent. It is also used in
the dyeing and bleaching of fabrics, the production of ammonium
salts and aniline dyes, and -the extraction of alkaloids from
plants.
No plants with a discharge were found in this subcategory.
Therefore, this industry has been recommended as a Paragraph 8
exclusion candidate.
Barium carbonate. Barium carbonate is used in glass manu-
facturing, as a flux in ceramics and enameling, as an intermedi-
ate in the production of barium oxide and hydroxide, and as a
coating for photographic paper. It is also used in the synthetic
dyestuff industry and for the removal of soluble sulfate in brick
manufacturing.
No toxic pollutants were found at significant levels in the waste
during screening of barium carbonate plant 360. On the basis of
these findings, this subcategory has been recommended as an
exclusion candidate under Paragraph 8.
Borax. Borax is produced by dissolving sodium borate ores
in recycled mother liquors and water. The insolubles settle out
in ponds or are removed by thickeners, and the clarified borax
solution (mother liquor) is fed to crystallizers where a slurry
of borax crystals is formed.
Because existing BPT regulations require zero discharge of process
wastewater pollutants to navigable waters, this subcategory has
been recommended as an exclusion candidate under Paragraph 8.
Boric acid. Boric acid is used in the manufacture of chro-
mic oxide, glazes, enamels, textile fiberglass, and heat resist-
ant glass. It is also used medicinally as a mild antiseptic and
in atomic power plants as a nuclear moderator.
Only one plant manufactures boric acid from mined ore. There is
an indication that this plant will discontinue operation. All
other plants manufacture boric acid using the Trona process and
have zero discharge. This subcategory is excluded under Paragraph
8 of the Consent Decree.
Bromine. Most bromine is produced from brines pumped from
brine wells. A small amount is produced from brines from Searles
Lake near Trona, CA. This is not a navigable water because it is
35% solids. The brine, after appropriate dilution and degassing
is extracted by debromination with chlorine and steam. The steam
and chlorine are condensed, separated, and distilled to obtain
bromine.
Date: 8/31/82 R Change 1 II.5-27
-------
Since the raw wastes are returned to the brine well or brine
source, discharge is near zero. Therefore, this subcategory has
been recommended for exclusion under Paragraph 8.
Calcium carbide. Calcium carbide is produced by the reac-
tion of calcium oxide and coke. Calcium carbide is used to pro-
duce acetylene by reaction with water. Because the process for
calcium carbide production is dry, little wastewater is gen-
erated.
This subcategory has limited water effluent from the production
plants and has been recommended as an exclusion candidate under
Paragraph 8.
Calcium carbonate. Calcium carbonate is manufactured both
in pure and impure form and it is extensively used in many indus-
tries. In the pure form, it is used in the rubber, paint,
cement, paper, and pharmaceutical industries.
No toxic pollutants were found at significant levels in the raw
waste during screening of calcium carbonate plant 883. On the
basis of these findings, this subcategory has been recommended as
an exclusion candidate under Paragraph 8.
Carbon dioxide. Carbon dioxide is produced in gaseous, liq-
uid, or solid form. A major portion of the production is used
captively for the production of urea and for the secondary recov-
ery of oil and natural gas. It is also used for refrigeration,
in the food industry, for the carbonation of beverages, in fire
extinguishing equipment, and for oil well stimulation.
The only toxic pollutant found at a significant concentration in
the raw waste during screening at plant 241 was zinc at a concen-
tration of 910 vg/L. When the data were reviewed with plant per-
sonnel, it was discovered that the high zinc level was due to
zinc corrosion inhibitors; it was not process related. There-
fore, this subcategory has been recommended as an exclusion
candidate under Paragraph 8.
Carbon monoxide and byproduct hydrogen. In the production
of hydrogen by refining natural gas, carbon monoxide is also pro-
duced. Carbon monoxide is recovered from several gas sources in-
cluding partial combustion of oil or natural gas, coke oven gas,
blast furnace gas, water gas, and methane reformer gas.
Carbon monoxide and byproduct hydrogen form the building blocks
for other chemicals such as ammonia and methanol. The major use
of carbon monoxide is for the manufacture of methanol. It is al-
so used as a gaseous fuel for reducing oxides for special steels,
in nickel refining, and in the manufacture of ammonia, acetic
acid, and zinc white pigments.
Date: 9/25/81 II.5-28
-------
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WET
SPAR"
HOSE DOWN
WATER
'51
(HOSE DOWN WATER
AHF PLANT
LEGEND
SAMPLING POINTS.
WATER
EFFLUENT
12
ALKALINE STREAMS AND
ACID FROM OTHER PLANTS
Figure 5-2. General process flow diagram at plant 251 showing
the sampling points (aluminum fluoride manufacturing).
-------
TABLE 5-34. FLOW AND POLLUTANT LOADING DATA OF THE
SAMPLED WASTESTREAMS FOR PLANT 251 PRO-
DUCING ALUMINUM FLUORIDE [2-6]
Stream
4
6
2
3
Flow,
Wastestream m3/Mg
description A1F3
A1F3 scrubber water 12 . 6
S02 scrubber water (a) 6.10
Gypsum pond influent(b) 25.1
Gypsum pond effluent(b) 25.1
TSS
16
ND
470
0.23
kg/Mg A1F3
Fluoride Aluminum
5.9 0.60
0.14 0.001
17 0.65
8.0 0.55
Analytic methods: V.7.3.4, Data sets 1,2.
ND, not detected.
(a)Half of the SO2 scrubber water flow has been assumed to contri-
bute to the A1F3 process and half to the HF process.
(b)Consists of HF and A1F3 wastewater.
TABLE 5-35. WATER USAGE, WASTEWATER FLOW, AND SOLIDS
GENERATION FOR ALUMINUM FLUORIDE PLANTS
705 and 251 [2-6]
(m3/Mg A1F3)
Plant Plant
Description 705 251
Water usage
Noncontact cooling
Indirect process contact 1.15
(pumps, seals, leaks, spills)
Maintenance 2.39 1.02
(cleaning and work area
washdown)
Scrubber 8.92 18.7
Wastewater flow
Scrubber water 8.92 18.7
Maintenance (equipment cleanup 2.39 1.02
and work area washdown)
Other
Solids generated 54 69
Blanks indicate data not available.
Date: 8/31/82 R Change 1 II.5-62
-------
Waste flow data from the various sampling points at plants 736
and 967 are contained in Table 5-43. Table 5-44 presents the
results of asbestos sampling at the two plants.
TABLE 5-43.
WASTE FLOW DATA FOR CHLOR-ALKALI
PLANTS USING DIAPHRAGM CELLS [2-6]
Flow. cu.m/Mq CI2
Plants with
metal anodes
Was test ream description Minimum
Cell room wastes and cell wash 0.02
Chlorine condensate 0.16
Spent sulfuric acid
Ta i 1 gas scrubber 0.10
Caustic filter wash
Brine filter backwash
Caustic cooling blowdown 0.82
Brine mud 0.04
Average Maximum
0.38 0.67
0.49 0.90
0.01
0.17 0.29
0.86 0.89
0.42 1.5
Plant with
graphite anode
1 .2
0.78
0. 1 1
5.4
0.45
Blanks indicate data not available.
TABLE 5-44.
RESULTS OF ASBESTOS SAMPLING AT CHLOR-ALKALI
PLANTS USING DIAPHRAGM CELLS [2-6]
Plant
736
967(a)
Wastestream description
Supply
Cel 1 wash
Ce 1 1 room waste
Barometric condenser
Barometric condenser
Barometric condenser
Supply
Ce 1 1 waste
Pond effluent
Caustic wash
Brine filter backwash
Cathode wash waste
Condensate and spent acid
Neutra 1 izer waste
Mi 1 1 ion
Total asbestos
fibers
0.7
20,000,000
290
1.8
5.3
140
970
24,000
2,400
7,800
800
320,000
270
2, 100
f i bers/ 1 i ter
Chrysot i le
0.7
20,000,000
280
NO
5.3
140
970
24,000
2,400
7,800
620
320,000
180
2, 100
Amph ibo le
ND
ND
8
1 .8
ND
ND
ND
800
ND
ND
180
ND
89
ND
ND, not detected.
(a) Uses graphite anode.
Date: 8/31/82 R Change 1 II.5-75
-------
II.5.3.3 Chrome Pigments
Two plants were selected for detailed description from the avail-
able data on the chrome pigment subcategory based on the lowest
concentration of toxic pollutants in the final effluent stream.
Plant 894
Screening and verification data are provided for plant 894, which
produces over 100 products including organic pigments such as
copper phthalocyanine. All wastes are combined and treated
together. Treatment consists of chromium VI reduction, equali-
zation, and neutralization, followed by clarification and filtra-
tion. Sulfur dioxide is added to reduce the hexavalent chromium
to the trivalent state at a low pH prior to hydroxide precipita-
tion. The backwash from the sand filters is recycled to the
equalization tank. Sludge from the clarifiers is passed through
filter presses and then hauled to a landfill, which has a bottom
composed of two clay layers with gravel in between to allow the
collection of leachate drainage. Water from the sludge is
trapped in the gravel layer, then pumped out and returned to the
plant for retreatment.
Figure 5-8 shows the treatment system flow diagram and the sam-
pling points. Table 5-45 provides waste flows and pollutant
loadings data. Table 5-46 presents influent and effluent verifi-
cation data for the treated effluent.
TABLE 5-45.
FLOW AND POLLUTANT LOADING DATA OF THE
SAMPLED WASTESTREAMS FOR PLANTS PRODUCING
CHROME PIGMENTS [2-6]
Plant
891
( Veri fi cat ion
phase)
Wastestream
descr [pt ton
Trea tment
inf-luent
Treatment
effluent
Leachate
Flow,
cu . m/Mg
product
170
170
kq/Mq product
TSS Chromium
130 NO
0.66 0.0039
ND NO
1 ron
8.2
0.051
Sand fiIter
reed
170
ND
0. 17
002
(Verification
phase)
Untreated
waste
78.
Analytic methods: V.7.3.14, Data set 2
Blanks indicate no data available.
ND, not detected.
55
0. 13
Onf i 1 tered
treated
waste 78. "4
Fi 1 tered
treated
waste 78. M
76 9.U 0.18
0.001(7
Date: 8/31/82 R Change 1 II. 5-76
-------
CAUSTIC
I #2-U
r
RAW WASTE S0
#1
ACID
CHROME TREATMENT
TANK
pH 3.0
CAUSTIC ADDITION
THROUGH
pH 8.5
J.AB FILTERED
OUTFALL
TO SEWER
FILTER FEED
TANK
I
FILTER AID
BACKWASH
(FILTERS NOT WORKING SO
1 WERE BEING BYPASSED.
• THIS WOULD BE THE FLOW
* PATTERN IF FILTERS WERF
OPERATING.)
LEGEND
SAMPLING POINTS.
Figure 5-9,
General wastewater treatment process flow
diagram at plant 002, manufacturing chrome
pigment, showing the sampling points
Date: 9/25/81
II.5-79
-------
TABLE 5-47. TOXIC POLLUTANT LOAD IN RAW WASTE
AT CHROME PIGMENT PLANTS [2-6]
(kg/Mg product)
Pollutant Plant 894 Plant 002
Cyanide
Chromium
Cadmium
Copper
Lead
Zinc
Antimony
Nickel
0.84
14
0.15
0.70
0.82
0.71
0.13
0.0028
0.056
24
0.016
0.11
4.2
13
0.11
0.025
Analytic methods: V.7.3.4, Data set 2
TABLE 5-48. WATER USAGE IN THE CHROME PIGMENTS
SUBCATEGORY [2-6]
Unit flow (m3/Mg)
Plant Plant Plant
Use 464 436 214
Noncontact cooling
Direct process contact
Indirect process contact
Maintenance
Scrubbers
Boiler feed
Total
9.50
18.6
7.18
12.0
3.3
2.52
53.1
6.45
147
1.78
9.56(a)
11.1
176
32.6
0.152
0.152
32.9
(a)Iron blue pigment process.
Blanks indicate data not available.
II.5.3.4 Copper Sulfate
One plant was selected for detailed description from the avail-
able data on the copper sulfate subcategory based, on the lowest
effluent concentration of toxic pollutants in the final effluent
stream.
Plant 034
Verification data are provided for plant 034. Waste from the
plant drains into a sump from which it is pumped to two neutral-
ization tanks where lime is added. The waste is then passed
Date: 8/31/82 R Change 1 II.5-80
-------
TABLE 5-57. SUMMARY OF RAW WASTE LOADING AND CONCEN-
TRATION DATA AT HYDROGEN CYANIDE PLANT 765,
VERIFICATION DATA [2-6]
Influent
Pollutant mg/L kg/Mg
TSS
Cyanide,
Cyanide,
NH3-N
total
free
35
29
14
480
2.0
1.6
0.82
27
Analytic methods: V.7.3.4, Data set 2
Plant 782
Verification data are provided for plant 782, which combines the
plant wastewater with other production wastewater and treats the
combined flow in a complex biological treatment system. A part
of the commingled wastewater is sent to an ammonia stripper from
which the aqueous effluent is mixed with the rest of the waste-
water and sent to the treatment facility. The primary treatment
facility consists of oil skimmers, grit removal, and pH adjust-
ment. Effluent from the primary treatment goes through an API
separator and into an aerated lagoon. Effluent from the lagoon
is flocculated and sent to a clarifier. Overflow from the clar-
ifier is sent to a final settling basin before discharge. Surface
drainage from the hydrogen cyanide and other process areas is
collected separately. It is treated chemically and passed through
a trickling filter. It then merges with the treated process
wastewaters in the clarifier.
A general flow diagram of the treatment process including the
streams sampled is shown in Figure 5-14. Table 5-58 provides
the flow data and concentrations of the important pollutants.
Because of the intermixing of the various product wastewaters,
unit pollution loads are uncertain and not given. The total
wastewater generated from HCN manufacture and the amount
going to the treatment facility was verified during the plant
visit and was confirmed in the 308 Questionnaire response pro-
vided by the industry. Based on that flow and the concentrations
determined by analysis, the raw waste load is that shown below:
Total Free Ammonia
Flow, cyanide, cyanide, nitrogen, TSS,
CU.m/Mg kq/Mq HCN kq/Mq HCN kg/Mq HCN kq/Mq HCN
Effluent from 9.9 0.022 0.017 0.055 0.7t
combined plant
waste treatment
Date: 8/31/82 R Change 1 II.5-91
-------
#1
DISTILLATION
BOTTOM PURGE
f
#2
AMMONIA
STRIPPER
PRIMARY
TREATMENT
BIOLOGICAL
TREATMENT
CLARIFIER
SETTLING
POND
#5
DISCHARGE
OTHER PRODUCT
WASTE WATERS
OTHER PRODUCT
WASTE WATER
SURFACE DRAINS
CHEMICAL AND
BIOLOGICAL
TREATMENT
LEGEND
SAMPLING POINTS
Figure 5-14. General wastewater treatment process flow
diagram at plant 782, manufacturing hydrogen
cyanide, showing the sampling points
Date: 9/25/81
II.5-92
-------
bisulfite waste to sulfite. The sulfite is then oxidized to
sulfate with air. The treated waste (stream #6) is discharged
to a river after a 17-hour retention period.
Figure 5-17 provides a process flow diagram of plant 987, includ-
ing sampling points. Table 5-65 provides flow and pollutant
loading data on the sampling points.
TABLE 5-65.
FLOW AND POLLUTANT LOADING DATA OF THE SAMPLED
WASTESTREAMS FOR PLANTS PRODUCING SODIUM BISULFITE,
VERIFICATION DATA [2-6]
Plant
987
586
Wastestream description
F i 1 ter wash (#1 )
f loo r wash, sp i 1 1 s, etc.
Fi 1 ter wash (#2)
Treatment influent
(streams 1+2+3)
54-hour aeration (#5)
Treated effluent (#6)
MBS sump 1
MBS sump 2
Amine oxidation pond
ZnSO(4) pond effluent
Lime treatment influent
Truck washdown
S0(2) wastes
Final treated effluent
Flow,
cu.m/Mg
product
0.055
0.013
0.041
0. 1 1
0. 14
0. 14
9.68(a)
9.68(a)
2.77(b)
78.5(b)
1 I0(b)
0. I34(b)
85.9(b)
I88(C)
kq/Mq product
TSS
0. 1 1
0.046
0.0052
0.32
0.38
0.0031
0. 19
0.051
2.4
12
1 1
0.012
2.0
4.3
COD
1 .4
0.30
0.91
3.5
1 .2
1 .0
1 . 1
0.46
2.3
0.76
29
0.098
53
22
Analytic methods: V.7.3..4, Data set 2.
(a)Includes noncontact process water that does not contribute
to the pollutant load.
(b)Flows are not directly related to the sodium bisulfate
industry, but are currently treated in combination with
raw process waste that is related.
(c)Treated effluent from combined treatment of a number of
different raw process wastestreams not all related to
sodium bisulfite production,
Plant 586
The sodium bisulfite wastes at plant 586 are combined with pro-
cess wastes from an amine plant, a zinc sulfate plant, and truck
wash waste. Lime is added to the wastes, which are then passed
through an aeration tank with an 8-hour retention time. Treated
waste goes through primary and secondary settling before final
discharge.
Figure 5-18 is a general flow diagram of plant 586 showing the
sampling point locations. Table 5-65 provides flow and pollutant
loading data for the sampled streams.
Date: 8/31/82 R Change 1 II.5-99
-------
rt
(D
vo
\
10
en
\
00
O
O
MJWUNE SUURRV
(J) WASTE STREAMS SAMPLED
DWVINS, DRIPS,
SPIUS.
|2
FT
Ndrtl A1H
TO RIVER
Figure 5-17. General process flow diagram at plant 987, manufacturing
sodium bisulfite, showing the sampling points
-------
rt
CD
oo
00
O
tf
(U
3
iQ
(D
tn
I
^FDW.
DISCHARGE
e
U9G80
Sanpllng points.
Figure 5-21. General process flow diagram at plant 672,
manufacturing sodium hydrosulfite.
-------
Table 5-72 presents final treated effluent concentrations and
loadings; raw waste pollutant loadings are presented in Table
5-73.
TABLE 5-72.
SCREENING RESULTS FROM SODIUM HYDROSULFITE
PLANT 672, VERIFICATION DATA [2-6]
Raw waste Influential
Treated effluent!bl
Pol lutant
Arsenic
Cadmium
Chromium
Copper
Lead
Nickel
Si Ivor
Zinc
Mercury
Selenium
Cyanide
Phenol
Pentach 1 oropheno 1
UQ/L
30
36
7,1400
1,000
380
1,1400
U3
5,900
3
NO
NO
160
370
kg /Ma
0.00006
0.00007
0.015
0.0021
0.0008
0.0039
0.00009
0.012
0.000006
NO
NO
0.0003
0.0008
ua/L
NO
25
35
NO
65
160
34
34
2
NO
100
NO
NO
kq/Ma
ND
0.0001
0.0002
ND
0.0003
0.0008
0.0002
0.0002
0.00001
ND
0.0005
ND
NO
Analytic methods: V.7.3.U, Data set 2.
NO, not detected.
(a(Observed during sampling at sample point #3.
(b(Observed In treatment discharge at sample point it"4.
TABLE 5-73.
SUMMARY OF RAW WASTE LOADINGS FOUND AT A SODIUM
HYDROSULFITE PLANT (FORMATE PROCESS) 672,
VERIFICATION DATA [2-6]
Loadings(a)
Pollutant
Average,
kg/day
Average,
kg/Mg
Toxic pollutants
Arsenic
Cadmium
Chromium
Copper
Lead
Nickel
Silver
Zinc
Pentachlorophenol
Phenol
Mercury
Selenium
0.0067
0.0019
0.031
0.011
0.056
0.090
0.009
1.4
0.047
0.0084
0.011
0.0017
0.00012
0.000033
0.00056
0.00019
0.001
0.0016
0.00016
0.024
0.00083
0.00015
0.00002
0.00003
Classical pollutants
TSS
COD
33
5,700
0.57
100
Analytic methods: V.7.3.4, Data set 2.
(a)Based on sampling at streams #1 and #2.
Date: 9/25/81
II.5-110
-------
TABLE 5-84. EFFLUENT TOXIC POLLUTANT CONCENTRATIONS
FOLLOWING MERCURY TREATMENT, VERIFICATION
DATA [2-6]
Pollutant, jig/L
Antimony
Arsenic
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Silver
Thallium
Zinc
747
<250
<10
120
<50
<25
73
100
<50
BDL
<45
<25
106
<450
<5
16
BDL
43
380
BDL
140
260
260
88
Plant
317
<250
20
<25
<50
<30
170
190
<67
BDL
<250
510
299
150
63
73
<60
38
<50
29
<50
BDL
200
100
167
65
380
10
<50
<25
120
320
<50
BDL
90
<25
Analytic methods: V.7.3.4, Data set 2.
BDL, below detection limit.
Diaphragm Cells
Existing regulations in diaphragm cell-graphite anode chlorine
plants call for lead discharge to be less than 0.0025 kg/Mg as a
daily average over 30 days. Other toxic pollutants to be con-
trolled include asbestos, antimony, arsenic, chromium, copper,
nickel, and chlorinated organics.
The use of graphite anodes, in either mercury cell or diaphragm
cell plants, results in the generation of a variety of simple
chlorinated hydrocarbons as a result of the attack of the product
chlorine on the anodes. These organic pollutants are sometimes
produced by the reaction of the chlorine with process exposed
rubber.
Toxic heavy metals are normally controlled by sulfide or carbon-
ate precipitation. Asbestos is trapped in a chemical flocculant
or may be settled or filtered to remove the toxic fibers. Chlo-
rinated organics are normally controlled by a reboiler on the
chlorine purifier or by a vacuum stripper. Carbon adsorption and
steam stripping are also used for this purpose.
Alternate metal removal methods include ion exchange and xanthate
precipitation. Hydrocarbons may be removed by waste incinera-
tion. Membrane separation for metal control has not proven to be
a viable alternative.
Date: 8/31/82 R Change 1 II.5-131
-------
Table 5-85 gives a subcategory profile of treatment effluents at
reported plants for the diaphragm cell subdivision of the chlor-
alkali industry. Table 5-86 shows the removal efficiency of a
lead treatment facility associated with graphite anode-diaphragm
cell plant 967, and of metal anodediaphragm cell plant 261.
TABLE 5-85.
EFFLUENT LOADINGS - CHLOR-ALKALI
DIAPHRAGM CELL PLANTS [2-6]
(kg/Mg)
Plant
589(a)
738(a)
261(a)
014(a)
967(c)
Average
0.002
0.001
0.0025
0.006
0.0064
Lead
Maximum
0.030
0.015
0.019
0.026
TSS
Average
2.8(b)
Blanks indicate data not available.
(a)Plant uses metal anodes.
(b)Plant has "once-through" barometric condenser water.
(c)Long-term data.
TABLE 5-86.
TOXIC POLLUTANT REMOVAL CHLOR-ALKALI
DIAPHRAGM CELL SUBCATEGORY [2-6]
Pol lutant
Cadmium
Arsenic
Chromium
Copper
Nickel
Zinc
Influent,
UQ/L
<23
280
100
1,600
70
930
Plant 967
Effluent(a) Percent
UQ/L
50
98
>29
>89
Influent,
ua/L
37
170
1,900
17,000
22,000
1,500
Plant 261
Effluent,
ua/L
i|
120
<50
<25
<50
<25
Percent
remove
89
29
>97
>99
>99
>98
"I
Analytic methods: V.7.3.1, Data sets 1,2.
NM, not meaningful.
(a)Flow-proportioned average discharge, consisting of lead treatment discharge
and untreated filter backwashes, condensates and scrubber wastes.
II.5.4.3 Chrome Pigments Industry
The toxic pollutants found within the chrome pigments industry in
significant amounts are the heavy metals often found in chromium
ore, including chromium, antimony, copper, cadmium, nickel, lead,
and zinc. In some raw wastes, ferro- and ferricyanide are found,
presumably from metal complexing steps in the ore processing and
the manufacture of iron blues. These complex cyanides may pass
through the treatment processes and could slowly revert to simple
cyanide ions.
Date: 8/31/82 R Change 1 II.5-132
-------
Among potential treatment technologies, ion exchange can remove
metals from clarified solutions, but it is seldom specific enough
to remove only the trace metals and is not effective in solutions
saturated with calcium. Lime treatment combined with ferric iron
may be the most effective means of controlling arsenic concentra-
tions.
Table 5-94 and Table 5-95 show verification and screening effluent
data for the chloride process and sulfate process, respectively.
TABLE 5-94. VERIFICATON AND SCREENING DATA WASTESTREAMS
FOR A PLANT PRODUCING TITANIUM DIOXIDE
(CHLORIDE PROCESS) [2-6].
Pollutant
TSS
Iron
Chromium
Lead
Nickel
Zinc
Influent
Vig/L
1,100,000
290,000
13,000
500
500
300
Plant 559
Effluent
ug/L
23,000
4,400
30
BDL
BDL
60
Percent
Removal
98
98
>99
98*
95*
80
Analytic methods: V.7.3.4, Data set 2.
BDL, below detection limits.
NM, not meaningful.
*Approximate value.
Date: 9/25/81 II.5-141
-------
TABLE 5-95. VERIFICATION DATA FOR COMBINED WASTE
WATER TREATMENT DISCHARGE AT TITANIUM
DIOXIDE PLANT 559 (SULFATE PROCESS) [2-6]
Percent
Pollutant Influent Effluent removal
Toxic pollutants, yg/L
Antimony 74 15 80
Arsenic 28 10 64
Cadmium BDL BDL NM
Chromium 3,100 BDL 99*
Copper 160 BDL 88*
Lead 960 BDL 99*
Nickel 140 BDL 82*
Thallium 7 BDL 71*
Zinc 1,000 62 94
Selenium BDL BDL NM
Classical pollutants, mg/L
TSS 200 23 88
Iron, total 840 4.4 >99
Analytic methods:V.7.3.4, Data set 2.
BDL, below detection limit.
ND, not detected.
*Approximate value.
Date: 8/31/82 R Change 1 II.5-142
-------
ft
(D
c»
\
U)
TABLE 6-10. WASTEWATER CHARACTERIZATION OF TOXIC POLLUTANTS FOR
THE BASIC OXYGEN FURNACE SUBCATEGORY [2-10]
00
NJ
O
&
0)
iQ
0
I
K)
VD
Toxic pollutant. ug/L
Number
of
samp les
Number
of
detect ions
Metals and inorganics
Arsen ic
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Se lenium
Si Iver
Tha 1 1 ium
Zinc
4
4
4
4
4
4
4
4
4
4
4
2
4
4
4
4
4
4
2
4
2
4
Range
of
detect ions
Wet-open
54
21
24
21
41
0. 1
5
8
1
80
2,000
combust ion
- 75
- 1,800
- 17,000
- 12,000
- 14,000
- 34
- 1,000
- 37
- 500
- 130
- 49,000
Med ian
of
detect ions
230
1,700
630
1, 100
17
380
1 10
3,600
Average
of
detect ions
64
570
5,200
3,300
3,900
17
440
22
180
100
15,000
Toxic organics
Chloroform
MetaIs and
Cadmium
Chromium
Copper
Lead
Nickel
SiIver
Zinc
inorganics
13-56
52
44
Wet-suppressed combustion
2
2
3
3
3
I
3
40 - 98
170 - I,100
73 - 320
230 - 27,000
32 - 550
30
610 - 8,400
80
1,500
340
1,200
69
640
160
9,600
310
3,400
Analytic methods:. V.7.3.5, Data set I
-------
rt
(D
c»
\
OJ
GO
to
o
tr
(D
\->
en
I
OJ
o
TABLE 6-11. WASTEWATER CHARACTERIZATION OF TOXIC POLLUTANTS FOR ELECTRIC
ARC FURNACE-WET SUBCATEGORY [2-10]
Pol lutant. ug/L
Metals and inorganics
Antimony
Arsenic
Cadmium
Chromium
Copper
Lead
Nickel
Si 1 ve r
Zinc
Number
of
samples
3
3
3
3
3
3
3
3
3
Number
of
detections
1
Range
of
detect ions
670
1,200
3,300
4,300
1,300
23,000
43
63
2,000 - 190,000
Med fan
of
detect ions
100,000
Average
of
detect ions
97,000
Toxic organics
4-Nitrophenol
PentachIoropheno I
Benzene
Fluoranthene
Pyrene
2
2
3
2
2
7-31
3-40
7-25
3-58
3-53
10
19
22
30
28
Analytic methods: V.7.3.5, Data set I
TABLE 6-12. TOXIC AND CLASSICAL POLLUTANT DATA FOR VACUUM
DEGASSING SUBCATEGORY [2-10]
Pollutant
Number of
samples
Number of Range of
detections detections
Median of
detections
Mean of
detect ions
Classical pollutant, mg/L
TSS
pH, pH units
12-30
4.5 - 9.I
29
7.9
Analytic methods: V.7.3.5, Data set I.
24
Toxic pollutant, |ig/L
Ch rom i urn
Copper
Lead
Nickel
Zinc
3
3
3
3
3
3
3
3
2
3
25
20
240
23
260
- 3,000
- 440
- 3,200
- 500
- 24,000
33
130
470
2,500
1,000
200
1,300
260
8,900
-------
presents wastewater characterization data for sampled plants in
the vacuum degassing subcategory.
II.6.2.6 Continuous Casting [2-10]
In the continuous casting process, the cast product is only
partially solidified when it emerges from the molds. The in-
terior core of the product is still molten steel at this time.
The cast product spray cooling water system sprays water directly
onto the product for further cooling. As the cast product sur-
face oxidizes, scale is washed away by the cooling water. The
spray water also becomes contaminated with oils and greases which
are released by the hydraulic and lubrication systems. As the
cast product is discharged onto the run-out tables for final
cooling, additional scale flakes off which is sluiced to the
spray cooling pit.
Approximately 5-10% of the water sprayed on the product is evapo-
rated with the balance being discharged to a scale pit. Tempera-
tures of discharged spray waters range from 54° to 60°C (130° to
140°F). Other minor wastewater systems include spray cooling of
cast product, acetylene torch cut-off, and miscellaneous cooling
or sluicing.
Table 6-13 presents toxic and classical pollutant data for the
continuous casting subcategory.
II.6.2.7 Hot Forming [2-11]
Hot forming wastewaters are comprised of direct contact cooling
and descaling waters. Roll cooling water is used to flush the
the mill stands to prevent surface cracking of the steel rolls
due to sudden temperature changes. When the hot steel product is
being rolled, iron oxide scale (called mill scale) forms on the
surface of the hot steel. The scale is removed by direct contact
high pressure sprays. Approximately 4% of the water sprayed on
the hot steel evaporates and the balance is discharged beneath
the rolling mill to trenches called flumes.
Wastewaters from descaling, rolls, hot shear equipment cooling,
roll tables, and flume flushing are generally discharged through
flumes to inground settling chambers called scale pits. Scale
pits often contain underflow weirs with launders to trap oils and
greases picked up by the process waters. The major sources of
oils are the oil cellars where recirculated oils are conditioned,
and leaks from lubricating and hydraulic systems. The wastewater
oils are discharged to waste oil storage tanks and periodically
removed by contract haulers. The scale pit effluents are dis-
charged to plant sewers or are paritally recycled back to the
mills.
Date: 9/25/81 II.6-31
-------
Toxic metal pollutants have been detected in the wastewaters from
rolling mills. The appearance of chromium, cppper, lead, nickel,
and zinc result from the use of these metals in steelmaking and
alloying and possibly in lubricants used at certain mills.
Relatively few toxic organic pollutants were detected in the
sampled mills. The waste charcteristics of the subdivisions of
the hot forming subcategory are briefly discussed below.
Primary rolling-mills. Blooming or slabbing rolling mills
generally have six main contact water systems:
• High pressure descaling spray water,
• Mill stand roll and roll table spray cooling water,
• Hot shear spray cooling water,
• Flume flushing,
• Hot scarfer spray flushing and cooling system, and
• Hot scarfer wet gas cleaning system.
The first four sources, which are common to all hot forming
operations, have previously been discussed. The last two sources
are unique to primary rolling mills. The use of automatic hot
scarfing machines for surface finishing results in the generation
of fumes, smoke, and slag. Wastewaters are produced from the
flushing of the slag and equipment spray cooling water. Addi-
tional wastewater results when wet type dust collectors are used
to clean the exhaust gases from the scarfer. These discharge
waters may be acidic if resulphurized steels are being scarfed.
Table 6-14 presents toxic and classical pollutant data for the
primary rolling mill subdivision.
Section rolling mills. These mills generally have four main
mill contact water systems:
• High pressure descaling spray water,
• Mill stand roll and roll table spray cooling water,
• Hot shear spray cooling water, and
• Flume flushing.
Table 6-15 presents toxic and classical pollutant data for the
section rolling mill subdivision.
Flat mills-plate. Plate rolling mills have three contact
water systems:
• Descaling water sprays,
• Mill stand roll and roll table water sprays, and
• Flume flushing.
Table 6-16 represents toxic and classical pollutant data for the
flat mills-plate subcategory.
Date: 8/31/82 R Change 1 II. 6-32
-------
Relatively low concentrations of toxic organic pollutants were
found in raw wastewaters from all coating operations during the
toxic pollutant survey. The phthalates and methylene chloride
were universally present but it is believed that they are attri-
butable to sampling and analytical techniques. The remaining
toxic organics tended to be present in plant intakes at levels
equal to or greater than those found in hot coating wastewaters.
Tables 6-31 and 32 present toxic and classical pollutant data for
galvanizing and terne-coating operation wastewaters, respectively.
One plant was sampled for aluminizing wastewaters and these data
are presented in Section II.6.3, Table 6-68.
II.6.3 PLANT SPECIFIC DESCRIPTIONS [2-9,10,11,12,13]
The following paragraphs describe classical and toxic pollutant
data and treatment methods at selected plants within each subcat-
egory of the Iron and Steel Industry. Selection was based on the
availability of data and description of the treatment method
used.
II.6.3.1 Cokemaking; By-Product Recovery Coke [2-9]
Plant 009
This plant uses a physical/chemical treatment system. Excess
ammonia liquor from three coke plants (one off-site) is mixed and
then passed through a gas flotation unit (with a side stream
through dephenolization), a mixed media filtration unit, an
activated carbon adsorption unit, and free and fixed ammonia
strippers. Benzol plant wastewaters from two plants are mixed
and passed through the gas flotation, mixed media filtration, and
activated carbon adsorption units prior to disposal in coke*
quenching. Table 6-33 presents plant specific classical and
toxic pollutant data for plant 009 in the byproduct coke subcate-
gory.
Plant 001
Excess ammonia liquor is equalized; stripped of free ammonia;
dephenolized by vapor recirculation; diluted (85:1) with cooling
water and other wastewater flows; and discharged to a receiving
stream. Final cooler blowdown is diluted 2:1 and disposed of by
coke quenching. Quench runoff recycles to extinction. The in-
stallation of adsorption by activated carbon following chlorina-
tion was under construction at the time of the survey. Table 6-34
presents plant specific classical and toxic pollutant data for
plant 001.
Date: 8/31/82 R Change 1 II.6-53
-------
TABLE 6-31. TOXIC AND CLASSICAL POLLUTANT DATA FOR HOT COATING GALVANIZING,
NET RAW WASTEWATER [2-13]
rt
(D
CO
\
u>
00
NJ
O
3
uQ
(D
H
I
cn
Pol lutant
ISS
0 i I and g roase
pH, pH units
Tota 1 i ron
Di sso 1 ved i ron
Toxic pollutants, |jg/L
Toxic metals
Arsen ic
Chromium
Copper
Cyanide
Lead
Nickel
Si Iver
Zinc
Toxic organics
Benzene
1, 1, l-Frichlo methane
Chloroform
1 , 3-Dichlorobenzene
Fluoranthene
Methylene chloride
Pen tacn 1 o ropheno 1
Bis(2-ethylhexyl )
phthlate
Butyl benzyl phtha late
Di-n-butyl phthalate
Di-n-octyl phthalate
Oiethyl phthalate
Dimethyl phthalate
Tetrachloroethylene
Tr ich loroe thy t ene
Number of
samp les
6
6
6
2
6
2
6
6
6
5
5
5
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
Number of Range of
detections detections
6
6
6
2
6
2
6
6
6
5
5
5
6
3
3
6
1
5
6
2
6
5
5
1
3
5
5
1
5
5
1 .7
10
0.03
21
<25
y
20
6
<50
<20
<20
600
5
3
10
5
10
5
35
5
10
5
5
5
- 330
- 210
- 7.i|
- 97
- 200
- 30
- 10,000
~ 7 , 000
- 2,500
- 20
- 25,000
- 1 , 300
- 50
- 82,000
- 10
- 67
- 7tj
150
- 2'l
- 2,500
- 22
- 310
- Ill
- D7
57
- 1 1
- 19
- IM
"6
Median of
90
33
5.1
14
180
*i . 5
90
10
200
30
<20
10,000
5
10
13
10
17
96
5
26
10
10
10
Mean of
120
51
51
18
26
<2,200
1 , '100
U80
12
<5,200
<290
<26
26,000
6.7
27
31
12
410
11
120
13
27
8.7
9.8
9.U
Analytic methods: V.7.3.5, Data set I
TABLE 6-32. TOXIC AND CLASSICAL POLLUTANT DATA FOR HOT COATING TERNE
NET RAW WASTEWATER [2-13]
Pol lutant
Classical pollutants, Mg/L
TSS
Oil and grease
Tin
Iron, total
Iron, dissolved
pH, pH units
Toxic pollutants, |ig/L
Chloroform
Methylene chloride
Phenol
Bis(2-ethylhexyl )
phthalate
Tet rach 1 o roe thy 1 ene
Ch roa i urn
Copper
Lead
Nickel
Zinc
Number of
samples
3
3
3
3
3
3
3
3
3
3
3
Number of Range of
detections detections
3 9
3 1)
3
-------
basis for this process is the assumption that all waste streams
contain components that flocculate or settle in the proper environ-
ment. The process consists of dividing the wastewater stream
into two equal parts, one of- which is treated with an acid solu-
tion, while the other is treated with an alkaline solution.
Flocculation occurs during this treatment and also upon the
reuniting of the two waste streams. The waste stream then goes
through a series of settling tanks, with agitation in each tank
mixing the settled sludge with the wastewater, which aids in
further flocculation. The final sludge removal has no oxygen
demand and is sterile. The system can be housed within a plant
which is important in cases where available adjacent land is
limited. The process has been reported to be highly effective in
removing toxic pollutants, including chromium, and classical
pollutants.
Activated carbon. The use of activated carbon in treating
industrial wastewaters has been generally successful depending on
the application, the soundness of engineering, the degree of
proper operation and maintenance, and the performance criteria
established for the system. A relatively new application of
powdered activated carbon (PAC) is being tested and evaluated in
combined carbon-biological systems because of the ability of
activated carbon to improve the performance of biological systems.
This concept is now undergoing extensive testing, using powdered
carbon in activated sludge systems. The carbon is metered into
the system with the influent at a concentration normally less
than 100 mg/L. It is recirculated and purged along with the
biological solids at a rate that maintains an equilibrium con-
centration of 1,000 to 2,000 mg/L. Since the powdered carbon is
added directly to the activated sludge process, this eliminates
the need for carbon-adsorption beds or columns.
Date: 8/31/82 R Change 1 II. 7-27
-------
-------
rt-
n>
00
LO
H
CO
to
V
O
tr
(a
iQ
CD
H
H
H
00
1
H
TABLE 8. 1-4.
Operation
Direct chill cooling
Continuous rod
cast i ng coo 1 ing
Continuous sheet
casting
Rolling with emulsions
Extrusion die cleaning:
caustic bath
rinse
Extrusion dummy block
cool ing
Drawing with emulsions
or soaps
Heat treatment quench
Annealing furnace, air
pollution control
Cleaning and etch line.
rinse
Cleaning and etch line.
air pollution control
Saw oil 1 ubricants
Numbe r
of
Plantslb)
37
1
14
20
1 1
5
3(c)
6
51
1
20
3
6
SUMMARY OF WASTEWATER FLOWS REPORTED FOR ALUMINUM
FORMING INDUSTRY PROCESSES [2-16]
Numbe r
of
Discru
29
1
2
20
1 1
5
3
5
M3
1
20
3
5
Mini mum
iraers cu. m/Mq
0.0003
0.001
0.0003
0.0002
0.001
2. 1
0.003
0.021
0.001
0.514
0.0001.
(qa I/ton)
(0.08)
(0.214)
( 0 . 08 )
(0.06)
(0.31)
(500)
(0.81)
(5)
(0.314)
( 130)
(0. 10)
cu. m/Mq
10.14
0.002
0.035
O.OHi
0.018
2. 1
2,000
1 . 1
22
2.0
0.002
Wastewater Flows(a)
Mean
(qal/ton)
(2,500)
(0.1414)
(8.14)
(3.3)
(1.14)
(510)
(480,000)
(1,700)
(5,300)
(1490)
(0.50)
Median
cu. m/Mq
2.0
0.002
0.005
0.008
0.012
1 . 1
2.8
5.0
1 .0
0.001
foal /ton)
(1470)
(0.1414)
(1.2)
( 1.9)
(2.8)
(260)
(670)
( 1,200)
(2MO)
(0.314)
Maximum
cu. m/Ma
92
1.0
0.003
0.3
0.0514
0.0514
2.2
10,000
32
0.026
150
14.6
0.006
(gal/ton)
(22,000)
(250)
(0.614)
(73)
(13)
(13)
(520)
(2,1*00,000)
(7,700)
(6.3)
(36,000)
( 1. 100)
(1.5)
(a)Based only on discharging facilities.
(b)lncludes only those plants with available wastewater data.
(c)Only 2 of 3 dischargers had sufficient data for inclusion in calculatio
I at ions.
-------
D
JD
rt
CD
oo
\
oo
oo
to
n
£*•
o»
3
iQ
(D
H
H
•
00
•
I-1
I
TABLE 8.1-5. SUMMARY OF POLLUTANT DATA FOR THE DIRECT CHILL CASTING SUBCATEGORY,
VERIFICATION DATA [2-16]
Pol
1 utant
Number
Number
of
of
samp les/
detect ions
Range
detect
of
ions
Med ian
detect
of
ions
Mean of
detect ions
Classical pollutants, mg/L
COD
Suspended sol ids
Oil and grease
TOC
pH, pH units
Phenols, total
Toxic pollutants, ng/L
Toxic metaIs
Lead
Me rcu ry
Zinc
Toxic organics
Bis(2-ethylhexyl) phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Di-n-octyl phthalate
Phenol
2-Chlorophenol
Benzene
Chloroform
Methylene chloride
Polychlorinated biphenyls
PCB 1232, 1248, 1260, 1016
12/12
12/12
13/13
12/12
12/12
12/12
12/12
12/12
12/12
12/9
12/4
12/7
12/3
12/5
12/2
12/8
12/11
12/12
12/5
<5 - 420
-------
rt
(D
TABLE 8.1-6. SUMMARY OF POLLUTANT DATA FOR THE ROLLING WITH EMULSIONS
SUBCATEGORY, VERIFICATION DATA [2-16]
CO
\
CO
CO
to
o
(D
H
H
CO
I-1
I
M
LO
Pol lutant
Classical pollutants, mg/L
Dissolved sol ids
Suspended sol ids
TOC
Phenols, total
Oil a nd g rea se
Al umi num
Ca 1 c i urn
Magnes i um
pH, pH units
Toxic pollutants, Mg/L
Metals and inorganics
Arsenic
Cad.T, ium
Chrom ium
Copper
Cyanide
Lead
Nickel
Zinc
Toxic orqanics
Bis(2-ethylhexyl) phthalate
Butyl benzyl phthalate
Oi-n-butyl phthalate
2,M,6-Trichlorophenol
Phenol
Toluene
Ethyl benzene
Acenapthene
Napthalene
Chrysene
Anthracene
Fluorene
Phenanthrene /
Pyrene
Methylene chloride
Tetrach loroethy lene
Polychlorinated biphenyls
PCB-I2M2, I25M, 1221, total
PCB-1232, 1218, 1260, 1016,
Pesticides
M,M'-DDE
Alpha-endosulfan
Endrin aldehyde
Alpha-BHC
Beta-BHC
Number of samples/
Number of detections
2/2
3/3
3/3
I/I
M/M
3/3
3/3
3/3
I/I
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
M/l
M/l
M/l
M/l
M/2
3/3
3/2
M/l
M/3
M/2
M/3
M/3
M/3
M/2
3/3
3/3
3/1
total 3/1
3/1
3/1
3/1
3/1
3/1
Range of
detect i ons
27,000 - 3M.OOO
890 - 3,900
1,800 - 23,000
0.2M
1,300 - 31,000
MM - 210,000
22 - 27,000
II - 17, 000
7.0
BDL - 16
15 - ISO
Ml - 120
630 - 7, MOO
BDL - 9MO
2,000 - 57,000
86 - 210-
I,MOO - M.200
1,900
190
19,000
22
60 - 9,900
BDL - 130
MO - MO
95
10 - 380
-------
II.8.1.2.3 Extrusion
The wastewater characterization data for the extrusion die clean-
ing rinse are summarized by classical and toxic pollutants in
Table 8.1-7.
II.8.1.2.4 Forging
Of the approximately 15 aluminum forging plants, three use wet
scrubbers to control particulates and smoke generated from the
partial combustion of oil-based lubricants in the forging pro-
cess. The summaries of the classical and toxic pollutant data on
the air pollution controls for the forging subcategory are con-
tained in Table 8.1-8.
II.8.1.2.5 Drawing with Emulsions or Soaps
Eight of the 266 plants in the Aluminum Forming Industry draw
aluminum products using oil-in-water emulsions and three use soap
solutions as drawing lubricants. These solutions are frequently
recycled and discharged periodically after their lubrication
properties are exhausted. Table 8.1-9 summarizes the classical
and toxic pollutant data for the drawing with emulsions subcate-
gory.
II.8.1.2.6 Heat Treatment
Heat treatment of aluminum products frequently involves the use
of a water quench in order to achieve the desired metallic prop-
erties. Of the 266 aluminum forming plants, 84 use heat treat-
ment processes that involve water quenching. The sampling data
for classical and toxic pollutants from heat treatment quenching
processes are presented in Tables 8.1-10 and 8.1-11 by the alum-
inum forming operation that it follows.
11. 8 .1. 2 . 7 Etch or Cleaning
Thirty plants in the Aluminum Forming Industry use etch or clean-
ing lines. Rinsing is usually required following successive
chemical treatments within these etch or cleaning lines. Waste-
water discharge values tend to increase as the number of rinses
increase. Table 8.1-12 summarizes the classical and toxic pollut-
ant data for etch line rinses.
II.8.1.3 PLANT SPECIFIC DESCRIPTION [2-16]
A very limited amount of individual plant specific data for the
Aluminum Forming Industry are available. Data available on the
influent and effluent streams are discussed briefly in the follow-
ing subsections for specific plants.
Date: 8/31/82 R Change 1 II.8.1-14
-------
0
pj
ft
(D
TABLE 8.1-1 I. SUMMARY OF POLLUTANT DATA FOR THE HEAT TREATMENT QUENCH FORGINC
SUBCATEGORY BY WASTE STREAM, VERIFICAT.ON DATA [2-16]
CO
to
CO
!*)
O
CD
M
H
H
CO
H1
I
H1
VD
Pollutant
Number of samples/
Number or detections
Range of
detections
Median or
detections
Mean of
detect ions
Classical pollutants, mg/L
Oil and grease
Suspended solids
pH, pH units
Aluminum
CaIc!um
Magneslum
COD
Dissolved solids
Sulfate
TOC
Phenols, total
Toxic pollutants, ug/L
Toxic orqanlcs
Bis (2-ethylhexyl) phthalate
Metals and inorganics
Cadmium
Ch romIum
Copper
Lead
Mercury
Nickel
Zinc
Classical pollutants, mg/L
011 and grease
Suspended solids
pH, pH units
COD
Phenols, total
TOC
Toxic pollutants, ug/L
Toxic orqanlcs
Benzene
Chloroform
Methylene chloride
Bis(Z-ethythexyl) phthalate
Dl-n-butyl phthalate
Dlethyl phthalate
Dimethyl phthalate
Tet rachIoroethy Iene
Toluene
T rIchIo roethy Iene
Polychlorinated biphenvls
PCB - I2U2, 1251), 1221
PCB - 1232, 121(8, 1260, 1016
Metals and inorganics
Ant imony
Copper
Cyanide
Mercury
Waste Stream: Forging
3/3
3/3
3/3
3/3
3/3
3/3
U/U
l)/i)
l)/i|
H/3
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
M -
7.7 -
38 -
8 -
<5 -
190 -
30 -
<2 -
0.003
87
2 HO
8.2
9
80
35
56
1,1)00
330
- 0.8
BDL - 890
BDL
7
<50
<50
BDL
BDL
50
12
72,000
380
17,000
0.5
<20
5,200
ID
22
7.7
-------
TABLE 8.I-I I.
SUMMARY OF POLLUTANT DATA FOR THE HEAT TREATMENT QUENCH
FORGING SUBCATEGORY BY WASTE STREAM (continued)
Number of samples/ Range of Median of
Pollutant Number of detections detections detections
Classical pollutants, mg/L
Oi 1 and grease
Suspended sol ids
pH, pH units
COD
TOC
Phenols, total
Toxic pollutants, Mg/L
Toxic orqanics
2-Ch 1 oropheno 1
1 ,2-trans-d ich lo roe thy lene
Methylene chloride
B i s( 2- ethy 1 hexy 1 )phtha 1 a te
Butyl benzyl phthalate
Metals and inorganics
Copper
Nickel
5/5
5/5
5/5
5/5
5/5
it /l>
5/1
5/2
5/5
5/14
5/5
'I/I
it/1
Waste Stre
8 -
-------
TABLE 8.1-12.
SUMMARY OF POLLUTANT DATA FOR THE ETCH LINE RINSES SUBCATEGORY,
VERIFICATION DATA [2-16]
Number of samples/ Range of
Pollutant Number of detections detections
Classical pollutants, mg/L
Oi 1 and grease
Suspended solids
pH, pH units
Al urn i num
Ca Ic i urn
1 ron
Magnes i urn
COD
D i sso 1 ved so 1 ids
Sulfate
TOC
Phenols, total
Toxic pollutants, ug/L
Toxic orqanics
Acenapthene
Benzene
Ch lo reform
1 , 2-t rans-d ich loroethy lene
2,14-Dimethyl phenol
Methylene chloride
1 sophorone
i4-Ni trophenol
Phenol
Bis(2-ethylhexyl ) phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Di-n-o^yl phthalate
Diethyl phthalate
Chlordane
Polychlorinated biphenyls
PCB-I2M2, I25<4, 1221
PCB-1232, I2U8, 1260, I0lt>
Metals and inorganics
Arsenic
Beryl 1 ium
Cadmium
Chromi urn
Copper
Lead
Mercury
Nickel
Zinc
18/16
18/18
16/16
19/19
19/18
18/15
I/I
17/17
19/19
19/19
18/18
18/18
19/5
19/9
19/18
19/5
19/2
19/18
19/2
19/1
19/9
19/18
19/9
19/14
19/5
19/9
19/12
19/11
19/12
19/17
19/15
19/15
19/15
19/15
19/16
19/15
19/15
19/15
2
-------
TABLE 8.1-13. MINIMUM DETECTION LIMITS FOR TOXIC
POLLUTANTS [2-16]
Toxic pollutant Concentration,
Organic pollutants 10
Pesticides 5
Metals
Antimony 100
Arsenic 10
Asbestos 1 x 107fibers/L
Beryllium 10
Cadmium 2
Chromium 5
Copper 9
Cyanide 100
Lead 20
Mercury 0.1
Nickel 5
Selenium .10
Silver 20
Thallium 100
Zinc 50
II.8.1.3.1 Plant 47432
This aluminum processing plant uses lime precipitation (pH
adjustment) followed by coagulant addition and sedimentation as
its treatment system. Data on the pollutant removal efficiency
at plant 47432 are summarized in Table 8.1-14. No production or
water usage data are available for this plant.
II.8.1.3.2 Plant B
No plant specific identification number was available for this
facility. The wastewater from Plant B contains pollutants from
both metals processing and finishing operations. It is treated
by precipitation-settling followed by filtration with a rapid
sand filter. A clarifier is used to remove much of the solids
load. Table 8.1-15 summarizes the data on the pollutant removal
efficiency at Plant B.
II.8.1.4 POLLUTANT REMOVABILITY [2-16]
This section describes the treatment techniques currently used or
available to remove or recover wastewater pollutants normally
generated by aluminum forming facilities. In general, these
pollutants are removed by oil removal (skimming, emulsion break-
Date: 9/25/81 II.8.1-22
-------
TABLE 8.1-14. REMOVAL OF POLLUTANTS BY LIME PRECIPITATION
AT METAL PROCESSING PLANT 47432 [2-16]
Pollutant
pH, pH units
TSS, mg/L
Copper, jig/L
Zinc, yg/L
Raw
wastewater
2.8
24
180,000
110,000
Treated
effluent
7.1
11
2,000
8,700
Percent
removal
54
99
92
Note: Data based on the average of three influent/effluent samples.
TABLE 8.1-15. REMOVAL OF POLLUTANTS BY A COMBINATION OF LIME
PRECIPITATION, SEDIMENTATION, AND FILTRATION
AT PLANT B [2-16]
Pollutant, yg/L
Chromium
Copper
Nickel
Zinc
Iron
Raw
wastewater
5,900
170
3,300
2,900
22,000
Treated
effluent
38
11
180
35
400
Percent
removal
99
94
95
99
98
Note: Treated effluent performance reported for the period 1974-1979,
Date: 8/31/82 R Change 1 II.8.1-23
-------
ing, and flotation), chemical precipitation and sedimentation, or
filtration. Most of the pollutants may be effectively removed by
precipitation of metal hydroxides or carbonates utilizing the
reaction with lime, sodium hydroxide, or sodium carbonate. For
some, improved removals are provided by the use of sodium sulfide
or ferrous sulfide to precipitate the pollutants as sulfide
compounds with very low solubilities. The effectiveness of
pollutant removal by several different precipitation methods is
summarized in Tables 8.1-16, 17, and 18. Table 8.1-19 presents
the removability of pollutants by two types of skimming systems--
the API (American Petroleum Institute oil-water separator) system
and the TEB (Thermal emulsion breaker) system.
Date: 8/31/82 R Change 1 II.8.1-24
-------
TABLE 8.1-16. REMOVAL OF POLLUTANTS BY SODIUM
HYDROXIDE PRECIPITATION [2-16]
Pollutant, yg/L
pH, pH units
Chromium
Copper
Iron
Lead
Manganese
Nickel
Zinc
TSS
Raw
wastewater
2.3
74
65
11,000
1,300
0.11
61
120
Treated
effluent
9
BDL
17
880
120
0.05
31
12
12,000
Percent
removal
_ _
93*
74
92
91
55
49
90
BDL, below detection limits.
^Approximate value.
TABLE 8.1-17. REMOVAL OF POLLUTANTS BY LIME AND SODIUM
HYDROXIDE PRECIPITATION [2-16]
Pollutant
pH, pH units
Aluminum, mg/L
Copper, vig/L
Iron, mg/L
Manganese, mg/L
Nickel, U9/L
Selenium, yg/L
Titanium, mg/L
Zinc, yg/L
TSS, mg/L
Raw
wastewater
9.4
35
670
150
210
6,100
29,000
130
17,000
3,600
Treated
effluent
8.3
0.35
BDL
0.55
0.12
BDL
BDL
BDL
27
12
Percent
removal
_ _
99
99*
>99
>99
>99*
>99*
>99*
>99
>99
BDL, below detection limits.
*Approximate value.
Date: 8/31/82 R Change 1 II.8.1-25
-------
TABLE 8.1-18.
REMOVAL OF POLLUTANTS BY SULFIDE PRECIPITATION
AT THREE PLANTS [2-16]
Pollutant
Plant 1
pH, pH units
Chromium, hexavalent, yg/L
Chromium, yg/L
Iron, mg/L
Zinc, yg/L
Plant 2
pH, pH units
Chromium, hexavalent, yg/L
Chromium, yg/L
Iron, mg/L
Nickel, yg/L
Zinc , yg/L
Plant 3
Chromium, hexavalent, yg/L
Chromium, yg/L
Copper, yg/L
Zinc, yg/L
Raw
wastewater
5.9
26,000
32,000
0.52
40,000
7.7
22
2,400
110
680
34,000
11,000
18,000
29
60
Treated
effluent
8.5
<14
<40
0.10
<70
7.4
<20
<100
0.6
<100
<100
BDL
BDL
BDL
BDL
Percent
removal
--
>99
>99
81
>99
--
>9
>96
>99
>85
>99
99*
99*
83*
92*
BDL, below detection limits.
*Approximate value.
Date: 8/31/82 R Change 1 II.8.1-26
-------
o
0)
ft
CD
00
00
to
n
&
JD
<£|
(D
H
H
t
00
•
to
I
to
Ul
TABLE 8.2-10.
WASTEWATER CHARACTERIZATION - LECLANCHE SUBCATEGORY TOTAL RAW WASTE,
VERIFICATION DATA [2-17]
Pol lutant
Toxic pollutants, u.g/L
Diethyl phthalate
Ant imony
Arsen ic
Cadm i urn
Chromium, total
Chromium, hexavalent
Copper
Lead
Mercury
Nickel
Se lenium
Zinc
Classical pollutant, mg/L
Manganese
Phenols, total
Oil and grease
Total suspended solids
pH, minimum
pH, maximum
Number of
samp les
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
6
Number of
detections
6
0
3
6
6
0
6
3
6
6
3
6
6
6
6
6
6
6
Range
of
samp les
BDL
ND
20
10
100
ND
10
90
ND
31,000
5.2
0.01
10
340
5. 1
8.6
- BDL
- 200
- 170
- 890
- 1, 100
- 290
- 130
- 3,200
- 180
- 310,000
- 130
- 0.24
- 390
- 4,400
- 6.2
- 10
Mean
of
samp les
BDL
40
60
210
260
50
80
760
35
120,000
37
0.06
1 10
1,200
5.7
9.5
Med ian
of
samp les
BDL
10
40
30
100
ND
70
320
10
98,000
22
0.03
57
460
6.0
9.4
Analytic methods: V.7.3.8, Data set 2.
BDL, below detection limit.
ND, not detected.
-------
D
PJ
rt
CD
TABLE 8.2-1 I.
WASTEWATER CHARACTERIZATION - LECLANCHE SUBCATEGORY POLLUTANT CONCENTRATION
BY INDIVIDUAL PROCESS ELEMENTS [2-17]
00
00
to
O
CT
fa
3
&
CD
oo
•
to
I
to
Pol lutant
Toxic pollutants, ug/L
Dlethyl phthalate
Antimony
Arsenic
Cadmium
Chromium, total
Chromium, hexavalent
Copper
Lead
Mercury
Nickel
Selenium
Zinc
Classical pollutants, mg/L
Manganese
Phenols, total
Oi 1 and grease
Total suspended solids
pH, minimum
pH, maximum
Toxic pollutants, ug/L
Dlethyl phthalate
Antimony
Arsenic
Cadmium
Chromium, total
Chromium, hexavalent
Copper
Lead
Mercury
Nickel
Selenium
Zinc
Classical pollutants, mg/L
Manganese
Phenols, total
Oi 1 and grease
Total suspended solids
pH, minimum
pH, maximum
Number of
samples
Number of
detections
Range
of
samples
Cooked paste separator waste streams
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Paper separator
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
2
0
0
3
0
0
3
0
3
3
0
3
3
3
3
3
3
3
(with mercury)
3
0
0
3
0
0
3
1
3
3
0
3
3
3
3
3
3
3
ND
10
80
130
30
85,000
3
0.01
1 1
11
5. 1
6.3
waste
BDL
20
80
NO
IllO
20
230
0.13
0.01
7
7
7.5
8.3
- BOL
- 20
- 130
- 160
- 100
- 150,000
- 114
- 0.01
- 39
- 120
- 5.9
- 6.8
streams
- BDL
- 170
- 1 10
- 70
- llOO
- Ii»0
- 1,200
- 1.2
- 0.09
- 83
- I
-------
TABLE 8.2-15.
WASTEWATER CHARACTERIZATION -ZINC SUBCATEGORY BY INDIVIDUAL
PROCESS ELEMENTS (continued)
ft
(D
00
00
to
O
t?
0)
3
iQ
(D
00
•
K)
I
OJ
co
Pollutant
Number of
samples
Number of
detections
Range
of
samples
Mean
of
samples
Med ian
of
samples
Zinc oxide powder-pasted or pressed reduced anode waste stream
Toxic pollutants, u.g/L
I, I, l-Trichloroethane 4
I,l-Dichloroethane 4
I,l-Dichloroethylene 4
I,2-Trans-dichloroethylene 4
Ethyl benzene 4
Methylene chloride 4
Naphthalene 4
PentachlorophenoI 0
Bis(2-ethylhexyl) phthalate 0
Diethyl phthalate 4
Tetrachloroethylene 4
Toluene 4
Trichloroethylene 4
Antimony 4
Arsenic 4
Cadmium 4
Chromium, total 4
Chromium, hexavalent 3
Copper 3
Cyanide, total 0
Cyanide, amn. to chlor. 0
Lead 3
Mercury 4
Nickel 4
Selenium 4
S iIve r 4
Z i nc U
Classical pollutants, mg/L
Aluminum 3
Ammoni a 0
I ron 0
Manganese U
Phenols, total 0
OiI and grease 0
Total suspended solids 4
pH, minimum 0
pH, maximum 0
I
2
0
0
0
I
0
0
0
0
0
2
0
0
2
4
2
0
2
0
0
2
3
2
0
2
4
I
0
0
2
0
0
4
0
0
ND - BDL
ND - BDL
ND - BDL
ND - BDL
ND - 110
10-70
ND - 60
ND - 610'
ND - 140
ND - 160
ND - 50
ND - 270
280 - 130,000
ND - 0.48
ND - BDL
5-120
BDL
BDL
BDL
BDL
50
40
20
300
73
70
20
100
46,000
0. 16
BDL
57
ND
BDL
ND
BDL
40
50
10
300
80
60
10
60
28,000
ND
BDL
51
-------
rt
ro
00
U)
H-"
\
00
50
n
0)
CD
TABLE 8.2-15.
WASTEWATER CHARACTERIZATION -ZINC SUBCATEGORY BY
PROCESS ELEMENTS (continued)
INDIVIDUAL
Pollutant
Number of
samples
Number of
detect ions
Range
of
samples
Mean
of
samples
Med ian
of
samples
03
*
NJ
I
U)
Zinc electrodeposited anode waste stream
Toxic pollutants, ng/L
1,1,I-Trichloroethane
I,I-Dichloroethane
I,l-Dichloroethylene
1,2-Trans-dichloroethylene
Ethyl benzene
Methylene chloride
Naphthalene
PentachIo rophenoI
Bis(2-ethyIhexyl) phthalate
Diethyl phthalate
Tetrachloroethylene
To Iuene
TrichIoroethylene
Ant imony
Arsenic
Cadmium
Chromium,
Chromium,
Copper
Cyan ide,
Cyanide,
Lead
Mercury
Nickel
Se len i urn
Si 1 ve r
Zinc
tota 1
hexava lent
tota 1
amn. to chlor.
Classical pollutants, mg/L
A I urn i num
Ammon i a
I ron
Manganese
Phenols, total
0iI and grease
Total suspended solids
pH, minimum
pH, maximum
3
3
3
3
3
3
3
0
0
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
0
3
3
3
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
0
3
3
3
2
2
I
0
3
3
0
3
0
0
I
3
3
0
0
10-20
10-20
10 - 10
10 - 10
ND - 140
ND - 31,000
ND - BDL
30 - 430
12,000 - 12,000
0.28 - 1.4
ND - BDL
I - 7.6
3.4 - 10
17
13
10
10
17
15,000
BDL
180
12,000
0.65
BDL
4.2
7.8
20
10
10
10
BDL
13,000
BDL
70
12,000
0.28
BDL
4. I
10
-------
ft
(D
00
co
M
\
00
n
3
(0
i-1
H
H
00
I
U)
U1
TABLE 8.2-15.
WASTEWATER CHARACTERIZATION - ZINC SUBCATEGORY BY
PROCESS ELEMENTS (continued)
INDIVIDUAL
Pol lutant
Number of
samples
Number of
detect ions
Range
of
samples
Mean
of
samples
Med ian
of
samples
Silver powder pressed and electroIvticaIly oxidized cathode waste stream
Toxic pollutants, u.g/L
I,I,l-Trichloroethane 5
I,I-Dichloroethane 5
I,l-Dichloroethylene 5
I,2-Trans-dichloroethylene 5
Ethyl benzene 5
Methylene chloride 5
Naphthalene 5
PentachlorophenoI 0
Bis(2-ethylhexyI) phthalate 0
Diethyl phthalate 5
Tetrachloroethylene 5
Toluene 5
Trichloroethylene 5
Antimony 5
Arsenic 5
Cadmium 5
Chromium, total 5
Chromium, hexavalent 4
Copper 5
Cyanide, total 0
Cyanide, amn. to chlor. 0
Lead 5
Mercury 5
Nickel 5
Selenium 5
S i Ive r 5
Zinc 5
Classical pollutants, mg/L
Aluminum 5
Ammonia 0
I ron 0
Manganese 5
Phenols, total 0
Oi I and grease 0
Total suspended solids 5
pH, minimum 3
pH, maximum 5
2
2
0
0
0
3
3
0
0
I
0
3
2
0
I
5
3
0
3
0
0
3
5
4
0
5
3
I
0
0
U
0
0
5
5
5
ND - BDL
ND - BDL
ND - BDL
ND - BDL
ND - BDL
ND - BDL
ND - BDL
ND - 110
BDL - 80
ND - 12,000
ND - 4,700
ND - 820
BDL - 70
ND - 590
320 - 3,900
ND - 240,000
ND - k.>4
ND - O.Ot
5 - 360
11-12
11-12
BDL
BDL
BDL
BDL
BDL
BDL
BDL
20
40
2,300
2,000
340
30
190
1,900
65,000
0.89
0.02
140
I I
I I
ND
ND
BDL
BDL
ND
BDL
ND
ND
60
10
1,200
200
20
50
1,500
29,000
ND
0.01
86
I I
I I
-------
o
0)
ft
(D
GO
\
co
CO
ro
o
ID
(D
M
CO
I
co
cr\
TABLE 8.2-15.
WASTEWATER CHARACTERIZATION -ZINC SUBCATEGORY BY INDIVIDUAL
PROCESS ELEMENTS (continued)
Number of
Po 1 1 utant samples
S i 1 ve r
s intered.
Toxic pollutants, u,g/L
1,1,1 -Trichlo roe thane
1, l-Dichloroethane
1, 1 -Dichloroethylene
1 , 2-Trans-d ich 1 oroethy 1 ene
Ethyl benzene
Methylene chloride
Naphtha lene
Pentach loropheno 1
Bis(2-ethylhexyl ) phthalate
Diethyl phthalate
Tetrach 1 oroethy lene
To 1 uene
Trich 1 oroethy lene
Ant imony
Arsenic
Cadmium
Chromium, total
Chromium, hexavalent
Copper
Cyanide, total
Cyanide, amn. to chlor.
Lead
Mercury
Nickel
Se lenium
S i 1 ve r
Zinc
Classical pollutants, mg/L
Al uminum
Ammon ia
1 ron
Manganese
Phenols, total
Oi 1 and grease
Total suspended solids
pH, minimum
pH, maximum
Number of
detections
Range
of
samp les
Mean
of
samp les
oxide (Aq02) powder - thermally reduced and
e lectrolyt ica 1 ly formed cathode waste stream
2
2
2
2
2
2
2
0
0
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
0
2
2
2
2
2
2
0
1
2
0
0
1
2
0
0
2
0
0
0
0
0
0
2
0
0
1
2
0
2
0
0
2
2
1
2
0
0
1
2
2
2
2
ND -
BDL -
ND -
BDL -
BDL -
10 -
ND -
10 -
10 -
300 -
10 -
ND -
0.28 -
ND -
9.3 -
1 -
9.0 -
9.0 -
BDL
BDL
BDL
BDL
BDL
10
BDL
10
20
17,000
20
0.35
0.8U
0.02
12
6. 1
12
12
BDL
BDL
BDL
BDL
BDL
10
BDL
10
15
8,600
15
0. 18
0.56
0.01
1 1
3.6
10.7
10.7
-------
a
CD
• •
00
CO
to
O
53"
0)
id
(D
H
H
CO
TABLE 8.2-15.
WASTEWATER CHARACTERIZATION -ZINC SUBCATEGORY BY INDIVIDUAL
PROCESS ELEMENTS (continued)
Pollutant
Number of
samples
Number of
detect ions
Range
of
samples
Mean
of
samples
Med ian
of
samp Ies
Silver peroxide (AgO) powder cathode waste stream
Toxic pollutants, u.g/L
I,I,I-Trich Ioroethane
I,I-Dichloroethane
I, I -Dichloroethylene
1,2-Trans-d ichloroethylene
Ethyl benzene
Methylene chloride
Naphthalene
PentachIo rophenoI
Bis(2-ethylhexyl) phthalate
Diethyl phthalate
Tetrachloroethylene
To I uene
T r i chIoroethyIene
Antimony
Arsen ic
Cadmium
Chrom i urn,
Chromium,
Copper
Cyanide,
Cyanide,
Lead
Mercury
Nickel
Selen ium
Si 1 ve r
Zinc
tota 1
hexava lent
tota 1
amn. to chlor.
Classical pollutants, mg/L
Aluminum
Ammon ia
I ron
Manganese
Phenols, total
Oil and grease
Total suspended solids
pH, minimum
pH, maximum
4
4
4
4
4
4
4
0
0
4
4
4
4
4
4
4
4
I
4
I
I
4
I
I
0
4
I
I
4
4
4
I
0
I
0
0
2
2
0
0
I
0
0
0
0
3
3
4
0
3
4
4
I
I
0
0
I
I
4
4
4
ND - BDL
ND - BDL
ND - BDL
ND - BDL
ND - BDL
ND - 5,800
ND - 6,000
10 - 220
ND - BDL
10
10
10
ND'- 10
ND - 3,900
8,800 - 71,000
10 - 450
ND - 3.6
I . I
BDL
16
180 - 730
9.0 - I I.0
9.0 - 13.0
BDL
BDL
BDL
BDL
BDL
3,300
2,900
120
BDL
BDL
2,200
43,000
140
0.89
460
10.0
12.0
ND
ND
BDL
BDL
ND
3,700
2,800
120
ND
ND
2,500
47,000
40
ND
460
10.0
12.0
-------
a
&
rt
0>
oo
\
U>
M
\
00
n
n>
M
•
00
•
NJ
I
(jJ
OO
TABLE 8.2-15.
WASTEWATER CHARACTERIZATION -ZINC SUBCATEGORY BY
PROCESS ELEMENTS (continued)
INDIVIDUAL
Pollutant
Number of
samples
Number of
detect ions
Range
of
samples
Mean
of
samples
Med ian
of
samples
Toxic pollutants, M9/L
1,1,l-Trichloroethane
I,l-Dichloroethane
I,I-Dichloroethylene
1,2-Trans-d ichloroethylene
Ethyl benzene
Methylene chloride
Napthalene
Pentachlorophenol
Bis(2-ethylhexyl) phthalate
Diethyl phthalate
Tetrachloroethylene
To Iuene
Trichloroethylene
Ant itnony
Arsen ic
Cadmium
Chrom i urn,
Chromium,
Copper
Cyanide,
Cyan ide,
Lead
Mercury
Nickel
Se len ium
Si 1 ve r
Zinc
tota 1
hexava lent
tota 1
amn. to chlor.
Classical pollutants, mg/L
AI urn inurn
Ammon ia
I ron
Manganese
Phenols, total
Oil and grease
Total suspended solids
pH, minimum
pM, maximum
Cell wash waste stream
12 9
6 4
6 4
6 3
6 I
12 4
6 5
2 0
6 6
6 6
6 3
6 I
12 8
12 0
12 4
12 12
12 12
9 3
12 12
6 6
3 3
12 4
9 9
12 12
6 4
12 9
12 12
6 I
3 3
0 0
12 12
9 6
9 9
12 I I
9 9
9 9
ND -
ND -
ND -
ND -
ND -
ND -
ND -
20 -
BDL -
ND -
ND -
ND -
ND -
BDL -
BDL -
ND -
10 -
10 -
2, 100 -
ND -
20 -
210 -
ND -
ND -
430 -
ND -
1.5 -
0.06 -
ND -
3.0 -
ND -
5.8 -
5.8 -
20
BDL
BDL
BDL
BDL
BDL
20
160
BDL
BDL
BDL
10
3,400
180
320,000
59,000
630
7,200
4,900
140
5,300
24,000
2, 100
1,400
33,000
0. 17
8.4
70
0.09
200
160
9.7
12.0
BDL
BDL
BDL
BDL
BDL
BDL
BDL
70
BDL
BDL
BDL
BDL
710
50
77,000
9,200
250
2,200
3,600
20
1,000
5,000
910
200
10,000
0.03
4.0
16
0.02
72
40
7.5
9.7
BDL
BDL
BDL
BDL
ND
ND
BDL
50
BDL
BDL
ND
BDL
ND
10
4,900
ND
230
I, 100
3,900
ND
410
2,700
840
20
3,700
ND
2.2
7.7
0.01
30
31
7.5
I I
-------
TABLE 8.2-15.
WASTEWATER CHARACTERIZATION -ZINC SUBCATEGORY BY
PROCESS ELEMENTS (continued)
INDIVIDUAL
rf
(D
oo
00
to
n
tr
0)
PoI lutant
Number of
samples
Number of
detect ions
Range
of
samples
Mean
of
samples
Med ian
of
samples
00
•
M
I
Silver powder production waste stream
Toxic pollutants, ug/L
1,1,1-Trichloroethane
I,I-Dichloroethane
I, I -Dichloroethylene
1,2-Trans-dichloroethylene
Ethyl benzene
Methylene chloride
Naphthalene
Pentachloropheno I
Bis(2-ethyIhexyl) phthalate
Diethyl phthalate
Tetrachloroethylene
To Iuene
Tr ichloroethylene
Ant imony
Arsen ic
Cadmium
Chrom i urn,
Chromium,
Copper
Cyan ide,
Cyanide,
Lead
Mercury
Nickel
Se len ium
Si Iver
Zinc
tota 1
hexava
tota 1
amn. to
lent
ch lor
Classical pollutants, mg/L
Aluminum
Ammonia
I ron
Manganese
Phenols, total
Oi I and grease
Total suspended solids
pH, minimum
pH, maximum
3
3
3
3
3
3
3
0
0
3
3
3
3
3
3
3
3
3
3
0
0
3
3
3
3
3
3
3
0
0
3
0
0
3
3
3
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
1
3
0
3
0
0
2
I
3
0
3
3
3
0
0
3
0
0
3
3
3
ND - BDL
580 - 1,500
- 10,000
ND - 280
ND - 10
570 - 1,400
12,000 - 24,000
180 - 440
0.48 - 12
0.08 - 0. I I
13-27
2.0 - 2.2
2.5 - 2.6
BDL
930
6,300
150
BDL
860
17,000
330
5.3
0. 10
21
2. I
2.5
ND
700
4,400
160
ND
610
14,000
380
3.4
0. 10
23
2. I
2.5
-------
o
P>
rt
(D
oo
\
Ul
M
\
00
n
u
cu
3
00
•
M
I
>fe.
NJ
TABLE 8.2-15.
Pollutant
WASTEWATER CHARACTERIZATION -ZINC SUBCATEGORY BY INDIVIDUAL
PROCESS ELEMENTS (continued)
Number of
samples
Number of
detect ions
Concentration of
sample
Silver peroxide production waste stream
Toxic pollutants, u,g/L
1,1, l-Trichloroethane
1, 1 -Dich loroethane
1, 1 -Dich 1 oroethylene
1 ,2-Trans-d ich 1 oroethylene
Ethyl benzene
Methylene chloride
Naphtha lene
Pentach loropheno 1 (
Bi s(2-ethylhexyl ) phthalate (
Diethyl phthalate
Tetrachl oroethylene
To luene
Tr ich 1 oroethylene
Ant imony
Arsen ic
Cadmium
Chromium, total
Chromium, hexavalent
Copper
Cyanide, total C
Cyanide, amn. to chlor. C
Lead
Mercury
Nickel
Se len ium
Si 1 ve r
Zinc
Classical pollutants, mg/L
Al uminum
Ammonia C
1 ron C
Manganese
Phenols, total C
Oi 1 and grease C
Total suspended solids
pH, minimum
pH, maximum 1
1
0
0
0
0
1
0
) 0
) 0
0
0
0
0
0
1
0
1
0
0
0
0
0
1
0
1
1
1
0
0
0
0
0
0
1
1
1
BDL
BDL
5,900
90
UO
4,800
770
80
31
1 1 .0
12
Analytic methods: V.7.3.8, Data set 2.
ND, not detected.
BDL, below detection limit.
-------
Battery manufacturing wastewater is readily treatable. The major
end-of-pipe treatment technologies employed in the industry are
chemical precipitation (for removal of dissolved metals and
cyanides), chemical reduction of chromium, settling, pressure
filtration, and oil skimming. Table 8.2-16 presents a summary of
treatment operations practiced in the battery manufacturing
industry. Chemical precipitation followed by the settling of
resulting solids is the most widely used technology. Adjustment
of pH is a required pretreatment step in most instances. Table
8.2-17 lists the treatment technologies reported in use by the
various subcategories.
Tables 8.2-18 to 21 present effluent quality achieved at plants in
different subcategories. Influent characteristics for these
treatment facilities were not reported. Table 8.2-21 also lists
treatment technologies used in the respective plants.
Date: 8/31/82 R Change 1 II.8.2-43
-------
TABLE 8.2-16. SUMMARY OF TREATMENT OPERATIONS
PRACTICED IN BATTERY MANUFACTURING
INDUSTRY [2-17]
Treatment Number of plants
Chemical Precipitation 76
Settling
« Settling tank 55
• Tube or plate settler 1
• Lagoon 10
Oil skimming 7
Pressure filtration 6
Evaporation 1
Flotation 2
Gravity sludge thickening 7
Ion exchange
• Nickel recovery 1
• Silver and water recovery 1
• Trace nickel and cadmium removal 1
Membrane filtration 1
Reverse osmosis* 2
Vacuum filtration 2
*To treat process wastewater for boiler feed.
Date: 9/25/81 II.8.2-44
-------
The dissolved inorganic pollutants for the coil coating category
are hexavalent chromium, chromium (total), copper, lead, nickel,
zinc, cadmium, iron, and phosphorus. Removal of these inorganics
is often a major step toward detoxifying wastewater. Chromium
reduction, which can be carried out chemically or electrochemi-
cally, is frequently a preliminary step. The next major step in
the classic treatment system is chemical precipitation, which is
often accomplished by the addition of lime, sodium sulfide, sodi-
um hydroxide, sodium carbonate, or ammonia. These additives
result in the precipitation of metal hydroxides.
Cyanide destruction in coil coating facilities is necessary to
reduce the cyanide concentration in wastewater from the plating
and cleaning baths. Cyanide is generally destroyed by oxidation.
Alkaline chlorination is the standard technique used in the Coil
Coating Industry, but oxidation by ozone, hydrogen peroxide, or
electrochemically have been suggested for use. These alternate
techniques, however, have not been demonstrated at this time.
Plant sampling data show that organic compounds tend to be re-
moved in standard wastewater treatment equipment. Oil separation
not only removes oil but also removes organics that are more
soluble in the oil than in water. Clarification also removes
organic solids by adsorption on inorganic solids. Carbon adsorp-
tion to remove organics has been demonstrated in the electro-
plating industry but is not presently used in the Coil Coating
Industry.
Sedimentation is the most common technique used for the removal
of precipitates. In this process sedimentation is preceded by
chemical precipitation, which converts dissolved pollutants to
solid form, and by coagulation, which enhances settling by coagu-
lating suspended precipitates into larger, faster settling parti-
cles. The major advantage of sedimentation is the simplicity of
the process. Sedimentation is used in 55 coil coating plants in
various forms, including ponds, lagoons, slant tube clarifiers,
and Lamella clarifiers.
Granular bed filters are used in 10 coil coating plants to remove
residual solids from the clarifier effluent. Chemicals may be
added upstream to enhance the solids removal. Pressure filtra-
tion is also used in this industry to reduce the solids concen-
tration in clarifier effluent and to remove excess water from the
clarifier sludge. Other sludge dewatering technologies used
include vacuum filtration, centrifugation, and sludge bed drying.
No pollutant removability data are currently available for this
industry.
Date: 8/31/82 R Change 1 II.8.3-19
-------
-------
II.8.5 ELECTRICAL AND ELECTRONIC COMPONENTS
II.8.5.1 INDUSTRY DESCRIPTION
II.8.5.1.1 General Description [2-20]
The Electrical and Electronic Components Industry encompasses the
manufacturing of a wide range of electrical products from the
following product areas:
Carbon and graphite
Switchgears and fuses
Resistance heaters
Incandescent lamps
Fluorescent lamps
Electron tubes
Cathode and television tubes
Insulators - mica
Insulators - plastic and laminates
Capacitors
Semiconductors (simple)
Semiconductors (complex)
Electric and electronic components
Wet transformers.
Table 8.5-1 is a listing of the SIC codes included in the Elec-
trical and Electronic Components Industry. Most of these SIC
codes were included in the Electrical Products Category in the
NRDC Consent Decree. Table 8.5-2 presents the Electrical Pro-
ducts Industry Summary in terms of the number of subcategories
and discharges.
TABLE 8.5-1. SIC CODES FOR ELECTRICAL AND ELECTRONIC
COMPONENTS CATEGORY [2-20]
SIC 3612 - Power, Distribution, and Specialty Transformers
SIC 3613 - Switchgear and Switchboard Apparatus
SIC 3621 - Motors and Generators
SIC 3622 - Industrial Controls
SIC 3623 - Welding Apparatus, Electric
SIC 3624 - Carbon and Graphite Products
SIC 3629 - Electrical Industrial Apparatus, Not Elsewhere
Classified
Date: 1/24/83 R Change 2 II.8.5-1
-------
SIC 3631 - Household Cooking Equipment
SIC 3632 - Household Refrigerators and Home and Farm Freezers
SIC 3633 - Household Laundry Equipment
SIC 3634 - Electric Housewares and Fans
SIC 3635 - Household Vacuum Cleaners
SIC 3639 - Household Appliances, Not Elsewhere Classified
SIC 3641 - Electric Lamps
SIC 3643 - Current-Carrying Wiring Devices
SIC 3644 - Noncurrent-Carrying Wiring Devices
SIC 3645 - Residential Electric Lighting Fixtures
SIC 3646 - Commercial, Industrial, and Institutional Electric
Lighting Fixtures
SIC 3647 - Vehicular Lighting Equipment
SIC 3648 - Lighting Equipment, Not Elsewhere Classified
SIC 3651 - Radio and Television Receiving Sets, Except Communi-
cation Types
SIC 3652 - Phonograph Records and Prerecorded Magnetic Tape
SIC 3661 - Telephone and Telegraph Apparatus
SIC 3662 - Radio and Television Transmitting, Signaling, and
Detection Equipment and Apparatus
SIC 3671 - Radio and Television Receiving-Type Electron Tubes,
Except Cathode Ray
SIC 3672 - Cathode Ray Television Picture Tubes
SIC 3673 - Transmitting, Industrial, and Special Purpose Electron
Tubes
SIC 3674 - Semiconductors and Related Devices
SIC 3675 - Electronic Capacitors
SIC 3676 - Resistors, for Electronic Applications
SIC 3677 - Electronic Coils, Transformers, and Other Inductors
SIC 3678 - Connectors, for Electronic Applications
SIC 3679 - Electronic Components, Not Elsewhere Classified
SIC 3693 - Radiographic X-Ray, Fluoroscopic X-Ray, Therapeutic
X-Ray, and Other X-Ray Apparatus and Tubes; Electro-
medical and Electrotherapeutic Apparatus
SIC 3694 - Electrical Equipment for Internal Combustion Engines
SIC 3699 - Electrical Machinery, Equipment, and Supplies, Not
Elsewhere Classified
TABLE 8.5-2 INDUSTRY SUMMARY [2-20]
Industry: Electrical Products
Total Number of Subcategories for
Which Effluent Limitations Are
Required: 6
Number of Subcategories Studied: 6
Number of Dischargers in Industry:
• Direct: 2,000
• Indirect: 8,000
• Zero: Unknown
Date: 1/24/83 R Change 2 II.8.5-2
-------
II.8.5.1.2 Subcategory Description
Based on product type, the Electrical and Electronic Components
Industry can be divided into 21 subcategories as follows:
Semiconductors
Electronic Crystals
Electron Tubes
Phosphorescent Coatings
Capacitors, Fixed
Capacitors, Fluid Filled
Carbon and Graphite Products
Mica Paper
Incandescent Lamps
Fluorescent Lamps
Fuel Cells
Magnetic Coatings
Resistors
Transformers, Dry
Transformers, Fluid Filled
Insulated Devices, Plastic and Plastic Laminated
Insulated Wire and Cable, Nonferrous
Ferrite Electronic Parts
Motors, Generators, and Alternators
Resistance Heaters
Switchgear
The Electrical and Electronic Components Industry is derived from
categories found in the Standard Industrial Code (SIC) major
group 36, composed of Electrical and Electronic Machinery, Equip-
ment, and Supplies. Many of the categories listed under this
major classification, however, were never evaluated as part of
the Electrical and Electronic Components Industry because it was
concluded that the wastewater discharges from these categories
were primarily associated with the Metal Finishing Industry. In
addition, other categories have been recommended for exclusion
under Paragraph 8 as a result of the nature or volume of the
wastewater generated by the industries. Two subcategories of the
Electrical and Electronic Components Industry are presently
subject to regulation: semiconductors and electronic crystals.
A description of these subcategories is presented below in con-
siderable detail while the descriptions are abbreviated for
subcategories which are being excluded or deferred from regula-
tion.
Semiconductor Subcategory
Semiconductors are solid state electrical devices which perform a
variety of functions. These functions include information pro-
cessing and display, power handling, and the conversion between
light energy and electrical energy. The semiconductors range
Date: 1/24/83 R Change 2 II.8.5-3
-------
from the simple diode, which may be turned on or off like a light
bulb, to the integrated circuit, which may have the equivalent of
250,000 active switching components in a 0.64-cm (0.25-inch)
square.
Semiconductors are used throughout the electronics industry. The
major semiconductor products are:
• silicon-based integrated circuits which include bipolar,
MOS (metal oxide silicon), and digital and analog devices;
• gallium arsenide and gallium phosphide wafers for the
production of light emitting diodes (LED's);
• silicon and germanium wafers for diode and transistor
production; and
• glass wafer devices such as for liquid crystal display
(LCD) production.
Silicon-based integrated circuits require high purity,
single crystal silicon as a basis material which can be purchased
as ingots (cylindrical crystals which can be sliced into wafers),
slices, or wafers. These slices or wafers are lapped or polished
by means of a mechanical grinding machine, or they are chemically
etched to provide a smooth surface and remove surface oxides and
contaminants. Commonly used etch solutions are hydrofluoric acid
or hydrofluoric-nitric acid mixtures. The presence of hydro-
fluoric acid is generally necessary because of the solubility
characteristics of silicon and silicon oxide. Other acids such
as sulfuric or nitric may be used depending on the nature of the
material to be removed. Wastewater results from cooling the
diamond-tipped saws used for slicing and from deionized water
rinses following chemical etching and milling operations.
The next step in the process is the growth of either silicon
dioxide, silicon nitride, or an epitaxial silicon layer on the
surface of the wafer. The wafer is then coated with a photo-
resist, a photosensitive emulsion that hardens and clings to the
wafer when exposed to light. The wafer is next exposed to ultra-
violet light using glass photomasks that allow the light to
strike only selected areas. After exposure to ultraviolet light,
unexposed resist is removed from the wafer, usually in a de-
ionized water rinse. The wafer is then visually inspected under
a microscope and etched in a solution containing hydrofluoric
acid (HF). The etchant produces depressions, called holes or
windows, where the diffusion of dopants later occurs. Dopants
are impurities such as boron, phosphorus, and other specific
metals. These impurities eventually form circuits through which
electrical impulses can be transmitted. The wafer is then rinsed
Date: 1/24/83 R Change 2 II.8.5-4
-------
in an acid or solvent solution to remove the remainder of the
hardened photoresist material.
Diffusion of dopants is generally a vapor phase process in which
the dopant, in the form of a gas, is injected into a furnace
containing the wafers. Gaseous phosphine and boron trifluoride
are common sources for phosphorus and boron dopants, respec-
tively. The gaseous compound breaks down into elemental phos-
phorus or boron on the hot wafer surface. Continued heating of
the wafer allows diffusion of the dopant into the surface through
the windows at controlled depths to form the electrical pathways
within the wafer. Solid forms of the dopant may also be used.
For example, boron oxide wafers can be introduced into the fur-
nace in close proximity to the silicon wafers. The boron oxide
sublimes and deposits boron on the surface of the wafer by con-
densation and then diffuses into the wafer upon continued heat-
ing. This photolithographic-etching-diffusion-oxide process
sequence may occur a number of times depending upon the appli-
cation of the semiconductor.
During the photolithographic-etching-diffusion-oxide processes,
the wafer may be cleaned many times in mild acid or alkali solu-
tions followed by deionized water rinses and solvent drying with
acetone or isopropyl alcohol. This is necessary to maintain
wafer cleanliness.
After the diffusion processes are completed, a layer of metal is
deposited onto the surface of the wafer to provide contact points
for final assembly. The metals used for this purpose include
aluminum, copper, chromium, gold, nickel, platinum, and silver.
One of the following three processes is used to deposit this
metal layer:
• Sputtering - a process whereby the source metal and the
target wafer are electrically charged, as the cathode and
anode, respectively, in a partially evacuated chamber.
The electric field ionizes the gas in the chamber and
these ions bombard the source metal cathode, ejecting
metal which deposits on the wafer surface.
• Vacuum deposition - a process whereby the source metal is
treated in a high vacuum chamber by resistance or elec-
tron beam heating to the vaporization temperature. The
vaporized metal condenses on the surface of the silicon
wafer.
• Electroplating - a process whereby the source metal is
electrochemically deposited on the target wafer by immer-
sion in an electroplating solution and application of an
electrical current.
Date: 1/24/83 R Change 2 II.8.5-5
-------
Finally, the wafer receives a protective oxide layer (passiva-
tion) coating before being backlapped to produce a wafer of the
desired thickness. Then the individual chips are diced from the
wafer and are assembled in lead frames for use. Many companies
involved in semiconductor production in the United States do not
dice finished wafers. Rather, the completed wafer is packed and
sent to overseas facilities where dicing and assembly operations
are less costly.
Light emitting diodes are produced from single crystal
gallium arsenide or gallium phosphide wafers. These wafers are
purchased from crystal growers and upon receipt are placed in a
furnace where a silicon nitride layer is grown on the wafer. The
wafer then receives a thin layer of photoresist, is exposed
through a photomask, and is developed with a xylene-based devel-
oper. Following this, the wafer is etched using hydrofluoric
acid or a plasma-gaseous-etch process, rinsed in a deionized
water, and then stripped of resist. The wafer is again rinsed in
deionized water before a dopant is diffused into the surface of
the wafer. A metal oxide covering is applied next, and then a
photoresist is applied. The wafer is then masked, etched in a
solution of aurostrip (a cyanide-containing chemical commonly
used in gold stripping), and rinsed in a deionized water. The
desired thickness is produced by backlapping, and a layer of
metal, usually gold, is sputtered onto the back of the wafer to
provide electrical contacts. Testing and assembly complete the
production process.
Diodes and resistors are produced from single crystal sil-
icon or germanium wafers. These devices, called discrete de-
vices, are manufactured on a large scale, and their use is mainly
in older or less sophisticated equipment designs, although dis-
crete devices still play an important role in high-power switch-
ing and amplification.
The single crystal wafer is cleaned in an acid or alkali solu-
tion, rinsed in deionized water, and coated with a layer of
photoresist. The wafer is then exposed and etched in a hydro-
fluoric acid soluton. This is followed by rinsing in deionized
water, drying, and doping in diffusion furnaces where boron or
phosphorus are diffused into the surface of the wafer. The
wafers are then diced into individual chips and sent to the
assembly area. In the assembly area electrical contacts are
attached to the appropriate areas and the device is sealed in
rubber, glass, plastic, or ceramic material. Wires are attached
and the device is inspected and prepared for shipment.
Liquid crystal display (LCD) production begins with opti-
cally flat glass that is cut into 10-cm (4-inch) squares. The
squares are then cleaned in a solution containing ammonium hy-
droxide, immersed in a mild alkaline stripping solution, and
rinsed in deionized water. The plates are spun dry and sent to
the photolithography area for further processing.
Date: 1/24/83 R Change 2 II.8.5-6
-------
In the photolithographic process a photoresist mask is applied
with a roller, and the square is exposed and developed. This
square then goes through deionized water rinses and is dried,
inspected, etched in an acid solution, and rinsed in deionized
water. A solvent drying step is followed by another alkaline
stripping solution. The square then goes through deionized water
rinses, is spun dry, and inspected.
The next step of the LCD production process is passivation. An
oxide layer is deposited on the glass by using liquid silicon
dioxide, or by using silicon and oxygen gas with phosphene gas as
a dopant. This layer is used to keep harmful sodium ions on the
glass away from the surface where they could alter the electronic
characteristics of the device. Several production steps may
occur here if it is necessary to rework the piece. These include
immersion in an ammonium bifluoride bath to strip silicon oxide
from a defective piece followed by deionized water rinses and a
spin dry step. The glass is then returned to the passivation
area for reprocessing.
After passivation, the glass is screen printed with devitrified
liquid glass in a matrix. Subsequent baking causes the devitri-
fied glass to become vitrified, and the squares are cut into the
patterns outlined by the vitrified glass boundaries. The saws
used to cut the glass employ contact cooling water which is
filtered and discharged to the waste treatment system.
The glass is then cleaned in an alkaline solution and rinsed in
deionized water. Following inspection, a layer of silicon oxide
is evaporated onto the surface to provide alignment for the
liquid crystal. The two mirror-image pieces of glass are aligned
and heated in a furnace, bonding the vitrified glass and creating
a space between the two pieces of glass. The glass assembly is
immersed in the liquid crystal solution in a vacuum chamber, air
is evacuated, and the liquid crystal is forced into the space
between the glass pieces. The glass is then sealed with epoxy,
vapor-degreased in a solvent, shaped on a diamond wheel, in-
spected, and sent to assembly.
Contact water is used throughout the production of semiconduc-
tors. Plant incoming water is first pretreated by deionization
to provide ultrapure water for processing steps. This ultrapure
water or deionized water is used to formulate acids; to rinse
wafers after processing steps; to provide a medium for collecting
exhaust gases from diffusion furnaces, solvents, and acid baths;
and to clean equipment and materials in semiconductor production.
Water also cools and lubricates the diamond saws and grinding
machines used to slice, lap, and dice wafers during processing.
Date: 1/24/83 R Change 2 II.8.5-7
-------
Electronic Crystals Subcategory
Based on their properties and their uses in the industry, elec-
tronic crystals can be divided into three types:
• piezoelectric crystals,
• semiconducting crystals, and
• liquid crystals.
Piezoelectric crystals are transducers which interconvert
electrical voltage and mechanical force. The three principal
types are quartz, ceramic, and yttrium-iron-garnet (YIG).
Quartz crystals are the most widely used of the piezoelectric
crystals, with applications as timing devices in watches, clocks,
and record players; frequency controllers, modulators, and de-
modulators in oscillators; and filters. Some quartz is mined,
but the main supply comes from synthesized material produced by
about forty companies in the United States.
The growth of quartz crystals is a hydrothermal process carried
out in an autoclave under high temperature and pressure. The
vessel is typically filled to 80 percent of the free volume with
a solution of sodium hydroxide or sodium carbonate. Particles of
a-quartz nutrient are placed in the lower portion of the vessel
where they are dissolved. The quartz is then transferred by
convection currents through the solution and deposited on seed
crystals which are suspended in the upper portion of the vessel.
Seeds are thin wafers or spears of quartz about six inches long.
A vessel normally contains 20 seeds. Nutrient quartz will dis-
solve and deposit onto the seed crystals because a small temper-
ature gradient exists between the lower and upper portion of the
autoclave, promoting the migration of quartz to the upper portion
of the vessel. Upon completion of the growth cycle (45 to 60
days), crystals are removed and cleaned for the fabrication
process.
The quartz crystals are cut or sliced using diamond blade saws or
slurry saws. Diamond blade saws are used when one wafer at a
time is cut. Slurry saws are utilized in mass production lines
for cutting many wafers at a time. The crystal wafers are then
lapped to the desired thickness. After lapping, the crystal is
usually etched with hydrofluoric acid or ammonium bifluoride and
subsequently rinsed with water. Crystal edges are then beveled
using either a dry grinding grit or a water slurry. Following
this, metals are deposited on the crystal by vacuum deposition.
The crystal wafers are mounted on a masking plate and placed in
an evacuated bell jar. Metal strips in the jar are vaporized,
coating the unmasked area of the wafer. The metal coating (gold,
silver, or aluminum are often used) functions as the crystal's
conducting base. The metal coating operation is covered by
regulations for the Metal Finishing Industry. During fine tune
Date: 1/24/83 R Change 2 II.8.5-8
-------
deposition, the crystal is allowed to resonate at a specified
frequency and another thin layer of metal is deposited on it.
Wire leads are attached to the crystal and it is sealed in a
nitrogen atmosphere. At this point the crystal is ready for sale
or insertion into an electronic circuit.
Ceramic crystals are basically fired mixtures of the oxides of
lead, zirconium, and titanium. They are used in transducers,
oscillators, utrasonic cleaners, phonograph cartridges, gas
igniters, audible alarms, keyboard switches, and medical elec-
tronic equipment.
Ceramic crystal production begins by mixing lead oxide, zirconium
oxide and titanium oxide powders plus small amounts of dopants to
achieve desired specifications in the final product. The powders
are mixed with water to obtain uniform blending, then filtration
takes place and the waste slurry is sent to disposal. This
mixture is roasted, ground wet, and blended with a binder (poly-
vinyl alcohol) in a tank called a blundger. The mixture is then
spray dried, pressed, and fired to drive off the binder, which is
not recovered. Formed crystals are enclosed in alumina and
refired. After this final firing crystals are polished, lapped,
and sliced as in quartz production. Electrodes, usually made of
silver, are then attached to the crystals. Approximately ten
percent of the crystals have electrodes deposited by electroless
nickel plating. This plating operation is covered by regulations
for the Metal Finishing Industry. Poling, the final process
step, gives the crystal its piezoelectric properties. This step
is performed with the crystal immersed in a mineral oil bath.
Some companies sell the used mineral oil to reclaimers. After
poling the crystal is ready for sale and use. Ceramic crystal
production is very small.
YIG crystals are made by the slow crystal growth of a melt of
yttrium oxide, iron oxide, and lead oxide. Their primary use is
in the microwave industry for low frequency applications as in
sonar. Their incorporation into microwave circuits makes wide-
band tuning possible.
The production of YIG crystals involves the melting of metal
compounds to form large single crystals which are processed to
yield minute YIG spheres for use in microwave devices. Yttrium
oxide, iron oxide and lead oxide powders are mixed, placed in a
platinum crucible and melted in a furnace. After the melt equi-
librates at this temperature the furnace is cooled, the slag is
poured off, leaving the YIG crystals attached to the crucible.
This growth process takes approximately 28 days. The crucible is
soaked in hydrochloric and nitric acid to remove the crystals
which are then sliced by a diamond blade saw to form cubes 0.10 cm
(0.04 inches) on a side. These cubes are placed in a rounding
machine, and the rounding process is followed by polishing to
obtain perfectly spherical crystals for use in a microwave device.
Date: 1/24/83 R Change 2 II.8.5-9
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The production of YIG and ceramic crystals with piezoelectric
properties constitutes a minor portion of the piezoelectric
crystal industry. The entire YIG production for the USA is less
than 6.8 kg (fifteen pounds) per year.
Semiconducting crystals have properties intermediate between
a conductor and an insulator, thus allowing for a wide range of
applications in the field of microelectronics. In conductors,
current is carried by electrons that travel freely throughout the
atomic lattice of the substance. In insulators the electrons are
tightly bound and are therefore unavailable to serve as carriers
of electric current. Semiconductors do not ordinarily contain
free charge carriers but generate them with a modest expenditure
of energy.
There are several types of semiconducting crystals such as sili-
con, sapphire, gallium gadolinium garnet (GGG), and gallium
arsenide crystals.
Silicon crystals are widely used in the manufacture of microelec-
tronic chips: transistors, diodes, rectifiers, other circuit
elements, and solar cells. The raw material used to produce the
crystals is polycrystalline silicon. Reduction of purified
trichlorosilane with hydrogen is the usual method of producing
the high purity polycrystalline ("poly") silicon. Single crys-
tals of silicon are then grown by the Czochralski method, the
most common crystal growing technique for semiconductor crystals.
This method functions by lowering a seed crystal (a small single
crystal) into a molten pool of the crystal material and raising
the seed slowly (over a period of days) with constant low rota-
tion.
Because the temperature of the melt is just above the melting
point, material solidifies onto the seed crystal, maintaining the
same crystal lattice. Crystals up to 15.24 cm (6 in) in diameter
and 1.22 m (4 ft) long can be grown by this method.
After a crystal has been grown, the outside diameter is ground to
produce a crystalline rod of constant diameter. The ends are cut
off and used to evaluate the quality of the crystal. At the same
time, its orientation is determined and a flat is ground the
length of the rod to fix its position. Rods are then sliced into
wafers. Silicon dust and cutting oils mixed with water are waste
products of the grinding and cutting operations.
Lapping is a machining operation using an alumina and ethylene
glycol abrasive medium which produces a flat polished surface and
reduces the thickness of the wafers. After lapping, the wafers
are polished using a hydrated silica medium. The final cleaning
is done with various acids, bases, and solvents.
Date: 1/24/83 R Change 2 II.8.5-10
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Crystals of pure silicon are poor conductors of electricity. In
order to make them better conductors, controlled amounts of
impurity atoms are introduced into the crystal by a process
called doping. When silicon is doped with an element whose atoms
contain more or fewer valence electrons than silicon, free elec-
trons or electron "holes" are thus available to be mobilized when
a voltage is applied to the crystal. Phosphorus and boron are
common dopants used in silicon crystals.
Sapphire crystals are used as single crystal wafers which act as
inactive substrates for an epitaxial film of silicon, that is,
substrates upon which a thin layer of silicon is deposited in a
single-crystal configuration. This is referred to as silicon on
sapphire (SOS). In addition to being a dielectric material,
single crystal sapphire exhibits a combination of optical and
physical properties which make it ideal for a variety of demand-
ing optical applications. Sapphire, the hardest of the oxide
crystals, maintains its strength at high temperatures, has good
thermal and excellent electrical properties, and is chemically
inert. Therefore, it can be used in hostile environments when
optical transmission ranging from vacuum ultraviolet to near
infrared is required. Sapphire crystals have found application
in semiconductor substrates, infrared detector cell windows, UV
windows and optics, high power laser optics, and ultracentrifuge
cell windows.
Gallium gadolinium garnet (GGG) is the most suitable substrate
for magnetic garnet films because of its excellent chemical,
mechanical, and thermal stability, nearly perfect material and
surface quality, crystalline structure, and the commercial avail-
ability of large diameter substrates. GGG is the standard sub-
strate material used for epitaxial growth of single crystal iron
garnet films which are used in magnetic bubble domain technology.
To produce sapphire and gallium gadolinium garnet (GGG) crystals
a raw material called crackle (high purity alumina waste from a
European gem crystal growing process) is melted in an iridium
crucible. Sapphire is pure alumina. Gadolinium oxide and gal-
lium oxide powders are added to the crucible if GGG is the desired
product. These are melted using an induction furnace under a
nitrogen atmosphere with a trace of oxygen added. Crystals are
pulled from the melt using the Czochralski method.
These crystals are annealed in oxygen-gas furnaces after growth
in order to remove internal stress and make the crystalline rods
less brittle. Sapphire and GGG rods are ground and sliced using
diamond abrasives and a coolant consisting of a mixture of oil
and water. Wafers are lapped using a diamond abrasive compound
and lubricants, and are polished with a colloidal silica slurry.
GGG wafers are coated with a thin film using liquid-phase epi-
taxy. The film has small permanent magnetic domains, which make
Date: 1/24/83 R Change 2 II.8.5-11
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it useful for "magnetic bubble" memory devices. The sapphire
wafers are coated with a layer of epitaxial silicon to produce
the SOS substrates for microelectronic chip manufacture.
Gallium arsenide and gallium phosphide crystals were developed
under the need for a transistor material with good high temper-
ature properties. These crystals exhibit low field electron
mobility, and are therefore useful at high frequencies, in such
devices as the field effect transistor (FET). The technology of
manufacturing high performance gallium arsenide FET's is maturing
at a rapid rate and the devices are experiencing a greatly expand-
ing role in oscillators, power amplifiers, and low noise/ high
gain applications.
Most gallium arsenide/phosphide is presently being used for
production of light emitting diodes (LEDs) which can convert
electric energy into visible electromagnetic radiation. The
interconversion of light energy and voltage in gallium arsenide
is reversible. Hence this material is also undergoing intensive
development as a solar cell, in which sunlight is converted
directly to electricity.
Indium arsenide and indium antimonide crystals, formed by direct
combination of the elements, are used as components of power
measuring devices. These crystals are uniquely suited to this
function because they demonstrate a phenomenon known as the Hall
Effect, the development of a transverse electric field in a
current-carrying conductor placed in a magnetic field.
Bismuth telluride crystals demonstrate a phenomenon known as
thermoelectric cooling because of the Peltier Effect. When a
current passes across a junction of dissimilar metals, one side
is cooled and the other side heated. If the cold side of the
junction is attached to a heat source, heat will be carried away
to a place where it can be conveniently dissipated. Devices
utilizing this effect are used to cool small components of elec-
trical circuits.
The formation of gallium arsenide, gallium phosphide, and indium
bismuth telluride takes place by a chemical reaction which occurs
in an enclosed capsule. When gallium arsenide or phosphide
crystals are produced, the gallium, on one side of the capsule,
is heated to more than 1200°C. The arsenic or phosphorus on the
other side of the capsule is heated separately until it vapor-
izes. The vapor and hot metal react to form a molten compound.
(In the case of phosphorus, high pressure is required.) The
molten compound can then be crystallized in situ by the Chalmers
technique or cooled and crystallized by the Czochralski method.
These crystals undergo the fabrication operations mentioned
earlier.
Date: 1/24/83 R Change 2 11.8.5-12
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To produce indium antimonide, indium arsenide, and bismuth tellu-
ride, the elements are mixed together, melted to form the com-
pound and frozen into a polycrystalline ingot. These materials
are used in a polycrystalline state so no crystal growing step
occurs. The ingot is fabricated into wafers by normal machining
operations. Because these materials are relatively soft, carbide
abrasives with water cooling are sufficient for machining the
ingots. The wafers are milled into small pieces and incorporated
into electronic components.
Liquid crystals are organic compounds or mixtures of two or
more organic compounds which exhibit properties of fluidity and
molecular order simultaneously over a small temperature range.
An electric field can disrupt the orderly arrangement of liquid
crystal molecules, changing the refractive properties. This
darkens the liquid enough to form visible characters in a display
assembly, even though no light is generated. This effect is
achieved by application of a voltage and does not require a
current flow. Therefore minimal use of power is .required, allow-
ing the display in battery operated devices to be activated
continuously. Liquid crystals are used in liquid crystal display
(LCD) devices for wrist watches, calculators, and other consumer
products requiring a low power display.
Liquid crystals are produced by organic synthesis. Precursor
organic compounds are mixed together and heated until the reac-
tion is complete. The reacted mass is dissolved in an organic
solvent such as toluene, and is crystallized and recrystallized
several times to obtain a product of the desired purity. Several
of these organic compounds are then mixed to form a eutectic
mixture with the correct balance of properties for LCD applica-
tion.
The major source of wastewater from the manufacture of electronic
crystals is from rinses associated with crystal fabrication,
although some wastewater may be generated from crystal growing
operations. Fabrication steps generating wastewater are slicing,
lapping, grinding, polishing, etching, and cleaning of grown
crystals. Certain growth processes generate a large volume of
wastewater from the discharge of spent solutions of sodium hydrox-
ide and sodium carbonate after each crystal growth cycle.
Electron Tube Subcategory
Electron tubes are devices in which electrons or ions are con-
ducted between electrodes through a vacuum or ionized gas within
a gas-tight envelope which may be glass, quartz, ceramic, or
metal. A large variety of electron tubes are manufactured,
including klystrons, magnetrons, cross field amplifiers, and
modulators. These products are used in aircraft and missile
guidance systems, weather radar, and specialized industrial
applications. The electron tube subcategory also includes
Date: 1/24/83 R Change 2 II.8.5-13
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cathode-ray tubes and T.V. picture tubes that transform elec-
trical current into visual images. Cathode-ray tubes generate
images by focusing electrons onto a luminescent screen in a
pattern controlled by the electrical field applied to the tube.
In T.V. picture tubes, a stream of high-velocity electrons scans
a luminescent screen. Variations in the electrical impulses
applied to the tube cause changes in the intensity of the elec-
tron stream and generate the image on the screen.
Processes involved in the manufacture of electron tubes include
degreasing of components; application of photoresist, graphite,
and phosphors to glass panels; and sometimes electroplating
operations including etching and machining. The application of
phosphors is unique to T.V. picture tubes and other cathode-ray
tubes. The phosphor materials may include sulphides of cadmium
and zinc and yttrium and europium oxides. The electroplating
operations are covered under the Metal Finishing Industry. Raw
materials can include copper and steel as basis materials, and
copper, nickel, silver, gold, rhodium, and chromium to be elec-
troplated. Phosphors, graphite, and protective coatings contain-
ing toluene or silicates and solders of lead oxide may also be
used. Process chemicals may include hydrofluoric, hydrochloric,
sulfuric, and nitric acids for cleaning and conditioning of metal
parts; and solvents such as methylene chloride, trichloroethyl-
ene, methanol, acetone, and polyvinyl alcohol.
Phosphorescent Coatings Subcategory
Phosphorescent coatings are coatings of certain chemicals, such
as calcium halophosphate and activated zinc sulfide, which emit
light. Phosphorescent coatings are used for a variety of appli-
cations; those specific to the Electrical and Electronic Com-
ponents Industry are in fluorescent lamps and television picture
tubes. The most important fluorescent lamp coating is calcium
halophosphate phosphor. The intermediate powders are calcium
phosphate and calcium fluoride. There are three T.V. powders:
red phosphor (yttrium oxide activated with europium), blue phos-
phor (zinc sulfide activated with silver), and green phosphor
(zinc-cadmium sulfide activated with copper). The major process-
ing steps in producing phosphorescent coatings are reacting,
milling, and firing the raw materials; recrystallizing raw mater-
ials, if necessary; and washing, filtering, and drying the inter-
mediate and final products.
Fixed Capacitors Subcategory
The primary function of capacitors is to store electrical energy.
Fixed capacitors are layered structures of conductive and di-
electric materials. The layering of fixed capacitors is either
in the form of rigid plates or in the form of thin sheets of
flexible material which are rolled. Typical capacitor applica-
tions are energy storage elements, protective devices, filtering
Date: 1/24/83 R Change 2 II.8.5-14
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devices, and bypass devices. Some typical processes in manu-
facturing fixed capacitors are anode fabrication, formation
reactions, dipping, layering, cathode preparation, welding, and
electrical evaluation. All manufacturing processes are covered
under the Metal Finishing Industry by unit operation. Fixed
capacitor types are distinguished from each other by type of
conducting material, dielectric material, and encapsulating
material. This subcategory has been excluded under Paragraph 8
of the NRDC Consent Decree.
Fluid Filled Capacitors
As with fixed capacitors, the primary function of fluid-filled
capacitors is to store electrical energy. Wet capacitors contain
a fluid dielectric that separates the anode (in the center of the
device) from the cathode (the capacitor shell), which also serves
to contain the fluid. Fluid-filled capacitors are used for
industrial applications as electrical storage, filtering, and
circuit protection devices. Some typical processes in manufac-
turing fluid-filled capacitors are anode fabrication, formation
reactions, metal can preparation, dielectric addition, soldering,
and electrical evaluation. All manufacturing processes are
covered under the Metal Finishing category by unit operation.
This subcategory has been excluded under Paragraph 8 of the NRDC
Consent Decree.
Carbon and Graphite Products Subcategory
Carbon and graphite (elemental carbon in amorphous crystalline
form) products exhibit unique electrical, thermal, physical, and
nuclear properties. The major carbon and graphite product areas
are (1) carbon electrodes for aluminum smelting and graphite
furnace electrodes for steel production, (2) graphite molds and
crucibles for metallurgical applications, (3) graphite anodes for
electrolytic cells used for production of such materials as
caustic soda, chlorine, potash, and sodium chlorate, (4) non-
electrical uses such as structural, refractory, and nuclear
applications, (5) carbon and graphite brushes, contacts, and
other products for electrical applications, and (6) carbon and
graphite specialties such as jigs, fixtures, battery carbons,
seals, rings, and rods for electric arc lighting, welding, and
metal coating. This subcategory has been excluded under
Paragraph 8 of the NRDC Consent Decree.
Mica Paper
Mica paper is a dielectric (non-conducting) material used in
the manufacture of fixed capacitors. Mica paper is manufactured
in the following manner: Mica is heated in a kiln and then
placed in a grinder where water is added. The resulting slurry
is passed to a double screen separator where undersized and
oversized particles are separated. The screened slurry flows to
Date: 1/24/83 R Change 2 II.8.5-15
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a mixing pit and then to a vortex cleaner. The properly-sized
slurry is processed in a paper-making machine where excess water
is drained or evaporated. The resulting cast sheet of mica paper
is fed on a continuous roller to a radiant heat drying oven,
where it is cured. From there, the mica paper is wound onto
rolls, inspected, and shipped. This subcategory has been ex-
cluded under Paragraph 8 of the NRDC Consent Decree.
Incandescent Lamps Subcategory
An incandescent lamp is an electrical device that emits light.
Incandescent tungsten filament lamps operate by passage of an
electric current through a conductor (the filament). Heat is
produced in this process, and light is emitted if the temperature
reaches approximately 500°C. Most lamp-making operations are
highly automated. The mount machine assembles a glass flare, an
exhaust tube, lead-in wires, and molybdenum filament support. A
glass bulb is electrostatically coated with silica and the bulb
and mount are connected at the exhaust and seal machine. The
bulb assembly is annealed, exhausted, filled with an inert gas,
and sealed with a natural gas flame. The finishing machine
solders the lead wires to the metallic base which is then
attached to the bulb assembly by a phenolic resin cement or by a
mechanical crimping operation. The finished lamp is aged and
tested by illuminating it with excess current for a period of
time to stabilize its electrical characteristics. This sub-
category has been excluded under Paragraph 8 of the NRDC Consent
Decree.
Fluorescent Lamps Subcategory
A fluorescent lamp is an electrical device that emits light by
electrical excitation of phosphors that are coated on the inside
surface of the lamp. Fluorescent lamps utilize a low pressure
mercury arc in argon. Through this process, the lowest excited
state of mercury efficiently produces short wave ultraviolet
radiation at 2,537 Angstroms. Phosphor materials that are com-
monly used are calcium halophosphate and magnesium tungstate,
which absorb the ultraviolet photons into their crystalline
structure and re-emit them as visible white light.
There are two types of fluorescent lamps: hot cathode and cold
cathode. Cold cathode manufacture is primarily an electroplating
operation. Hot cathode fluorescent lamp manufacturing is a
highly automated process. Glass tubing is rinsed with deionized
water and gravity-coated with phosphor. Coiled tungsten fila-
ments are assembled together with lead wires, an exhaust tube, a
glass flare, and a starting device to produce a mount assembly.
The mount assemblies are heat pressed to the two ends of the
glass tubing. The glass tubes are exhausted and filled with an
inert gas. The lead wires are soldered to the base and the base
is attached to the tube ends. The finished lamp receives a
silicone coating solution. The lamp is then aged and tested
Date: 1/24/83 R Change 2 II.8.5-16
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before shipment. This subcategory has been excluded under Para-
graph 8 of the NRDC Consent Decree.
Fuel Cells Subcategory
Fuel cells are electrochemical generators in which the chemical
energy from a reaction of air (oxygen) and a conventional fuel is
converted directly into electricity. The major fuel cell pro-
ducts, basically in research and development stages, are:
(1) fuel cells for military applications, (2) fuel cells for
power supply to vehicles, (3) fuel cells used as high power
sources, and (4) low temperature and low pressure fuel cells with
carbon electrodes. Some typical processes in the manufacture of
fuel cells are extrusion or machining, heat treating, sintering,
molding, testing, and assembling. Some typical raw materials are
base carbon or graphite, plastics, resins, and Teflon. This
subcategory has been excluded under Paragraph 8 of the NRDC
Consent Decree.
Magnetic Coatings Subcategory
Magnetic coatings are applied to tapes to allow the recording of
information. Magnetic tapes are used primarily for audio, video,
computer, and instrument recording. The process begins with
milling to create sub-micron magnetic particles. Ferric oxide
particles are used almost exclusively with trace additions of
other particles or alloys for specific applications. The par-
ticles are mixed, through several steps, with a variety of sol-
vents, resins, and other additives. The coating mix is then
applied to a flexible tape or film material (for example, cellu-
lose acetate). After the coating mix is applied, particles are
magnetically oriented by passing the tape through a magnetic
field, and the tape is dried and slit for testing and sale. This
subcategory has been excluded under Paragraph 8 of the NRDC
Consent Decree.
Resistors Subcategory
Resistors are devices commonly used as components of electric
circuits to limit current flow or to provide a voltage drop.
Resistors are used for television, radios, and other applica-
tions. Resistors can be made from various materials. Nickel-
chrome alloys, titanium, and other resistive materials can be
vacuum-deposited for thin film resistors. Glass resistors are
also available for many resistor applications. Two examples of
glass resistors are the precision resistor and the low power
resistor. This subcategory has been excluded under Paragraph 8
of the NRDC Consent Decree.
Date: 1/24/83 R Change 2 II.8.5-17
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Dry Transformers Subcategory
A transformer is a stationary apparatus for converting electrical
energy at one alternating voltage into electrical energy at
another (usually different) alternating voltage by means of
magnetic coupling (without change of frequency). Dry trans-
formers use standard metal working and metal finishing processes
(covered by the Metal Finishing Industry). The main operations
in manufacturing a power transformer are the manufacture of a
steel core, the winding of coils, and the assembly of the coil/
core on some kind of frame or support. This subcategory has been
excluded under Paragraph 8 of the NRDC Consent Decree.
Fluid Filled Transformers Subcategory
Wet transformers perform the same functions as dry transformers,
but the former are filled with dielectric fluid. Wet trans-
formers use standard metal working and metal finishing processes
which are covered by the Metal Finishing Industry. The only wet
process unique to the Electrical and Electronic Components
Industry are the cleanup and management of residual dielectric
fluid. The main operations in manufacturing a power transformer
are the manufacture of a steel core, the winding of coils, and
the assembly of the coil/core on some kind of frame or support.
In the manufacture of wet transformers there is the need for a
container or tank to contain the dielectric fluid. This sub-
category has been excluded under Paragraph 8 of the NRDC Consent
Decree.
Insulated Devices, Plastics and Plastic Laminated Subcategory
An insulated device is a device that prevents the conductance of
electricity (dielectric). Plastic and plastic laminates are
types of insulators. Plastics are used in electronic applica-
tions as connectors and terminal boards. Other uses include
switch bases, gears, cams, lenses, connectors, plugs, stand-off
insulators, knobs, handles, and wire ties. Thermosetting plas-
tics are melted and injected into a closed mold where the solidi-
fy. These insulating moldings include polyethylene, polyphenyl-
ene, and poly vinyl chloride. Laminates are used in transformer
terminal boards, switchgear arc chutes, motor and generator slot
wedges, motor bearings, structural support, and spacers. Lami-
nates are made by bonding layers of a reinforcing web. The
reinforcements consist of fiberglass, paper, fabrics, or syn-
thetic fibers. The bonding resins are usually phenolic, mela-
mine, polyester, epoxy, and silicone. Laminates are made by
impregnating the reinforcing webs in treating towers, partially
polymerizing, pressing and finally polymerizing them to shape
under heat and pressure. Manufacturing processes associated with
these products are studied 'as part of the Plastics Molding and
Forming Industry. This subcategory has been excluded under
Paragraph 8 of the NRDC Consent Decree.
Date: 1/24/83 R Change 2 II.8.5-18
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Insulated Wire and Cable, Non-Ferrous Subcategory
Insulated wires and cables are products containing a conductor
covered with a non-conductive material to eliminate shock hazard.
The major products in this segment are: (1) insulated non-ferrous
wire, (2) auto wiring systems, (3) magnetic wire, (4) bulk cable
appliances, and (5) camouflage netting. Typical processes used
in the manufacture of insulated wire and cable are drawing, spot
welding, heat treating, forming, and assembling. All manufac-
turing processes are included in the Metal Finishing Industry.
Some of the basis materials are copper, carbon, stainless steel,
steel, brass-bronze, and aluminum. This subcategory has been
excluded under Paragraph 8 of the NRDC Consent Decree.
Ferrite Electronic Parts Subcategory
Ferrite electronic parts are electronic products utilizing metal-
lic oxides. The metallic oxides have ferromagnetic properties
that offer high resistance, making current losses extremely low
at high frequencies. Ferrite electronic products include:
(1) magnetic recording tape, (2) magnetic tape transport heads,
(3) electronic and aircraft instruments, (4) microwave connectors
and components, and (5) electronic digital equipment. Some
typical processes to manufacture ferrite electronic parts are
shearing, slitting, fabrication, and machining. All production
processes in this segment are included in the Metal Finishing
Industry. Some typical raw materials are aluminum, magnesium,
bronze, and brass. This subcategory has been excluded under
Paragraph 8 of the NRDC Consent Decree.
Motors, Generators, and Alternators Subcategory
Motors are devices that convert electric energy into mechanical
energy. Generators are devices which convert an input mechanical
energy into electrical energy. Alternators are devices that con-
vert mechanical energy into electrical energy in the form of an
alternating current. The major motor, generator, and alternator
products are: (1) variable speed drives and gear motors,
(2) fractional horsepower motors, (3) hermetic motor parts,
(4) appliance motors, (5) special purpose electric motors,
(6) electrical equipment for internal combustion engines, and
(7) automobile electrical parts. Some typical processes are
casting, stamping, blanking, drawing, welding, heat treating,
assembling and machining. All production processes are included
in the Metal Finishing Industry. Some basis materials are carbon
steel, copper, aluminum, and iron. These materials are used as
sheet metal, rods, bars, strips, coils, casting, and tubing.
This subcategory has been excluded under Paragraph 8 of the NRDC
Consent Decree.
Date: 1/24/83 R Change 2 II.8.5-19
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Resistance Heaters Subcategory
Resistance heaters convert electrical energy into usable heat
energy. Three types of resistance heaters are made; rigid encased
elements used for electric stoves and ovens, bare wire heaters
used in toasters and hair dryers, and insulated flexible heater
wire that is incorporated into blankets and heating pads. Some
typical processes used in the manufacture of resistance heaters
are plating, welding or soldering, molding, and machining. These
processes are included in the Metal Finishing Industry. Some raw
materials used are steel, nickel, copper, plastic, and rubber.
This subcategory has been excluded under Paragraphy 8 of the NRDC
Consent Decree.
Switchgear Subcategory
Switchgear are products used to control electrical flow and to
protect equipment from electrical power surges and short cir-
cuits. The major switchgear products are: (1) electrical power
distribution controls and metering panel assemblies, (2) circuit
breakers, (3) relays, (4) switches, and (5) fuses. Some typical
manufacturing processes are: chemical milling, grinding, electro-
plating, soldering or welding, machining, and assembly. All
processes are included in the Metal Finishing and Plastics Pro-
cessing Industries. Some typical basis materials are plastic,
steel, copper, brass, and aluminum. This subcategory has been
excluded under Paragraph 8 of the NRDC Consent Decree.
II.8.5.2 WASTEWATER CHARACTERIZATION [2-20, 2-69]
The following sections summarize characteristics of the waste-
water from sample plants in each of the subcategories in the
Electrical and Electronic Components Industry. Wastewater
characteristics for the regulated subcategories (semiconductors
and electronic crystals) are derived from plant specific data
presented in Reference 2-69. The unregulated subcategories are
then discussed in the sections following Electronic Crystals.
More than 250 plants were contacted to obtain data on the Elec-
trical and Electronic Components Industry. Seventy-eight of
these plants were visited for an on-site study of their manufac-
turing processes, water used and wastewater treatment. In addi-
tion, wastewater samples were collected at thirty-eight of the
plants visited in order to quantitate the level of pollutants in
the waste streams. Sampling was utilized to determine the source
and quantity of pollutants in the raw process wastewater and the
treated effluent from a cross-section of plants in the Electrical
and Electronic Components Industry. All of the 129 priority
pollutants were examined in one or more subcategories.
Date: 1/24/83 R Change 2 II.8.5-20
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II.8.5.2.1 Semiconductor Subcategory [2-69]
This section presents information on the wastewater characteris-
tics of the semiconductor subcategory. The data presented are a
summarization of the wastewater sampled from twelve plants in the
semiconductor subcategory. Of these twelve plants, five are
practicing solvent management which means that the facilities
segregate and collect spent solvents for sale to reclaimers or
contract disposers.
Contact water is used throughout the production of semiconduc-
tors. Plant incoming water is first pretreated by deionization
to provide ultrapure water for processing steps. This ultrapure
water or deionized (DI) water is used to formulate acids; to
rinse wafers after processing steps; to provide a medium for
collecting exhaust gases from diffusion furnaces, solvents, and
acid baths; and to clean equipment and materials used in semi-
conductor production. Water also cools and lubricates the dia-
mond saws and grinding machines used to slice, lap, and dice
wafers during processing.
The major pollutants found at facilities in the semiconductor
subcategory are as follows: fluoride, toxic organics, and pH.
The major source of fluoride comes from the discharge of spent
hydrofluoric acid after its use in etching. Minor quantities of
fluoride enter the plant wastewater from rinses of etched or
cleaned wafers.
The sources of toxic organics are solvents used for drying the
wafer after rinsing, developing of photoresist, stripping of
photoresist, and cleaning. While residual amounts of solvents in
wastewaters come from solvent rinses, their primary sources are
the dumping of solvent baths. The pH parameter may be very high
or very low. High pH results from the use of alkalis for caustic
cleaning. Low pH results from the use of acids for etching and
cleaning.
Several toxic metals were found in the wastewater because of
electroplating operations associated with semiconductor manu-
facture. These metals are chromium, copper, nickel, and lead and
are regulated under the Metal Finishing Industry.
The semiconductor subcategory is divided into the following wet
processes:
• scrubber,
• rinse,
• etch, and
• fluoride.
Date: 1/24/83 R Change 2 II.8.5-21
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Table 8.5-3 presents a summary of the wastewater sampled at the
twe1ve plants.
II.8.5.2.2 Electronic Crystals
This section presents information on the wastewater character-
istics of the electronic crystals subcategory. The data pre-
sented summarize the characteristics of samples obtained from
eight crystals facilities. The concentrations represent total
raw wastes after flow-proportioning individual discharge streams.
Table 8.5-4 summarizes the data obtained from each of these
plants.
The major source of wastewater from the manufacture of electronic
crystals is from rinses associated with crystal fabrication,
although some wastewater may be generated from crystal growing
operations. Fabrication steps generating wastewater are slicing,
lapping, grinding, polishing, etching, and cleaning of grown
crystals. Certain growth processes generate a large volume of
wastewater from the discharge of spent solutions of sodium hydrox-
ide and sodium carbonate after each crystal growth cycle.
The major pollutants of concern from the electronic crystals
subcategory are toxic organics, fluoride, arsenic, TSS, and pH.
Toxic organics are found in wastewater from the manufacture of
electronic crystals as a result of the use of solvents such as
isopropyl alcohol, 1,1,1-trichloroethane, Freon, and acetone.
These materials are used for cleaning, degreasing, and drying of
crystals. High concentrations of these toxic organics in waste
streams are the result of uncontrolled dumping of solvent rinse
tanks. Another source of toxic organics could be contaminants in
oils used as lubricants in slicing and grinding operations.
Fluoride comes from the use of hydrofluoric acid or ammonium
bifluoride for etching electronic crystals. A minor source of
fluoride is from the etch rinse process.
Arsenic originates from the gallium arsenide and indium arsenide
used as raw material for crystals. Process steps generating
wastewater containing arsenic are cleaning of the crystal-growing
equipment, slicing and grinding operations, and etching and
rinsing steps.
Total suspended solids are common in crystals manufacturing waste
streams as crystal grit from slicing and grinding operations.
Grit and abrasive wastes are also generated by grinding and
lapping operations.
The level of pH may be very high or very low. High pH results
from the presence of excess alkali such as sodium hydroxide or
Date: 1/24/83 R Change 2 II.8.5-22
-------
TABLE 8.5-3. SUMMARY OF CLASSICAL AND TOXIC POLLUTANTS IN SEMICONDUCTOR
SUBCATEGORY RAW WASTEWATER [2-69]
Po 1 1 u tant
Toxic organics, Mg/L
Benzene
Benz id ine
Ch 1 orobenzene
1 , 2,14- rr ichlorobenzene
1 , 2-Oichloroethane
1,1,1 -Trichloroe thane
1 , l-Oichloroethane
2, '4 , 6-T r i ch lo ropheno 1
Ch 1 o reform
2-Ch 1 o ropheno 1
t , 2-0 i ch 1 orobenzene
I , 3-D ichlorobenzene
1 ,14-Oichloro benzene
1 , l-Oichloroethylene
2, 14-0 i methyl pheno I
I ,2-Oiphenyl hydrazine
E thy 1 benzene
F 1 uoranthene
Mcthylcne chloride
Methyl chloride
0 ich lorobromome thane
Ch 1 orod i bromome thane
Naphtha 1 ene
2-N i t ropheno 1
'4-N i t ropheno 1
Pentach loropheno 1
Pheno 1
Bis ( 2-ethy 1 hexy 1 ) phthalate
Butyl benzyl phthalate
Dt-N-butyl phthalate
Di-N-octyl phthalate
Oiethyl phthalate
Anthracene
Phenanthrene
Tetrachloroethylene
To 1 none
Trichloroethylene
Cyan ide
Tox i c me ta 1 s , ng/L
Ant i mony
Arsen i c
Beryl 1 i um
Cadmi um
Chrom i um
Copper
Lead
Mercury
Nickel
Se leni um
Si Iver
Tha 1 1 ium
Zinc
Classical pollutants, mg/L
A 1 um i num
Ba r i um
Boron
Ca Ic i um
Coba 1 t
Co Id
1 ron
Magnes i um
Manganese
Molybdenum
Pa 1 lad ium
Plat inum
Sod i um
Te 1 1 ur ium
T in
T i tan ium
Vanad i um
Yttrium
Lithium
Pheno 1 s
Total organic carbon
F 1 uor ide
Oi I and grease
TSS
BOO
pH , pH un i t s
Plants Not Practicing
Number or detections
7/2
7/1
7/2
7/6
7/1
7/14
7/1
7/1
7/6
7/6
7/7
7/5
7/7
7/2
7/2
7/1
7/6
7/1
7/6
7/1
7/2
7/3
7/7
7/6
7/1
7/1
7/7
7/7
7/2
7/6
7/3
7/U
7/1
7/1
7/14
7/6
7/6
7/6
7/7
7/7
7/6
7/7
7/7
7/7
7/7
7/7
7/7
7/7
7/7
7/7
7/7
7/5
7/5
7/5
7/5
7/14
7/14
7/5
7/5
7/5
7/5
7/U
7/14
7/5
7/U
7/5
7/5
7/5
7/5
7/1
7/6
7/7
7/6
7/6
7/6
7/14
7/1
Solvent Manaa<
Minimum
< | o
< 10
< 1 0
< 10
< | o
< i o
9
2
1
< 10
10
< | o
< | o
<6
< 10
< 10
53
8
< 1 0
< 10
< 10
-------
TABLE 8.5-3. SUMMARY OF CLASSICAL AND TOXIC POLLUTANTS IN SEMICONDUCTOR
SUBCATEGORY RAW WASTEWATER (continued)
Plants Practicing Solvent Management*
Pol lutant
To.xic organics, M9/L
Benzene
Ch 1 orobenzene
1,1, l-Trichloroethane
Chloroform
2-Chlorophenol
1 , 2-D ich 1 orobenzene
1 , 3-D ichl orobenzene
1 , t-D ichl orobenzene
1 , l-Dichloroethylene
Ethyl benzene
Methylene chloride
Ch lorod i bromome thane
Naphtha 1 ene
2-Ni trophenol
Phenol
Bis (2-ethylhexyl ) phthalate
Butyl benzyl phthalate
Di-N-butyl phthalate
Diethyl phthalate
Tetrach loroethy lene
To 1 uene
T r i ch 1 o roe thy 1 ene
Cyanide
Toxic metals, ng/L
Antimony
Arsenic
Be ry 1 1 i urn
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
S i 1 ve r
Tha II i urn
Zinc
Classical pollutants, mg/L
At umi num
Ba r i urn
Boron
Ca 1 c i urn
Coba 1 t
Gold
1 ron
Magnes i urn
Manganese
Molybdenum
Pa 1 ladium
Pia t i num
Sod i urn
Tel lurium
Tin
Titanium
Vanadium
Yttrium
Lithium
Pheno 1 s
Total organic carbon
Fluoride
Oi 1 and grease
TSS
BOD
pH, pH units
Number of plants sampled/
Number of detections
5/3
5/1
5/3
5/M
5/3
5/3
5/2
5/3
5/1
5/1
5/14
5/1
5/3
5/3
5/14
5/3
5/1
5/14
5/1
5/3
5/14
5/i>
5/5
5/5
5/5
5/5
5/5
5/5
5/5
5/5
5/5
5/5
5/5
5/5
5/5
5/5
5/5
5/5
5/5
5/5
5/5
5/2
5/5
5/5
5/5
5/5
5/3
5/3
5/5
5/3
5/5
5/5
5/5
5/5
5/1
5/5
5/5
5/5
5/5
5/5
5/5
5/1
Mini mum
< 1 0
<8
9
8
< 1 0
5
< 1 0
18
<8
<0. 1
-------
TABLE 8.5-4.
SUMMARY OF CLASSICAL AND
SUBCATEGORY [2-69]
TOXIC POLLUTANTS IN ELECTRONIC CRYSTALS
rt
(D
K)
00
U)
n
tr
ro
to
H
H
•
00
•
cn
I
to
Pol lutant
Toxic organ ics, |ig/L
, 2,4-Tr ich lorobenzene
,2-Dich loroethane
, 1 , 1 -T rich loroethane
Ch lo reform
,2-Dich lorobenzene
, 3-Dich lorobenzene
, 4- D ich lorobenzene
Pentach 1 o ropheno 1
Methylene chloride
1 , 2-D i pheny 1 hyd raz i ne
Naphtha 1 ene
N-n i trosod i pheny lam i ne
Bis (2-ethylhexyl ) phthalate
Di-N-butyl phthalate
Anthracene
F 1 uorene
Benzene
Tetrach 1 o roe thy 1 ene
Tr ich 1 o roe thy 1 ene
2,4-Di n i tropheno 1
4,6-Dinitro-o-cresol
Toxic meta 1 s, u.g/L
Ant imony
Copper
Nickel
Zinc
Classical pollutants, mg/L
pH, pH units
Suspended so 1 ids
Oi 1 and grease
TOC
BOD
Fl uor ide
P 1 ant Pract i c i ng
Solvent Management*
ND
ND
170
-------
sodium carbonate. The alkali may come from crystal growth pro-
cesses or from caustic cleaning and rinsing. Low pH results from
the use of acid for etching and cleaning operations.
Several toxic metals were found in the wastewater because of
electroplating operations associated with electronic crystals
manufacture. These metals are chromium, copper, lead, nickel,
and zinc, and are regulated under the Metal Finishing Industry.
II.8.5.2.3 Carbon and Graphite Subcategory [2-20]
This section presents information on the wastewater characteris-
tics of the Carbon and Graphite Subcategory. The data presented
are based on the analysis of wastewater samples collected in
eight streams at four facilities which use wet processes. The
following wet processes are used by Carbon and Graphite Subcate-
gory plants:
• Post-extrusion quench,
• Post-impregnation quench,
• Machining (grinding), and
• Scrubbing.
Table 8.5-5 presents a summary of the classical and priority
pollutant concentrations in the raw waste from the four wet
processes sampled. The reference presented varying detection
limits for any one pollutant due to different labs conducting the
analyses at different plants. Therefore, the data presented in
the following tables do not adhere to the usual presentation of
BDL, below detection limit. Any value presented in the range or
median as being "less than" the reported concentration is, in
effect, below its detection limit, the detection limit being the
specific concentration reported. Calculations of the mean, in
such cases, assume the full value of the inequality and are
therefore approximate values.
II.8.5.2.4 Incandescent Lamps
This section presents information on the wastewater character-
istics of the Incandescent Lamps subcategory. The average flow
of wastewater from these plants manufacturing incandescent lamps
is 2.04 x 106 L/day (540,100 gal/day). The major pollutants
found and their concentrations are described on the following
page:
Date: 1/24/83 R Change 2 II.8.5-26
-------
rt
CD
TABLE 8.5-5. SUMMARY OF CLASSICAL AND TOXIC POLLUTANTS IN CARBON AND GRAPHITE SUBCATEGORY
RAW WASTEWATER BY INDIVIDUAL PROCESS UNITS [2-20]
to
00
U)
o
(D
NJ
H
H
00
U1
I
to
Extrusion quench
Flow = 13 L/_s
Pol lutant
Classical pollutants, mg/L
Oi I and grease
TOG
BOD
TSS
Phenols, total
pH, pH units
Ca Ic ium
Magnes i urn
Al umi num
Manganese
Vanad ium
Boron
Ba r i urn
Molybdenum
Tin
Yttrium
Cobalt
1 ron
T i tan i urn
Sod ium
Toxic pollutants, U9/I_
Metals and inorganics
Arsenic
Ant imony
Be ry 1 1 i urn
Cadm i urn
Chromi urn
Copper
Cyanide
Lead
Mercury
Nickel
Selenium
Si Iver
Tha Ilium
Zinc
Number of samples/ Range of
Number of detections detections
3/3
3/3
3/2
3/3
3/2
I/I
2/2
2/2
2/2
2/2
2/2
2/2
2/2
2/2
2/2
2/2
2/2
2/2
2/2
2/2
3/3
3/3
3/3
3/3
3/3
3/3
2/2
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3.5
1
2
1
<0.005
7.3
1.4
0.23
0.003
<0.002
0.031
0.023
0.005
-------
ft
(D
TABLE 8.5-5. SUMMARY OF CLASSICAL AND TOXIC POLLUTANTS IN CARBON AND GRAPHITE SUBCATEGORY
RAW WASTEWATER BY INDIVIDUAL PROCESS UNIT (continued)
00
CO
n
cr
n>
00
•
Ul
I
NJ
00
Pol lutant
Toxic orqanics
Acenaphthene
Benzene
Ch lorobenzene
1,1, l-Trichloroethene
Ch 1 o reform
2-Chlorophenol
1 , 2-Diphenylhydrazine
Ethylbenzene
F 1 uoranthene
Methylene chloride
Bromoform
Ch 1 o rod i b romome tha ne
Naphtha lene
N-Ni trososod iphenyl ami ne
Phenol
Bis(2-ethylhexyl ) phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Diethyl phthalate
Dimethyl phthalate
1 , 2-8enzanthracene
Benzol a) pyrene
Benzo(b) fluoranthene
Chrysene
Anthracene
Benzo(ghi) perylene
Fluorene
Dibenzo(ah) anthracene
lndeno( 1,2,3-cd) pyrene
Pyrene
Toluene
Trichloroethylene
Pesticides
Alpha-endosul fan
Alpha -BMC
Gamma-BHC
Number of samples/
Number of detections
3/1
3/3
3/1
3/1
3/2
3/0
3/1
3/1
3/3
3/2
3/1
3/1
3/2
3/1
3/1
3/3
3/1
3/3
3/2
3/1
3/2
3/1
3/2
3/2
3/3
3/1
3/2
3/1
3/1
3/1
3/3
3/2
3/0
3/1
3/1
Extrusion quench
Range of Mean of Median of
detections detections detections
-------
TABLE 8.5-5. SUMMARY OF CLASSICAL AND TOXIC POLLUTANTS IN CARBON AND GRAPHITE SUBCATEGORY
RAW WASTEWATER BY INDIVIDUAL PROCESS UNITS (continued)
Numbei
Pollutant Number
Classical pollutants, mg/L
TSS
TOC
BOO
Oil and g rease
Pheno 1 s
pH, pH units
Ca 1 c r um
Magnesium
Sod i um
Al umi num
Manganese
Vanad ium
Boron
Ba r i um
Molybdenum
Tin
Yttrium
Coba 1 1
1 ron
Ti tan ium
Toxic pollutants, ug/L
Metals and inorganics
Antimony
Arsen i c
Be ry 1 1 i um
Cadmi um
Chromi um
Copper
Cyanide
Lead
Mercury
Nickel
Se 1 en i um
S i 1 ve r
Tha 1 1 ium
Zinc
Toxic orqanics
Acenaphthene
Benzene
1,1, t-Trichloroethene
Ch loroform
2-ch 1 o ropheno 1
1 ,2-Diphenylhydrazine
F 1 uoranthene
Methylene chloride
Naphtha lene
N-N i t rosod i pheny 1 am i ne
Phenol
2-N it ropheno 1
D i ch 1 o rob romometha ne
Bi s(2-ethy Ihexyl ) phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Di-n-octyl phthalate
Oiethyl phthalate
Benzol, a) pyrene
Benzol b) fl uoranthene
Anthracene
Fluorene
Pyrene
Tetrachloroethylene
Toluene
Trichloroethylene
Pest ic ides
1,1' -ODD
Heptach 1 or
Alpha-BHC
Analytic methods: V.7.3.II, Data set 2
(a ) Interference present.
( b)Concent ra t ion found in blank.
^ of samples/
of detections
3/3
3/3
3/2
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/2
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/2
3/2
3/1
3/1
3/2
3/1
3/2
3/3
3/3
3/2
3/2
3/2
3/1
3/3
3/3
3/3
3/1
3/3
3/1
3/1
3/3
3/2
3/1
3/1
3/3
3/3
3/1
3/1
3/2
Mach in i ng
Flow = 0.82 L/s
Range of
detect ions
53 - 3,000
190 - 7,200
6-25
7-70
0.01 - 0. 12
8.5 - 38
1.2 - 8.3
11-20
0.23 - 2.2
0.006 - 0.071
0.023 - 0. 12
0.011 - 0.12
0.085 - 0.88
0.02 - 0.11
0.013 - 0.21
<0.001 - 0.007
0.013 - <0.05I
0.57 - 6.7
0.017 - 0.31
1 - 3
1 - 1(3)
-------
Toxic Pollutants
Chromium
Copper
Lead
Total toxic inorganics
Methylene chloride
Chloroform
Dichlorobromomethane
Total toxic organics
Raw Waste
Concentration
(mg/L)
0.71
0.42
0.11
1.4
0.05
0.02
0.01
0.08
Raw Waste Load
kg/day (Ibs/day)
1.5 (3.2)
0.86 (1.9)
0.23 (0.5)
2.8 (6.2)
0.05
0.10
0.03
0.17
(0.11)
(0.22)
(0.05)
(0.38)
Raw waste concentrations are based on flow weighted means from
three plants. For toxic inorganics only flow weighted mean
concentrations greater than or equal to 0.1 mg/L are shown. For
toxic organics only flow weighted mean concentrations greater
than or equal to 0.01 mg/L are shown.
II.8.5.2.5 Fluorescent Lamps
This section presents information on the wastewater characteris-
tics of the fluorescent lamps subcategory. The major pollutants
found in wastewaters from plants manufacturing fluorescent lamps
and their concentrations or mass loadings are presented below:
Toxic Pollutants
Antimony
Cadmium
Total toxic inorganics
Methylene chloride
Toluene
Total toxic organics
Raw Waste
Concentration
(mg/L)
0.46
0.31
0.063
0.011
Raw Waste Load
kg/day (Ibs/day)
0.08 (0.18)
0.07 (0.16)
Specific raw waste data from a representative fluorescent lamp
manufacturing plant is presented in Section II.8.5.3.5.
II.8.5.2.6 Mica Paper
This section presents summary data on the wastewater character-
istics of the mica paper subcategory. The average flow of waste-
water from the plants producing mica paper is 3.50 x 106 L/day
(926,000 gal/day). The major pollutants found and their concen-
trations are presented on the following page:
Date: 1/24/83 R Change 2
II.8.5-30
-------
Toxic Pollutants
Total toxic inorganics
1,1,1-Trichloroethane
Methylene chloride
Total toxic organics
Raw Waste
Concentration
(mg/L)
0.55
0.18*
0.029*
0.21
Raw Waste Load
kg/day (Ibs/day)
0.20 (0.44)
0.63
0.10
0.73
(1-4)
(0.22)
(1.6)
*Not confirmed by process or raw material usage.
Raw waste concentrations are based on raw waste data from one
plant. For toxic organics only concentrations greater than or
equal to 0.01 mg/L are shown.
II.8.5.2.7 Electron Tube
Information presently available on the wastewater resulting from
plants in the electron tube subcategory is insufficient to ade-
quately characterize the pollutants associated with this sub-
category. Preliminary data indicate that wastewater flows from
plants manufacturing cathode ray and T.V. picture tubes are in
the range of 200,000 to 500,000 L/day and that the major pollu-
tants are fluoride and lead.
II.8.5.2.8 Fuel Cells
Only a few plants manufacture fuel cells and these do not do so
on a regular basis. In addition, all pollutants found were at
quantities too low to be effectively treated.
II.8.5.2.9 Magnetic Coatings
This subcategory discharges only a small amount of pollutants to
water. The average wastewater discharge from this subcategory is
19,000 L/day (5,000 gal/day). The total toxic metals discharge
for the subcategory is 0.045 kg/day (0.099 Ibs/day), total toxic
organics is 0.018 kg/day (0.040 Ibs/day).
II.8.5.2.10 Resistors
No wastewaters result from the manufacture of resistors.
II.8.5.2.11 Dry Transformers
No wastewaters result from the manufacture of dry transformers.
II.8.5.2.12 Phosphorescent Coatings
Data presently available are insufficient to adequately charac-
terize the wastewater discharges for the phosphorescent coatings
Date: 1/24/83 R Change 2
II.8.5-31
-------
subcategory. Preliminary data indicate that wastewater flows
from these plants range from 100,000 to 700,000 L/day (30,000 to
200,000 gal/day; and the major pollutants are suspended solids,
fluorides, cadmium, and zinc.
II.8.5.2.13 All Other Subcategories
Information obtained from plant visits showed that wastewater
discharges in the following subcategories result primarily from
processes associated with metal finishing and plastics molding
and forming. Because these processes are studied elsewhere, the
Electrical and Electronic Components project limited its sampling
effort in these areas:
Switchgear and Fuses
Resistance Heaters
Ferrite Electronic Parts
Insulated Wire and Cable
Fluid-filled Capacitors
Fluid-filled Transformers
Insulated Devices -- Plastics and Plastic Laminated
Motors, Generators, and Alternators
Fixed Capacitors
II.8.5.3 PLANT SPECIFIC DATA [2-20]
Plant specific data are presented below for representative plants
from the semiconductor, carbon and graphite, mica paper, and
fluorescent lamps subcategories. Where sufficient data are not
available to adequately characterize the treated effluent, only
raw waste characteristics are presented. The data for represen-
tative plants of the electronic crystals subcategory have been
presented earlier in a table summarizing the raw waste character-
istics (Table 8.5-4). The data available for the electron tube,
incandescent lamps, and phosphorescent coatings subcategories are
insufficient for adequate characterization and therefore are not
presented. No data are presented for the fuel cells, magnetic
coatings, resistors, and dry transformers subcategories since
little or no wastewaters result from the process.
II.8.5.3.1 Plant 35035 [2-69]
This facility is representative of plants in the semiconductor
subcategory which are not practicing solvent management. The
data presented in Table 8.5-6 represent only raw waste character-
istics since no treated effluent data were available. No produc-
tion information is available for this plant.
Date: 1/24/83 . R Change 2 II.8.5-32
-------
II.8.5.3.2 Plant 42044 [2-69]
This facility represents those plants in the semiconductor sub-
category which are practicing solvent management. The data
presented in Table 8.5-6 represent only the raw waste character-
istics since no treated effluent data were available. No pro-
duction information is available for this plant.
II.8.5.3.3 Plant 36173 [2-20]
This plant is representative of the carbon and graphite manu-
facturing subcategory. The data presented are from three dif-
ferent wet processes which include:
• extrusion quench,
• impregnation quench, and
• machining (grinding).
No production information is available for this plant. Table
8.5-7 presents the wastewater characterization for Plant 36173.
II.8.5.3.4 Plant 43055 [2-20]
Mica paper, is manufactured at Plant 43055. Mica paper is a di-
electric material used in the manufacture of fixed capacitors.
This facility is a large mica paper dielectric manufacturing
facility using 3,800,000 L of water per day (1,000,000 gpd). The
raw waste is sent through a series of settling ponds in order to
settle out the mica properties. Table 8.5-8 presents the waste-
water characterization data for Plant 43055.
II.8.5.3.5 Plant 19121
This facility represents those plants involved in the manufacture
of fluorescent lamps. Fluorescent lamp manufacture utilizes wet
processes which include:
glass tube rinse,
tin chloride scrubber,
sulfur dioxide scrubber,
glass tube brush scrubbing, and
silicone coating.
Table 8.5-9 presents the wastewater characterization data for
Plant 19121. No production information is available for this
facility.
II.8.5.4 POLLUTANT REMOVABILITY [2-20]
This section reviews the technologies which are currently avail-
able and are used to remove pollutants from the wastewater gener-
ated in the Electrical and Electronic Components Industry. A
Date: 1/24/83 R Change 2 II.8.5-33
-------
TABLE 8.5-6. SEMICONDUCTOR MANUFACTURING PLANT SPECIFIC DATA,
PLANT 35035 AND PLANT 420UU* [2-69]
Pol lutant
Toxic organics, Mg/L
1 , 2, '(-T r i ch lorobenzene
1,1, l-Trichloroe thane
CH 1 o ro fo rm
2-Ch 1 oropheno 1
1 ,2-Dich lorobenzene
1 , 3 -Dich lorobenzene
1 , 14 -D ich 1 orobenzene
Ethyl benzene
Me thy lene chloride
Ch lorod i bromome thane
Naphtha lene
2-Ni trophenol
Phenol
Bis (2-ethylhexy I ) ph thai ate
Oi-N-butyl phthalate
Tet rach loroethy lene
Toluene
Trich loroethy lene
Cyanide
Toxic metals, |jg/L
Ant imony
Arsenic
Be ry 1 1 i urn
Cadm i urn
Chromi um
Copper
Lead
Mercury
Nickel
Selenium
S i 1 ve r
Tha 1 1 i um
Zinc
Classical pollutants, mg/L
Al um i num
Barium
Boron
Ca 1 c i um
Coba 1 t
Gold
1 ron
Magnes i um
Manganese
Mo lybdenum
Pa 1 1 ad i um
Platinum
Sod i um
Tel lurium
Tin
T i tan i um
Vanadium
Yttrium
Li thi'um
Phenol
Total organic carbon
F 1 uor ide
Oil and grease
TSS
BOO
35035(a)
( Not Prac t ic i ng
Solvent Management)
14 , 900
NU
10
t. 1
8.9
1 .6
1 .1
1 .6
114
95
NO
2<4
3140
8
1.5
3. 1
9.U
10
<5
l<40
25
-------
TABLE 8.5-7. WASTEWATER CHARACTERIZATION FOR PLANT 36173, CARBON AND GRAPHITE SUBCATEGORY [2-20]
H
•
00
to
Extrusion
Flow = 7
Pollutants influent
Classical pollutants, mg/L
TSS
TOC
BOO
Oil and grease
Pheno 1 s
Toxic pollutants, Mg/L
Metals and inorqanics
Antimony
Arsenic
Be ry 1 1 i um
Cadmium
Ch row i um
Coppe r
Cyanide
Lead
Mercury
Nickel
Se 1 en i um
Si Iver
Tha 1 1 1 um
Zinc
Toxic orqanics
Acenaphthene
Benzene
Chloroform
2-ch 1 o ropheno 1
1 , 2-Diphenylhydrazine
Fluoranthene
Methyl ene chloride
Dich lo rob romome thane
Naphtha lene
2-Ni trophenol
N-nitrosodiphenylajnine
Pheno 1
B i s( 2-ethy 1 hexy 1 ) phtha 1 a te
Butyl benzyl phtha late
Di-n-butyl phthalate
Diethyl phthalate
Dimethyl phthalate
1 ,2-Benzanthracene
3,l*-Benzopyrene
1 1 , l2-Benzo( kjf luoranthene
Chrysene
Anthracene
1 , l2-Benzo(ghi )perylene
F 1 no rene
Dibenzo (ah) anthracene
1 ndeno (1,2,3-cd) pyrene
Pyrene
Toluene
Trichloroethylene
Pest ic ides
ST*?1- DDE
Al pha-endosul f an
Alpha-BMC
Anafytic methods: V.7.3.II, Data set
Blanks indicate data not available.
NO, riot detected.
NM, not meaningful .
(b JConcentrat ion found in blank.
5.0
1 .0
2.0
14
0.02
99
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
>9
>23
>9
>9
NM
NM
NM
NM
NM
NM
NM
NM
Influent
19
99
NM
NM
23
NM
NM
>99
NM
NM
NM
NM
NM
117
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
>99
.._
Grinding Machining
Flow = 0.63 L/s Flow = 1.61 L/s
Influent
3,000
190
25
20
0.0114
3
1
•=5
<5
5U
5,300
-------
TABLE 8.5-8. MICA PAPER MANUFACTURING PLANT SPECIFIC VERIFICATION
DATA FOR THE DIELECTRIC SUBCATEGORY, PLANT 43055
[2-20]
Pol lutant
Toxic pollutant, ng/L
Toxic orqanics
Benzene
Ch lorobenzene
1,1, 1 -t rich lo roe thane
Chloroform
Ethyl benzene
Methylene chloride
Bi s(2-ethy 1 hexy 1 )phtha late
Butyl benzyl phthalate
Di-n-butyl phthalate
Te t rach 1 o roethy 1 ene
To I uene
Trich loroethy lene
Toxic meta 1 s
Ant imony
Arsen ic
Be ry 1 1 i urn
Cadm i urn
Chromium
Copper
Lead
Mercury
Nickel
Se len ium
Si 1 ve r
Tha 1 1 ium
Zinc
Classical pollutant, mg/L
Flow, L/s
Al uminum
Ba rium
Boron
Ca 1 c i urn
Coba 1 1
1 ron
Magnes ium
Manganese
Mo lybdenum
Sod i urn
Tin
Ti tan ium
Vanad i urn
PH
Yttrium
Cyanide, total
Oi 1 and grease
TOC
BOD
TSS
Pheno 1 s
Raw waste
-------
TABLE 8.5-9. FLUORESCENT LAMP MANUFACTURING PLANT SPECIFIC RAW WASTE DATA, PLANT 19 12 1 [2-20]
n-
(D
to
\
CD
n
tr
0)
CD
H
H
•
00
•
Ul
1
U>
-J
Pol lutant
Toxic organics, ug/L
Benzene
1,1, l-Trichlorethane
Chloroform
Methylene chloride
0 i ch 1 o rob romo methane
Phenol
Bis (2-ethylhexyl ) ph thai ate
Oi-n-butyl ph thai ate
Or ethyl ph thai ate
Dimethyl phthalate
Anthracene
Phenanthrene
To 1 uene
Toxic metals, ug/L
Antimony
Arsenic
Be ry 1 1 i un
Cadmium
Ch rom i urn
Copper
Lead
Hercury
Nickel
Se 1 en 1 urn
Si Iver
Tha 1 1 i urn
Zinc
Classical pollutants, mg/L
Calcium
Magnesium
Sodium
A 1 urn i nun
Manganese
Vanadium
Boron
Ba r i urn
Molybdenum
Tin
Yttrium
Coba 1 t
1 ron
Titanium
pH, pH units
Cyanide
Oi I and grease
Total organic carbon
BOD
TSS
Pheno 1 s
Fluoride
Glass Tube and Rack
Rinse Pre-Settle
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
600
<5
<5
ttOO
<8
150
22
-------
discussion of control practices and treatment options are dis-
cussed for the two subcategories currently being regulated:
semiconductors and electronic crystals. Treatment discussions
are not presented for those subcategories excluded from regula-
tion.
II.8.5.4.1 Semiconductor Subcategory
There are several in-process control techniques currently in
widespread use throughout the Semiconductor subcategory. They
include the collection of spent solvents for resale or reuse, and
treatment or contract hauling of the concentrated fluoride waste-
stream.
An estimated 75% of the semiconductor facilities collect spent
solvents for either contract disposal or reclaim. Fifteen of 45
plants surveyed either treat or contract out the removal of the
concentrated fluoride stream. In addition, three of the plants
practiced rinse water recycle. The pollutants present in the
reused process wastewater are removed in the deionized water
production area. However, the reuse of rinse water has been
found in some facilities to result in product contamination;
therefore the use of this technology is limited.
Treatment of the wastewater at the point of discharge consists
primarily of neutralization which is practiced by all dis-
chargers. One plant also uses end-of-pipe precipitation/clari-
fication for control of fluoride.
II.8.5.4.2 Electronic Crystals Subcategory
In-process control techniques similar to those employed at semi-
conductor plants are being practiced to some degree at most
electronic crystals facilities. These techniques include the
segregation of specific wastes such as solvents and cutting oils
for contract hauling or reclaiming. An estimated 70 to 80% of
the facilities within the subcategory practice solvent management
and these practices were observed at most of the plants visited.
Of eight plants visited, two treat their concentrated fluoride
stream while one plant has the fluoride waste hauled off by a
contractor.
End-of-pipe treatment technologies currently employed in elec-
tronic crystals plants include neutralization and precipitation
/clarification. Of the six plants visited which have direct
discharges, all treat the waste to control pH, suspended solids,
and fluoride. One of the direct dischargers also treats end-of-
pipe wastewater to reduce arsenic.
Date: 1/24/83 R Change 2 II. 8.5-38
-------
D
fl>
ft
00
\
oo
TABLE 8.6-10.
WASTEWATER CHARACTERIZATION OF TOXIC POLLUTANTS FOUND IN ALUMINUM CASTING FOUNDRIES,
VERIFICATION DATA [2-21]
00
to
O
tr
PJ
V
uQ
fD
00
Pol lutant. uq/L
Metals and inorganics
Ch rom I urn
Copper
Cyan ide
Lead
Mercury
Nickel
Se lenium
Zinc
Phthalates
Bis (2-ethylhexyl ) phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Di-n-octyl phthalate
Diethyl phthalate
Dimethyl phthalate
Nitrogen compounds
N-n i t rosod i -n-p ropy lam i ne
Ethers
Bis-(2-chloroethyl ) ether
Phenols
2,M, 6-Tr ichloropheno 1
Pa rach lorometacreso 1
2-Ch loropheno 1
2, M-Dich loropheno 1
2, i4-Di methyl phenol
2-Ni trophenol
l|,6-0ini tro-o-cresol
Pentachlorophenol
Phenol
Aromat ics
Benzene
Ch lorobenzene
Ethyl benzene
To 1 uene
Xy 1 ene
Number of samples
Number of detections
9/3
9/1
9/7
9/U
9/5
9/ii
9/3
9/9
9/6
9/5
9/9
9/3
9/5
9/M
9/2
9/1
9/7
9/5
9/3
9/7
9/7
9/5
9/6
9/3
9/6
9/9
I/I
3/3
6/6
3/3
Rnnge or
detect i ons
BDL - 100
'150
BDL - IM
50 - 2,000
BDL - BDL
BDL - 90
BDL - MO
90 - 8,800
51 - 5,500
BDL - 690
BDL - 5,1)00
BDL - BDL
BDL - 600
BDL - 35
31 - 210
BOL
IM - 380
10 - 280
BDL - 53
BDL - 5,700
BDL - 91
BDL - 330
BDL - 70
BDL - 1,600
BDL - 26,000
BDL - 8M
250
BDL - 78
BDL - 5MO
15 - M7.000
Median of
detect i ons
20
BDL
300
BDL
20
BDL
6MO
680
31
7M
BDL
91
20
2MO
32
53
BDL
141
29
35
BDL
570
BDL
BDL
BDL
75
Mean of
detect ions
M2
BDL
660
BDL
3M
17
1 ,500
1,300
160
650
BDL
160
21
120
300
93
37
1 , 000
MM
82
37
5 MO
M,700
21
29
98
16,000
-------
o
(II
ft
(D
CO
X.
oo
TABLE 8.6-10.
WASTEWATER CHARACTERIZATION OF TOXIC POLLUTANTS FOUND IN ALUMINUM CASTING FOUNDRIES,
VERIFICATION DATA (continued)
03
to
n
tf
(D
00
I
(-•
*»
Pollutant. liq/L
Number of samples
Number of detections
Range of
detections
Median or
detect ions
Mean of
detect ions
PoIvcvcIi c a roma t i c
hydrocarbons
Acenaphthene
Fluoranthene
Napthalene
Benzo( a)anthracene
Benzol ajpyrene
Chrysene
Acenapthylene
Anthracene/Phenanthrene
FIuorene
Polychlorinated biphenyls
Aroclor - 11)21), I25U, 1221
Aroclor - 1232, 121)8, 1260, 1016
Haloqenated aliphatics
Carbon tetrachloride
I,2-Dichloroethane
1,1,l-Trichloroethane
I,l-Dichloroethane
I,I,2-Trichloroethane
I,I,2,2-Tetrachloroethane
Ch loroform
Methylene chloride
Bromoform
DichIorobromomethane
Ch to rod i bromomethane
TetrachIoroethylene
TrIchIoroethylene
Pesticides and metabolities
Aldrin
0 i e I d r i n
Chlordane
I4,14'-DDT
-------
I
paper filter prior to discharge to the storage tanks. In the
storage tanks the solutions are "freshened" with makeup water or
new lubricants as needed. The wheeled tanks mentioned above are
then used to transport the die lubricants back to the machines.
An extensive maintenance program is followed to minimize leakage
of various fluids at the die casting machines, which would result
in contamination of the die lubricant solutions.
Plant 12040
Aluminum and zinc die casting waters are co-treated. After collec-
tion in a receiving tank where oil is skimmed, they are batch
treated by emulsion breaking, flocculation, and settling before
discharge. The released oil is returned to the receiving tank
for skimming, and the settled wastes are vacuum filtered and
dried before being landfilled. Filtrate water is returned to the
receiving tank.
Tables 8.6-15 and 8.6-16 present plant-specific information on
classical and toxic pollutants respectively, for the above facil-
ities .
II.8.6.3.2 Copper Foundries
Plant 6809
Mold cooling and casting wastewaters are recycled through a
cooling tower in this system; a portion of the process wastewater
flow is "blowndown" for treatment with other nonfoundry waste-
waters. The mold cooling and casting quench system blowdown
represents 3 percent of the combined wastewater flow. These com-
bined wastewaters are settled and skimmed in a lagoon and are
then discharged.
Plant 9979
This plant has a direct chill casting operation producing both
copper and aluminum castings. This 100 percent recycle operation
uses a cooling tower to reduce the wastewater system heat load.
Temperature probes activate the cooling tower when evaporative
cooling is required. The recirculating system of approximately
94,500 L (25,000 gallons) supplies water to: the direct chill
casting molds, the casting quench water, the cooling tower, and
noncontact cooling waters systems within the plant. The casting
molds are cooled by passing process wastewater through water
jackets around the mold. This water upon leaving the mold is
also sprayed on the casting as it leaves the mold. The addition
of water treatment chemicals to this 100 percent recirculation
system has limited the scale buildup within the molds.
Date: 8/31/82 R Change 1 II.8.6-19
-------
D
0)
rt
(D
00
U)
M
\
00
O
TABLE 8.6-15.
CONCENTRATIONS OF CLASSICAL POLLUTANTS FOUND IN VERIFICATION STUDY OF THE ALUMINUM
CASTING SUBCATEGORY, PLANT 4704, PLANT 12040, AND PLANT 20147 [2-21]
Plant 4701
Plant 120140
Investment Die
castina ooerations castina ooerations
Flow/DOl lutant
flow, cu.m/Hg
Pol lutant, mg/L
TSS
Total phenols
Su If ides
01 1 and grease
pH, pH units
Concc
Raw
20
930
IB
7
mtrfltlon
Treated
2f
83
10
7. 1
Percent Concentration
removal Raw Treated
91 510
0.09
36
l|>4 700
7.2
9.9
0.07
12
9.1
Percent Concenj
remova 1 Raw
0.10
98 1 , 700
22 66
98 5,600
6.9
Plant 20147
Die
lube operations
i ration
Treated
0.1)0
3,000
82
27,000
Percent
remova 1
NM
NM
NM
Analytic methods: V.7.3.12, Data set 2.
NM; not meaningful.
n>
TABLE 8.6-16.
00
I
NJ
O
CONCENTRATIONS OF TOXIC POLLUTANTS FOUND IN VERIFICATION STUDY OF
THE ALUMINUM CASTING SUBCATEGORY, PLANT 4704, PLANT 12040, AND
PLANT 20147 [2-21J
Plant 170I|
Investment
casting operation
Toxic pollutant
Metals and Inorganics
Cn roa I urn
Copper
Cyanide
Lead
Mercury
Nickel
Se 1 en I urn
Zinc
Ethers
Bis (2-chloroethyl ) ether
Bis (2-ethylhexyl ) phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Diethyl phthalate
Dimethyl phthalate
oi-n-octyl phthalate
N 1 1 rooen comoound s
N-nl troso-d I -n-p ropy famine
Pheno 1 s
2 , i|-D i ch 1 o ropheno 1
2,1-Dimethylphenol
2-Nitrophenol
Pentach 1 o ropheno 1
Pheno 1
2,1,6-TrichlorophenoI
£-Chtoro-m-cresol
,6-Dinltro-o-cresol
Aroaatics
Benzene
Chlorobenzene
Ethyl benzene
To 1 uene
Xylene
Concentration,
ug/L
Raw
20
150
NO
50
BDL
DDL
NO
190
NO
BOL
BDL
BDL
ND
BOL
BDL
BOL
BDL
BDL
ND
ND
BDL
BDL
BDL
ND
Treated
30
83
BOL
BDL
BDL
BDL
BDL
100
12
BOL
BDL
13
ND
BDL
BDL
BDL
BDL
BDL
BDL
BDL
Percent
remova 1
NM
82
NM
90«
NM
NM
NM
BO
NM
NM
NM
NM
NM
NM
NH
NM
NM
NM
NM
Plant 12040
Die
casting ooerali
Concentration,
ug/L
Raw
99
NM
88*
69*
11
NM
NM
93*
Plant 20117
Die
lube operations
Concentrat Ion,
ug/L
Raw
BDL
BDL
2,000
BDL
BDL
BDL
1,600
820,000
5,400
600
29
210
5,700
1,600
26,000
350
84
250
510
17,000
Treated
BOL
10
2, 100
BDL
BDL
BDL
1,500
16,000
9,300
1 1 , 000
ND
NO
34,000
69
50
170
180
12,000
Percent
remova 1
NM
NM
NM
NM
NM
NM
6
98
NM
NM
>99
>99
NM
80
10
NM
67
71
-------
than 100 percent of the wastewater; these normally treat the
nonrecycled wastewater before discharge.
Tables 8.6-15 through 8.6-23 (Sections II.8.6.3.1 through
11.8.6.3.5) present pollutant removability data for each foundry
subcategory. This information is the result of a verification
program. No data are currently available concerning the treat-
ability of wastewater emanating from the lead foundry subcategory
and limited data are available for the magnesium subcategory.
Date: 8/31/82 R Change 1 II.8.6-31
-------
-------
II.8.7 METAL FINISHING INDUSTRY
II.8.7.1 INDUSTRY DESCRIPTION
II.8.7.1.1 General Description [2-22]
The Metal Finishing Industry is comprised of 45 unit operations
involving the machining, fabrication, and finishing of metal
products (SIC groups 34 through 39). Industries not included in
this section include porcelain enameling, coil coating, battery
manufacturing, electrical components, photographic equipment and
supplies, iron and steel, aluminum and aluminum alloys, copper
and copper alloys, and shipbuilding. These industries have been
specifically excluded from this section. The industries in SIC
groups 34 through 39 are not exclusively part of the Metal Finish-
ing Industry. For example, all of the industries listed under
SIC group 36 are covered under both the Electrical and Electronic
Components Industry and the Metal Finishing Industry. The Elec-
trical and Electronic Components Industry considers all processes
specific to electronics, and the Metal Finishing Industry con-
siders all of the remaining processes used to manufacture the
products in SIC group 36.
There are approximately 13,000 manufacturing facilities in the
United States which are classified as being part of the Metal
Finishing Industry. These facilities are engaged in the manu-
facturing of a variety of products that are constructed primarily
by using metals. The operations performed usually begin with a
raw stock in the form of rods, bars, sheets, castings, forgings,
etc., and can progress to sophisticated surface finishing opera-
tions. The facilities vary in size from small job shops employ-
ing fewer than ten people to large plants employing thousands of
production workers. Wide variations also exist in the age of the
facilities and the number and type of operations performed within
the facilities. Because of the differences in size and processes,
production facilities are custom-tailored to the specific needs
of each plant. The possible variations in unit operations within
the Metal Finishing Industry are extensive. Some complex prod-
ucts could require the use of nearly all of the 45 possible unit
operations, while a simple product might require only a single
operation.
Each of the 45 individual unit operations is listed with a brief
description in the following discussion.
Date: 1/24/83 R Change 2 II.8.7-1
-------
1. Electroplating is the production of a thin coating of
one metal upon another by electrodeposition.
2. Electroless plating is a chemical reduction process
which depends upon the catalytic reduction of a metallic
ion in an aqueous solution containing a reducing agent
and the subsequent deposition of metal without the use
of external electric energy.
3. Anodizing is an electrolytic oxidation process which
converts the surface of the metal to an insoluble
oxide.
4. Chemical conversion coatings are applied to previously
deposited metal or basis material for increased corro-
sion protection, lubricity, preparation of the surface
for additional coatings, or formulation of a special
surface appearance. This operation includes chro-
mating, phosphating, metal coloring, and passivating.
5. Etching and chemical milling are used to produce speci-
fic design configurations and tolerances on parts by
controlled dissolution with chemical reagents or etch-
ants .
6. Cleaning involves the removal of oil, grease, and dirt
from the surface of the basis material using water with
or without a detergent or other dispersing material.
7. Machining is the general process of removing stock from
a workpiece by forcing a cutting tool through the
workpiece, removing a chip of basis material. Machining
operations such as turning, milling, drilling, boring,
tapping, planing, broaching, sawing and cutoff, shaving,
threading, reaming, shaping, slotting, nobbing, filing,
and chamfering are included in this definition.
8. Grinding is the process of removing stock from a work-
piece by the use of a tool consisting of abrasive
grains held by a rigid or semirigid binder. The pro-
cesses included in this unit operation are sanding (or
cleaning to remove rough edges or excess material),
surface finishing, and separating (as in cutoff or
slicing operations).
9. Polishing is an abrading operation used to remove or
smooth out surface defects (scratches, pits, tool
marks, etc.) that adversely affect the appearance or
function of a part. The operation usually referred to
as buffing is included in the polishing operation.
Date: 1/24/83 R Change 2 II.8.7-2
-------
10. Tumbling (barrel finishing) is a controlled method of
processing parts to remove burrs, scale, flash, and
oxides as well as to improve surface finish.
11. Burnishing is the process of finish sizing or smooth
finishing a workpiece (previously machined or ground)
by displacement, rather than removal, of minute surface
irregularities. It is accomplished with a smooth point
or line-contact and fixed or rotating tools.
12. Impact deformation is the process of applying an impact
force to a workpiece such that the workpiece is perma-
nently deformed or shaped. Impact deformation opera-
tions include shot peening, peening, forging, high
energy forming, heading, and stamping.
13. Pressure deformation is the process of applying force
(at a slower rate than an impact force) to permanently
deform or shape a workpiece. Pressure deformation
includes operations such as rolling, drawing, bending,
embossing, coining, swaging, sizing, extruding, squeez-
ing, spinning, seaming, staking, piercing, necking,
reducing, forming, crimping, coiling, twisting, winding,
flaring, or weaving.
14. Shearing is the process of severing or cutting a work-
piece by forcing a sharp edge or opposed sharp edges
into the workpiece, stressing the material to the point
of shear failure and separation.
15. Heat treating is the modification of the physical
properties of a workpiece through the application of
controlled heating and cooling cycles. Such operations
as tempering, carburizing, cyaniding, nitriding, anneal-
ing, normalizing, austenizing, quenching, austempering,
siliconizing, martempering, and malleabilizing are
included in this definition.
16. Thermal cutting is the process of cutting, slotting, or
piercing a workpiece using an oxyacetylene oxygen lance
or electric arc cutting tool.
17. Welding is the process of joining two or more pieces of
material by applying heat, pressure, or both, with or
without filler material, to produce a localized union
through fusion or recrystallization across the inter-
face. Included in this process are gas welding, re-
sistance welding, arc welding, cold welding, electron
beam welding, and laser beam welding.
Date: 1/24/83 R Change 2 II.8.7-3
-------
18. Brazing is the process of joining metals by flowing a
thin, capillary thickness layer of nonferrous filler
metal into the space between them. Bonding results
from the intimate contact produced by the dissolution
of a small amount of base metal in the molten filler
metal, without fusion of the base metal. The term
brazing is used where the temperature exceeds 425°C
(800°F).
19. Soldering is the process of joining metals by flowing a
thin, capillary thickness layer of nonferrous filler
metal into the space between them. Bonding results
from the intimate contact produced by the dissolution
of a small amount of base metal in the molten filler
metal, without fusion of the base metal. The term
soldering is used where the temperature range falls
below 425°C (800°F).
20. Flame spraying is the process of applying a metallic
coating to a workpiece using finely powdered fragments
of wire and suitable fluxes, which are projected to-
gether through a cone of flame onto the workpiece.
21. Sand blasting is the process of removing stock, in-
cluding surface films, from a workpiece by the use of
abrasive grains pneumatically impinged against the
workpiece. The abrasive grains used include sand,
metal shot, slag, silica, pumice, or materials such as
walnut shells.
22. Abrasive jet machining is a mechanical process for
cutting hard, brittle materials. It is similar to sand
blasting but uses much finer abrasives carried at high
velocities (150-910 mps [500-3,000 fps]) by a liquid or
gas stream. Uses include frosting glass, removing
metal oxides, deburring, and drilling and cutting thin
sections of metal.
23. Electrical discharge machining is a process which can
remove metal with good dimensional control from any
metal. It cannot be used for machining glass, ceramics,
or other nonconducting materials. Electrical discharge
machining is also known as spark machining or electron-
ic erosion. The operation was developed primarily for
machining carbides, hard nonferrous alloys, and other
hard-to-machine materials.
24. Electrochemical machining is a process based on the
same principles used in electroplating except the
workpiece is the anode and the tool is the cathode.
Electrolyte is pumped between the electrodes and a
potential applied, resulting in rapid removal of metal.
Date: 1/24/83 R Change 2 II.8.7-4
-------
25. Electron beam machining is a thermoelectric process in
which heat is generated by high velocity electrons
impinging the workpiece, converting the beam into
thermal energy. At the point where the energy of the
electrons is focused, the beam has sufficient thermal
energy to vaporize the material locally. The process
is generally carried out in a vacuum. The process
results in X-ray emission which requires that the work
area be shielded to absorb radiation. At present the
process is used for drilling holes as small as 0.05 mm
(0.002 in.) in any known material, cutting slots,
shaping small parts, and machining sapphire jewel
bearings.
26. Laser beam machining is the process of using a highly
focused, monochromatic collimated beam of light to
remove material at the point of impingement on a work-
piece. Laser beam machining is a thermoelectric pro-
cess, and material removal is largely accomplished by
evaporation, although some material is removed in the
liquid state at high velocity. Since the metal removal
rate is very small, this process is used for such jobs
as drilling microscopic holes in carbides or diamond
wire drawing dies and for removing metal in the balanc-
ing of high-speed rotating machinery.
27. Plasma arc machining is the process of material removal
or shaping of a workpiece by a high-velocity jet of
high-temperature ionized gas. A gas (nitrogen, argon,
or hydrogen) is passed through an electric arc causing
it to become ionized and raising its temperatures in
excess of 16,000°C (30,000°F). The relatively narrow
plasma jet melts and displaces the workpiece material
in its path.
28. Ultrasonic machining is a mechanical process designed
to remove material by the use of abrasive grains which
are carried in a liquid between the tool and the work
and which bombard the work surface at high velocity.
This action gradually chips away minute particles of
material in a pattern controlled by the tool shape and
contour. Operations that can be performed include
drilling, tapping, coining, and the making of openings
in all types of dies.
29. Sintering is the process of forming a mechanical part
from a powdered metal by fusing the particles together
under pressure and heat. The temperature is maintained
below the melting point of the basis metal.
30. Laminating is the process of adhesive bonding of layers
of metal, plastic, or wood to form a part.
Date: 1/24/83 R Change 2 II.8.7-5
-------
31. Hot dip coating is the process of coating a metallic
workpiece with another metal by immersion in a molten
bath to provide a protective film. Galvanizing (hot
dip zinc) is the most common hot dip coating.
32. Sputtering is the process of covering a metallic or
nonmetallic workpiece with thin films of metal. The
surface to be coated is bombarded with positive ions in
a gas discharge tube, which is evacuated to a low
pressure.
33. Vapor plating is the process of decomposition of a
metal or compound upon a heated surface by reduction or
decomposition of a volatile compound at a temperature
below the melting point of either the deposit or the
basis material.
34. Thermal infusion is the process of applying a fused
zinc, cadmium, or other metal coating to a ferrous
workpiece by imbuing the surface of the workpiece with
metal powder or dust in the presence of heat.
35. Salt bath descaling is the process of removing surface
oxides or scale from a workpiece by immersion of the
workpiece in a molten salt bath or a hot salt solution.
The work is immersed in the molten salt (temperatures
range from 400-540° C [750-1,000°F]), quenched with
water, and then dipped in acid. Oxidizing, reducing,
and electrolytic baths are available, and the partic-
ular type needed depends on the oxide to be removed.
36. Solvent degreasing is a process for removing oils and
grease from the surfaces of a workpiece by the use of
organic solvents, such as aliphatic petroleums, aro-
matics, oxygenated hydrocarbons, halogenated hydro-
carbons, and combinations of these classes of solvents.
However, ultrasonic vibration is sometimes used with
liquid solvent to decrease the required immersion time
with complex shapes. Solvent cleaning is often used as
a precleaning operation such as prior to the alkaline
cleaning that precedes plating, as a final cleaning of
precision parts, or as a surface preparation for some
painting operations.
37. Paint stripping is the process of removing an organic
coating from a workpiece. The stripping of such coat-
ings is usually performed with caustic, acid, solvent,
or molten salt.
38. Painting is the process of applying an organic coating
to a workpiece. This process includes the application
of coatings such as paint, varnish, lacquer, shellac,
Date: 1/24/83 R Change 2 II.8.7-*
-------
and plastics by methods such as spraying, dipping,
brushing, roll coating, lithographing, and wiping.
Other processes included under this unit operation are
printing, silk screening, and stenciling.
39. Electrostatic painting is the application of electro-
statically charged paint particles to an oppositely
charged workpiece followed by thermal fusing of the
paint particles to form a cohesive paint film. Both
waterborne and solvent-borne coatings can be sprayed
electrostatically.
40. Electrepainting is the process of coating a workpiece
by either making it anodic or cathodic in a bath that
is generally an aqueous emulsion of the coating materi-
al. The electrodeposition bath contains stabilized
resin, dispersed pigment, surfactants, and sometimes
organic solvents in water.
41. Vacuum metalizing is the process of coating a workpiece
with metal by flash heating metal vapor in a high-
vacuum chamber containing the workpiece. The vapor con-
denses on all exposed surfaces.
42. Assembly is the fitting together of previously manu-
factured parts or components into a complete machine,
unit of a machine, or structure.
43. Calibration is the application of thermal, electrical,
or mechanical energy to set or establish reference
points for a component or complete assembly.
44. Testing is the application of thermal, electrical, or
mechanical energy to determine the suitability or
functionality of a component or complete assembly.
45. Mechanical plating is the process of depositing metal
coatings on a workpiece via the use of a tumbling
barrel, metal powder, and usually glass beads for the
impaction media.
Table 8.7-1 presents an industry summary for the Metal Finishing
Industry including the total number of subcategories, number of
subcategories studied, and the type and number of dischargers.
Date: 1/24/83 R Change 2 II.8.7-7
-------
TABLE 8.7-1. INDUSTRY SUMMARY [2-68]
Industry: Metal Finishing
Total Number of Subcategories: 1
Number of Subcategories Studied: 1
Number of Dischargers in Industry: 13,470
• Direct: 10,561
• Indirect: 2,909
• Zero: None
II.8.7.1.2 Subcategory Descriptions
The primary purpose of subcategorization is to establish group-
ings within the Metal Finishing Industry such that each sub-
category has a uniform set of quantifiable effluent limitations.
Several bases were considered in establishing Subcategories
within the Metal Finishing Industry. These included the follow-
ing:
• Raw waste characteristics
• Manufacturing processes
• Raw materials
• Product type or production volume
• Size and age of facility
• Number of employees
• Water usage
• Individual plant characteristics.
After examination of the potential categorization bases, a single
metal finishing subcategory was established. All process waste-
waters in the Metal Finishing Industry are amenable to treatment
by a single system and one set of discharge standards results
from the application of a single waste treatment technology.
Figure 8.7-1 presents the waste treatment requirement for the
Metal Finishing Industry and illustrates the effect of raw waste
type upon the treatment technology requirements.
Seven distinct types of raw waste are present in wastewaters from
the Metal Finishing Industry. The raw waste characterization is
divided into two components: inorganic and organic wastes.
These components are further subdivided into the specific types
of wastes that occur within the components. Inorganics include
common metals, precious metals, complexed metals, hexavalent
chromium, and cyanide. Organics include oils, greases, and
solvents.
All of the process raw wastes resulting from each of the 45
individual unit operations previously described are encompassed
Date: 1/24/83 R Change 2 II. 8.7-8
-------
Manufacturing Facility
to Raw Waste Sources
\ T T T T '
u>
Raw Waste Discharge
^ (Treatment System
Influent)
g | ' j j * 1
| Waste Treatment ! Oily Waste Chromium j
ITD (If Applicable) 1 Removal ! Reduction j
1 J I 1
Treated
Jlj Effluent
00 to te_
Lj
1
vo
<
Conmon
{ Cyanide
j Destruction
I
Without
"*~
.
•i
1
5
-i
E
Cyanide
•8
I
c
4
i i
Solvents
Ccmplexed j 1 Precious •
Metals ! Metals
Removal j Recovery
,
11
Raw Waste
. (Cannon
1 J .
j Metals '
' Removal '
Final
Metals)
Treated
Effluent
Ireated
Effluent
i
i
i
i
i
i
i
J
1
i
I
I
|
Hauled Or
Reclaimed
Hauled Or
Reclaimed
Figure 8.7-1. Waste Treatment Schematic
-------
TABLE 8.7-2. WASTE CHARACTERISTIC DISTRIBUTION BY UNIT OPERATION [2-22]
O
0)
rt
CD
NJ
00
OJ
n
GO
I
M
O
Waste Characteristic
Common Precious Complexed
Unit Operation metals metals metals
1 .
2.
3.
H.
5.
6.
7.
8.
9.
10.
11 .
12.
13.
14.
15.
16.
17.
18.
19.
20.
21 .
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
140.
11.
42.
43.
44.
45.
El ectrop lat ing
Electroless plating
Anod i z i ng
Conversion coating
Etch ing
Clean ing
Mach i n ing
Grind i ng
Pol ishing
Tumb I i ng
Burn i shing
Impact deformation
Pressure deformation
Shea ring
Heat treating
Thermal cutting
We I d i ng
Brazing
So I de ring
Flame spraying
Sand blasting
Other jet machining
Elec. discharge machining
Electrochemical machining
Electron beam machining
Laser beam machining
Plasma arc machining
Ultrasonic machining
Sintering
Laminat ing
Hot d ip coat ing
Sputtering
Vapor plating
Therma I infus ion
Sa It bath desca I ing
Solvent degreasing
Paint stripping
Pa int ing
Electrostatic painting
Electropa int ing
Vacuum metalizing
Assemb ly
Ca I i brat ion
Test ing
Mechanical plating
X X
XX X
X
X X
XX X
XX X
X
X
X X
X
X X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Chromium
(hexavalent) Cyanide Oils
X X
X
X
X X
X
X XX
X
X
X
X XX
X X
X
X
X
X X
X
X
x x
X
x
X
X
X X
X
X
X
X
So I vents
x
x
x
x
x
x
x
x
x
-------
by one or more of the raw waste types. Table 8.7-2 presents a
tabulation of the manufacturing unit operations and the types of
raw waste that they have the potential to generate.
II.8.7.2 WASTEWATER CHARACTERIZATION
In this section the water uses in the Metal Finishing Industry
are presented and the waste constituents are identified and
quantified. Raw waste data are derived from an analysis of
samples taken at visited plants.
Water is used for rinsing workpieces, washing away spills, air
scrubbing, process fluid replenishment, cooling and lubrication,
washing of equipment and workpieces, quenching, spray booths, and
assembly and testing. Unit operations with significant water
usage include: electroplating, electroless plating, anodizing,
conversion coating, etching, cleaning, machining, grinding,
tumbling, heat treating, welding, sand blasting, salt bath de-
scaling, paint stripping, painting, electrostatic painting,
electropainting, testing, and mechanical plating. Unit opera-
tions with zero discharge, identified in DCP (data collection
portfolio) and plant sampling studies, were electron beam machin-
ing, laser beam machining, plasma arc machining, ultrasonic
machining, sintering, sputtering, vapor plating, thermal infu-
sion, vacuum metalizing, and calibration. While an operation may
tend to be zero discharge, associated preparatory operations,
i.e., cleaning, may have discharges.
Table 8.7-3 displays the ranges of flows found in the Metal
Finishing Industry. The flow information is based on data ob-
tained from visited plants. For those visited plants with common
metals waste streams, the average contribution of these streams
to the total wastewater flow within a particular plant was 67.6%
(range of 1.4% to 100%). All of the plants visited and sampled
had a waste stream requiring common metals treatment.
TABLE 8.7-3.
WASTEWATER FLOW CHARACTERIZATION OF THE
METAL FINISHING INDUSTRY [2-22]
Flow of plants,
Mega Iiters/day
Approximate percentage of
plants represented by this flow
<0.0378
0.0378 - 0.0757
0.0757 - 0. 1 III
0. Mil - 0. 151
0. 151 - 0. 189
0. 189 - 0.227
0.227 - 0.265
0.265 - 0.303
0.303 - 0.3"ll
0.311 - 0.378
0.378 - 0.757
0.757 - 1. Ill
1 . It - 1.51
1.51 - 1 . 89
1.89 - 2.27
2.27 - 2.65
2.65 - 3.03
3.03 - 3. Ill
3. Ill - 3.78
3.78 - l|. 16
It. 16 - 11.51
18.9 - 22.7
17.5
12.5
9
7
5
1
3.5
1:5
2.5
U
15
3.5
6
3.5
3.5
0
2
|
0
1
1
1
Date: 1/24/83 R Change 2 II.8.7-11
-------
Of the plants visited, 6.3% had production processes which gen-
erated precious metals wastewater. The average precious metals
wastewater flow was 20.1% of total plant flow.
The average contribution of the complexed metal streams to total
plant flow was 11.9%. The percentage was computed from data for
plants whose complexed metal streams could be segregated from the
total stream.
Of the plants visited and sampled, 24.1% had segregated hexa-
valent chromium waste streams. The average flow contribution of
these waste streams to the total wastewater stream is 23.4%. Of
the plants having hexavalent chromium streams, 100% segregate
those streams for treatment.
At those plants with cyanide wastes, the average contribution of
the cyanide-bearing stream to the wastewater generated is 14.6%
(range of 1.4% to 29.6%). Of the plants visited and sampled,
13.9% have segregated cyanide-bearing wastes.
Segregated oily wastewater is defined as oil waste collected from
machine sumps and process tanks. The water is segregated from
other wastewaters until it has been treated by an oily waste
removal system. Of the plants visited, 12.9% are known to segre-
gate their oily wastes. The average contribution of these wastes
to the total plant wastewater flow is 6.4% (range of approxi-
mately 0.0% to 31.7%).
In order to characterize the waste streams, raw waste data were
collected during the sampling visits. Discrete samples of raw
wastes were taken for the seven waste types and analyses on the
samples were performed. The results of these analyses are pre-
sented for each waste type in Tables 8.7-4 through 8.7-9. In
each table, data are presented on the number of detections of a
pollutant, the number of samples analyzed, the range, the mean,
and the median concentration of those samples analyzed. The
minimum detection limits for the toxic pollutants in the sampling
program are listed in Table 8.7-10. Any value below the detec-
table limit is listed in the following tables as BDL, below
detection limit.
II.8.7.2.1 Common Metals
Pollutant parameters found in the common metals raw waste stream
from sampled plants are shown in Table 8.7-4. The major constit-
uents shown are parameters which originate in process solutions
(such as from plating or galvanizing) and enter wastewaters by
dragout to rinses. These metals appear in waste streams in
widely varying concentrations.
Date: 1/24/83 R Change 2 II.8.7-12
-------
o
pj
ft
(D
NJ
CO
Ul
n
(D
NJ
H
H
CO
I
OJ
TABLE 8.7-4. AVERAGE DAILY CONCENTRATIONS OF POLLUTANTS FOUND
IN COMMON METALS RAW WASTEWATER, SCREENING AND
VERIFICATION DATA [2-22]
Pollutant
Number
of
samples
Number
of
detections
Range
of
samples
Med ian
of
samples
Mean
of
samp Ies
Toxic pollutants, u,g/L
Metals and inorganics
Antimony 106
Arsenic 105
Beryl Mum 27
Cadmium I 19
Chromium I 16
Copper I 19
Cyanide 99
Lead 122
Mercury 109
Nickel III
Selenium 26
SiIver 103
ThaI Ii urn 26
Z i nc I 22
Phthalates
Bis(2-ethylhexyl)phthalate 92
Butyl benzyl phthalate 64
Di-n-butyl phthalate 89
Di-n-octyl phthalate 64
Diethyl phthalate 83
Dimethyl phthalate 64
Nitrogen compounds
3,3-Dichlorobenzidene 4
N-nitroso-di-n-propylamine 4
PhenoIs
2-NitrophenoI 4
4-Nitrophenol 4
Phenol 24
PentachlorophenoI 4
Aromat ics
Benzene 6
Ethyl benzene 37
To Iuene 39
ParachlorometacresoI 4
PoIycycIi c a roma t i c
hyd roca rbons
Fluoranthene 4
Isophorone 8
22
30
13
71
100
I 16
70
87
42
91
21
44
21
121
90
37
79
24
66
6
I
16
I
4
9
17
I
I
4
NO -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
430
64
44
22,000
35,000
500,000
2,400,000
42,000
400
420,000
60
80
62
16,000,000
1,900
5
1,200
1
240
1
BDL
570
24
20
1,000
10
16
1,200
690
150
74
310
ND
ND
5
BDL
100
180
16
53
ND
78
5
ND
3
390
5
BDL
I
ND
I
ND
ND
ND
ND
ND
8
ND
BDL
ND
ND
ND
ND
7
7
5
8
610
2, 100
14,000
42,000
1,200
5
19,000
7
6
8
310,000
56
BDL
21
BDL
24
BDL
BDL
140
6
5
150
3
5
83
60
38
19
87
-------
D
P)
rt
(D
TABLE 8.7-4. AVERAGE DAILY CONCENTRATIONS OF POLLUTANTS FOUND
IN COMMON METALS RAW WASTEWATER, SCREENING AND
VERIFICATION DATA (continued)
CO
CO
50
O
tr
(D
to
H
H
CO
•
-J
t
Pollutant s
Nap thai one
Anthracene
Fluorene
Phenanthrene
Pyrene
Haloqenated aliphatics
Carbon tetrachloride
, 2-0 ichlo roe thane
, 1, l-Trlchloroethane
, 1 ,2-Trichloroethane
Chloroform
, l-Oichloroethylene
, 2-Trans-d ichloroethylene
, 2-D i ch 1 o rop ropy 1 ene
Methylene chloride
Methyl chloride
Methyl bromide
D i ch lo rob rotnome thane
Ch 1 o rod i b romome tha ne
Tetrachloroethylene
Trichloroethylene
Pesticides and metabolites
Dieldrin
Al pha-endosu 1 fan
Endrin aldehyde
Alpha-BHC
Beta-BHC
Oclta-BHC
Classical pollutants, ng/L
TSS
Aluminum
Ba r i urn
Boron
Calcium
Coba 1 1
Fluorides
I ron
Magnes i urn
Manganese
Mo 1 ybdenum
Phosphorus
Sod i urn
Tin
Titanium
Vanadium
Yttrium
Ammon i a
BOD
COD
Oi 1 and grease
Phenols, total
TDS
TOC
umber
of
amoles
89
83
i»
82
4
57
It
58
57
65
58
5
14
80
74
4
5
4
59
77
4
4
4
4
4
4
40
16
4
3
4
7
99
102
4
7
6
98
4
98
9
4
4
1 1
21
16
37
35
10
37
Number
of
detection
61
57
2
56
1
37
|
44
21
48
4
3
1
27
3
I
2
1
23
49
40
14
3
3
4
3
90
101
4
7
5
97
4
38
5
3
3
10
21
16
37
34
9
37
Range
of
i samples
ND - 2,000
ND - 30
ND - 160
ND - 30
ND - 190
ND - 1
ND - 2
ND - 550
ND - 3
ND - 140
ND - 1 10
ND - 5
ND - 2
ND - 570
ND - 60
ND - 2
ND - 8
ND - 8
ND - 66
ND - 480
ND - BDL
ND - 9
ND - BDL
ND - BDL
ND - 4
ND - BDL
280 - 150,000
ND - 200
ND - 0.071
1.7 - 4
25 - 76
ND - 0.023
ND - 36
ND - 13,000
5.6 - 31
0.059 - 0.5
ND - 0.3
NO - 77
17 - 310
ND - 15
ND - 4.3
ND - 0.22
ND - 0.02
ND - 270
10 - 17,000
310 - 1,500,000
BDL - 800,000
NO - 49
ND - 4,900
3 - 560,000
Median
of
samples
BDL
BDL
BDL
BDL
ND
BDL
ND
0. 1
ND
BDL
ND
1
ND
ND
ND
ND
ND
ND
ND
BDL
NO
ND
ND
ND
ND
ND
2,700
1.3
0.029
3.8
52
ND
0.88
2.4
14
0.085
0.018
3. 1
140
ND
0.006
0.023
0.01
6.4
1,400
12,000
6, 100
0.23
1,500
1,600
Mean
of
samples
57
2
40
1
48
BDL
BDL
13
0.2
4
2
2
BDL
18
0.9
BDL
2
2
3
14
BDL
2
BDL
BDL
1
BDL
16,000
27
0.032
3.2
51
0.007
4.3
500
16
0.23
0. 1
7.7
150
|
0.049
0.066
0.01
42
3,200
120,000
4 1 , 000
2.4
1,700
28,000
Analytic methods: V.7.3.13, Data set I.
ND, not detected.
BDL, below detection limit.
-------
II.8.7.2.2 Precious Metals
Table 8.7-5 shows the concentrations of pollutant parameters
found in the precious metals raw waste streams. The major con-
stituents are silver and gold, which are much more commonly used
in Metal Finishing Industry operations than palladium and rho-
dium. Because of their high cost, precious metals are of special
interest to metal finishers.
II.8.7.2.3 Complexed Metals
The concentrations of metals found in complexed metals raw waste
streams are presented in Table 8.7-6. Complexed metals may occur
in a number of unit operations but come primarily from electro-
less and immersion plating. The most commonly used metals in
these operations are copper, nickel, and tin. Wastewaters con-
taining complexing agents must be segregated and treated indepen-
dently of other wastes in order to prevent further complexing of
free metals in the other streams.
II.8.7.2.4 Cyanide
The cyanide concentrations found in cyanide raw waste streams are
shown in Table 8.7-7. The levels of cyanide range from 45 to
1,700,000 yg/L. Streams with high cyanide concentrations nor-
mally originate in electroplating and heat treating processes.
Cyanide-bearing waste streams should be segregated and treated
before being combined with other raw waste streams.
II.8.7.2.5 Hexavalent Chromium
Concentrations of hexavalent chromium from metal finishing raw
wastes are shown in Table 8.7-8. Hexavalent chromium enters
wastewaters as a result of many unit operations and can be very
concentrated. Because of its high toxicity, it requires separate
treatment so that it can be efficiently removed from wastewater.
II.8.7.2.6 Oils
Pollutant parameters and their concentrations found in the oily
waste streams are shown in Table 8.7-9. The oily waste subcate-
gory for the Metal Finishing Industry is characterized by both
concentrated and dilute oily waste streams that consist of a
mixture of free oils, emulsified oils, greases, and other assorted
organics. Applicable treatment of oily waste streams is depen-
dent on the concentration levels of the wastes, but oily wastes
normally receive specific treatment for oil removal prior to
solids removal waste treatment.
The majority of the pollutants listed in Table 8.7-9 are priority
organics that are used either as solvents or as oil additives to
extend the useful life of the oils. Organic priority pollutants,
Date: 1/24/83 R Change 2 II.8.7-15
-------
ft
CD
to
oo
CO
V
O
TABLE 8.7-5. AVERAGE DAILY CONCENTRATIONS OF POLLUTANTS FOUND
IN PRECIOUS METALS RAW WASTEWATER, SCREENING AND
VERIFICATION DATA [2-22]
Pol lutant
Classical pollutants, mg/L
Si 1 ve r
Gold
Pa 1 ladium
Rhod i um
Number
of
sa moles
15
15
13
12
Number
of
detections
12
1 I
3
1
Range
of
samples
ND - 600
ND - 43
ND - 0. 12
ND - 0.22
Median
of
samples
0.2U
0.56
ND
ND
Mean
of
samoles
69
9.3
0.023
0.018
Analytic methods:
ND, not detected.
V.7.3. 13, Data set I.
3
id
(D
K)
00
TABLE 8.7-6. AVERAGE DAILY CONCENTRATIONS OF POLLUTANTS
FOUND IN COMPLEXED METALS RAW WASTEWATER,
SCREENING AND VERIFICATION DATA [2-22]
Pol lutant
Toxic pollutants, ng/L
Cadmium
Copper
Lead
Nickel
Zinc
Classical pollutants, mg/L
Aluminum
Ca 1 c i um
1 ron
Magnes ium
Manganese
Phosphorus
Sod i um
Tin
TSS
Number Number
of of
samples detections
3
3
3
3
3
3
3
3
3
9
28
10
25
31
3
3
10
26
Range
of
samples
ND - 3,600
ND - 63,000
ND - 3,600
ND - 290,000
23 - 18,000
0. 1
17
0.038 - 99
2
0. 1
0.23 - 100
1 10
ND - 6
ND - 83
Med i a n
of
samples
ND
5,900
ND
550
210
0.7U
8.2
ND
3.3
Mean
of
samples
250
10,000
370
22,000
3,000
9.9
23
0.51
16
Analytic methods:
ND, not detected.
V.7.3.13, Data set I
-------
ft
(D
to
CO
to
O
TABLE 8.7-7. AVERAGE DAILY CONCENTRATIONS OF POLLUTANTS FOUND
CYANIDE RAW WASTEWATER, SCREENING AND VERIFI -
DATA [2-22]
Pol
Tox i c po 1
Cyanide
Cyan ide
lutant
lutants, ng/L
, Amn . *
Number
of
samp les
23
22
Number
of
detections
23
21
Range
of
samples
45 - 1,700,000
ND - 1 ,600,000
Med ian
of
samp les
77,000
7,600
Mean
of
samples
300,000
270,000
Analytic methods: V.7.3.13, Data set I,
ND, not detected.
*Amenable to chlorination.
3
iQ
0)
to
TABLE 8.7-8. AVERAGE DAILY CONCENTRATIONS OF POLLUTANTS FOUND IN
HEXAVALENT CHROMIUM RAW WASTEWATER, SCREENING AND
VERIFICATION DATA [2-22]
M
00
1
M
«J
Pol lutant
Toxic pollutants, (ig/L
Chromium, hexavalent
Number
of
samples
U6
Number
of
detect ions
H6
Range
of
same les
5 - 13,000,000
Med ian
of
samp les
16,000
Mean
of
samples
380,000
Analytic methods:
NO, not detected.
V.7.3.13, Data set I
-------
TABLE 8.7-9. AVERAGE DAILY CONCENTRATIONS OF POLLUTANTS
FOUND IN OILY RAW WASTEWATER, SCREENING AND
VERIFICATION DATA [2-22]
Pollutant
Toxic pollutants, tig/L
Hetals and Inoraanics
Antimony
Arsenic
Be ry 1 1 i um
Cadmium
Ch rom i um
Copper
Cyanide
Lead
Mercury
Nickel
Selenium
Si Iver
Tha 1 1 1 um
Zinc
Phthalates
Bis(2-ethylhexyl Jphthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Di-n-octyl phthalate
Diethyl phthalate
Dimethyl phthalate
Ethers
Bi s(chloromethyl )ether
Bis(2-chloroethyl (ether
B 1 s( 2-ch 1 oroi sop ropy 1 (ether
Bis(2-chloroethoxy (me thane
Nitrogen compounds
1 , 2-Dipheny Ihydrazine
Pheno 1 s
2 , 4 , 6-T r i ch 1 o ropheno 1
Parachlorometacresol
2-Chlo ropheno 1
2, U-Dichlo ropheno 1
2, it-Dimethyl phenol
2-N it ropheno 1
M-N it ropheno 1
2 , 4-0 1 n i t ropheno 1
N-N i t rosod i pheny 1 am i ne
Pentachlorophenol •
Pheno 1
i4,6-Dini tro-o-cresol
Number
of
samples
27
38
40
140
40
1)0
37
39
38
39
27
27
27
140
22
10
17
6
12
8
1
2
1
1
2
5
9
2
2
1 1
5
3
4
6
7
20
3
Number
of
detections
27
38
140
140
140
38
28
39
38
39
27
27
27
140
20
9
\5
2
9
3
1
2
1
1
2
3
8
2
2
6
3
1
3
5
3
13
2
Range
of
samples
i - 600
2-120
BDL - 1 10
BDL - 1,700
*> - 15,000
NO - 21,000
ND - 530
BDL - 390,000
BDL - 25
BDL - 5,700
1 - 50
1 - 22,000
1 - 500
14 - 80,000
ND - 9,300
ND - 10,000
ND - 3, 100
ND - 120
ND - 1,900
ND - 1,200
9
14-10
14
3
5-12
ND - 1,800
ND - 800,000
76 - 620
10 - 68
ND - 31,000
ND - 320
ND - 10
ND - 10,000
ND - 900
ND - 50,000
ND - 6,600
ND - 5,700
Median
of
samples
16
10
2
12
130
270
5
130
1
100
5
20
25
1,200
63
76
15
ND
16
ND
10
2,200
BDL
10
ND
12
380
ND
56
10
Mean
of
samoles
140
22
12
100
1,200
1,800
40
12,000
3
630
9
850
1 10
8,300
740
1,500
240
21
310
150
7
8
370
92,000
350
39
2,800
73
3
2,500
410
7,900
1, 100
1,900
Date: 1/24/83 R Change 2 II.8.7-18
-------
TABLE 8.7-9. AVERAGE DAILY CONCENTRATIONS OF POLLUTANTS
FOUND IN OILY RAW WASTEWATER, SCREENING AND
VERIFICATION DATA (continued)
Pol lutant
Aromatlcs
Benzene
Chlorobenzene
Nitrobenzene
To 1 uene
Ethyl benzene
Polvnuclear aromatic
hydrocarbons
Acenapthene
2-Ch 1 o rona ptha I ene
Fluoranthene
Naptha lene
Benzo(a Ipyrene
Chrysene
Acenapthylene
Anthracene
Fluorene
Phenanthrene
Pyrene
1,2-Benzanthracene
Halogenated hydrocarbons
Carbon tetrachloride
, l-Dichloroethane
,2-Oichloroethane
, 1, l-Trichloroethane
, 1 , 2-Trichloroethane
, 1 ,2,2-Tetrachloroethane
Chloroform
, l-Dichloroethylene
, 2- trans-Dichlo roethy lene
Methyl ene chloride
Methyl chloride
Bromoform
D ichlo rob romome thane
Trich lorofl uorome thane
Ch 1 o rod i b romome tha ne
Te t rach 1 o roethy 1 ene
Trichloroe thy lene
Pesticides and metabolites
Aldrin
Dieldrin
Chlordane
4,4'-DDT
i|,i»'-DDE
4, 4 '-ODD
A 1 pha-endosu 1 fan
Beta-endosu 1 fan
Endosulfan sulfate
Endrin
End r i n a 1 dehyde
Heptachlor
Heptachlor epoxide
Alpha-BHC
Gamma -BHC
Delta-BHC
Pol yen lor ina ted biphenvls
Aroclor 1251
Aroclor 1248
Classical pollutants, mg/L
Oil a nd grease
Number
of
samples
22
i»
2
29
19
t|
1
9
12
6
6
7
1 1
8
1 1
6
6
8
13
6
20
1*
It
19
14
12
29
4
3
6
2
6
19
15
3
2
2
3
4
3
2
2
4
2
2
2
1
3
14
3
3
3
37
Number Range
of of
detections samples
18
2
2
25
16
2
1
8
10
1
3
3
7
7
8
5
4
5
1 1
6
18
It
2
19
12
9
29
It
1
2
2
3
18
1 1
2
I
2
2
It
3
2
2
U
2
2
1
1
3
3
2
2
2
37
ND - 1 10
ND - 610
BOL - 10
ND - 37,000
ND - 5,500
ND - 5,700
130
ND - 55,000
ND - 260,000
NO - 10
ND - 73
ND - 1,000
ND - 2,000
ND - 760
NO - 2,000
ND - 150
ND - 170
ND - 10,000
ND - 1, 100
9 - 2,100
ND - 1,300,000
6 - 1,300
ND - 570
2 - 690
ND - 10,000
ND - 1,700
5 - 7,600
BDL - 4,700
ND - 10
ND - 10
260,000 - 290,000
ND - 10
ND - 1 10,000
ND - 130,000
ND - 1 1
ND - 3
0.8 - 13
ND - 10
BDL - 53
1 - 10
8-28
BDL - 6
BDL - 16
7-10
10 - III
ND - BDL
0.01
11-18
ND - 9
ND - 1 1
ND - 1, 100
ND — 1,800
4.7 - 800,000
Median
of
samples
it
6
18
8
29
66
6
ND
BDL
ND
5
46
5
62
U
3
310
1,400
190
10
3
10
120
28
92
10
ND
NO
BDL
10
5
4
2
2
4
1 1
13
4
4
76
160
6, 100
Mean
of
samples
10
160
5
1,500
320
1,400
7,300
30,000
2
13
170
230
150
290
66
31
1,600
420
1, 100
67,000
330
140
58
1,300
380
600
1,200
3
2
280,000
2
8,400
17,000
5
1.5
7
4
14
5
18
3
10
8
12
BDL
12
4
5
390
650
4 1 , 000
Analytic methods: V.7.3.13, Data set I.
ND, not detected.
BDL, below detection limit.
Date: 1/24/83 R Change 2 II.8.7-19
-------
such as solvents, should be segregated and disposed of or re-
claimed separately. However, when they are present in wastewater
streams they are most often at the highest concentration in the
oily waste stream because organics generally have a higher solu-
bility in hydrocarbons than in water. Oily wastes will normally
receive treatment for oil removal before being directed to waste
treatment for solids removal.
11.8.7.2.7 Solvent
The solvent raw wastes are generated in the Metal Finishing
Industry by the dumping of spent solvents from degreasing equip-
ment (including sumps, water traps, and stills). These solvents
are predominately comprised of compounds classified by the EPA as
toxic pollutants. Spent solvents should be segregated, hauled
for disposal or reclamation, or reclaimed on site. Solvents that
are mixed with other wastewaters tend to appear in the common
metals or the oily wastes stream.
II.8.7.3 PLANT SPECIFIC DESCRIPTION
Descriptions of individual plants within the Metal Finishing
Industry are not available at this time.
II.8.7.4 POLLUTANT REMOVABILTY [2-22]
This section reviews the technologies currently available and
used to remove or recover pollutants from the wastewater gener-
ated in the Metal Finishing Industry. Treatment options are
presented for each raw waste type within the Metal Finishing
Industry. Refer to Figure 8.7-1 for the wastewater stream segre-'
gation in common practice in the Metal Finishing Industry. This
stream segregation allows the recovery of precious metals, the
reduction of hexavalent chromium to trivalent chromium, the
destruction of cyanide, and the removal/recovery of oils prior to
the removal of the common metals that are also present in these
streams. Segregation of these streams reduces the flow rate of
wastewater to be treated in each component and accordingly
reduces the cost of this primary treatment. The complexed metals
wastewaters require segregated treatment to preclude the complex-
ing of other metal wastes in the treatment system.
II.8.7.4.1 Common Metals
The treatment methods used to treat common metals wastes fall
into two groupings—recovery techniques and solids removal tech-
niques. Recovery techniques are treatment methods used for the
purpose of recovering or regenerating process constituents which
would otherwise be discarded. Included in this group are evapor-
ation, ion exchange, electrolytic recovery, electrodialysis, and
reverse osmosis. Solids removal techniques are employed to
remove metals and other pollutants from process wastewaters to
Date: 1/24/83 R Change 2 II.8.7-20
-------
make these waters suitable for reuse or discharge. These methods
include hydroxide and sulfide precipitation, sedimentation,
diatomaceous earth filtration, membrane filtration, granular bed
filtration, sedimentation, peat adsorption, insoluble starch
xanthate treatment, and flotation.
Three treatment options are used in treating common metals wastes.
The Option 1 system consists of hydroxide precipitation followed
by sedimentation. This system accomplishes the end-of-pipe
metals removal from all common metals-bearing wastewater streams
that are present at a facility. The recovery of precious metals,
the reduction of hexavalent chromium, the removal of oily wastes,
and the destruction of cyanide must be accomplished prior to
common metals removal.
The Option 2 system is identical to the Option 1 treatment system
with the addition of filtration devices after the primary solids
removal devices. The purpose of these filtration units is to
remove suspended solids such as metal hydroxides which do not
settle out in the clarifiers. The filters also act as a safe-
guard against pollutant discharge should an upset occur in the
sedimentation device. Filtration techniques applicable to
Option 2 systems are diatomaceous earth and granular bed filtra-
tion.
The Option 3 treatment system for common metal wastes consists of
the Option 1 end-of-pipe treatment system plus the addition of
in-plant controls for lead and cadmium. In-plant controls would
include evaporative recovery, ion exchange, and recovery rinses.
In addition to these three treatments, there are several alter-
native treatment technologies applicable to the treatment of
common metals wastes. These technologies include electrolytic
recovery, electrodialysis, reverse osmosis, peat adsorption,
insoluble starch xanthate, sulfide precipitation, flotation, and
membrane filtration.
II.8.7 .A.2 Precious Metals
Precious metal wastes can be treated using the same treatment
alternatives as those described for treatment of common metal
wastes. However, due to the intrinsic value of precious metals,
every effort should be made to recover them. The treatment
alternatives recommended for precious metal wastes are the re-
covery techniques - evaporation, ion exchange, and electrolytic
recovery.
II.8.7.4.3 Complexed Metal Wastes
Complexed metal wastes within the Metal Finishing Industry are a
product of electroless plating, immersion plating, etching, and
printed circuit board manufacture. The metals in these waste
Date: 1/24/83 R Change 2 II.8.7-21
-------
streams are tied up or complexed by particular complexing agents
whose function is to prevent metals from coming out of solution.
This counteracts the technique employed by most conventional
solids removal methods. Therefore, segregated treatment of these
wastes is necessary. The treatment method well suited to treat-
ing complexed metal wastes is high pH precipitation. An alter-
native method is membrane filtration. The method is primarily
used in place of sedimentation for solids removal.
II.8.7.4.4 Hexavalent Chromium
Hexavalent chromium-bearing wastewaters are produced in the Metal
Finishing Industry in chromium electroplating, in chromate con-
version coatings, in etching with chromic acid, and in metal
finishing operations carried out on chromium as a basis material.
The selected treatment option involves the reduction of hexa-
valent chromium to trivalent chromium either chemically or elec-
trochemically. The reduced chromium can then be removed using a
conventional precipitation-solids removal system. Alternative
hexavalent chromium treatment techniques include chromium re-
generation, electrodialysis, evaporation, and ion exchange.
II.8.7.4.5 Cyanide
Cyanide.s are introduced as metal salts for plating and conversion
coating or are active components in plating and cleaning baths.
Cyanide is generally destroyed by oxidation. Chlorine, in either
elemental or hypochlorite form, is the primary oxidation agent
used in industrial waste treatment to destroy cyanide. Alter-
native treatment techniques for the destruction of cyanide in-
clude oxidation by ozone, ozone with ultraviolet radiation (oxy-
photolysis), hydrogen peroxide, and electrolytic oxidation.
Treatment techniques, which remove cyanide but do not destroy it,
include chemical precipitation, reverse osmosis, and evaporation.
II.8.7.4.6 Oils
Oily wastes and toxic organics that combine with the oils during
manufacturing include process coolants and lubricants, wastes
from cleaning operations, wastes from painting processes, and
machinery lubricants. Oily wastes are generally of three types:
free oils, emulsified or water-soluble oils, and greases. Oil
removal techniques commonly employed in the Metal Finishing
Industry include skimming, coalescing, emulsion breaking, flota-
tion, centrifugation, ultrafiltration, reverse osmosis, carbon
adsorption, aerobic decomposition, and removal by contractor
hauling.
Because emulsified oils and processes that emulsify oils are used
extensively in the Metal Finishing Industry, the exclusive occur-
rence of free oils is nearly nonexistent.
bate: 1/24/83 R Change 2 II.8.7-22
-------
Treatment of oily wastes can be carried out most efficiently if
oils are segregated from other wastes and treated separately.
Segregated oily wastes originate in the manufacturing areas and
are collected in holding tanks and sumps. Systems for treating
segregated oily wastes consist of separation of oily wastes from
the water. If oily wastes are emulsified, techniques such as
emulsion breaking or dissolved air flotation with the addition of
chemicals are necessary to remove oil. Once the oil-water emul-
sion is broken, the oily waste is physically separated from the
water by decantation or skimming. After the oil-water separation
has been carried out, the water is sent to the precipitation/
sedimentation unit used for metals removal.
Three options for oily waste removal are discussed in Reference
2-22. The Option 1 system incorporates the emulsion breaking
process followed by surface skimming (gravity separation is
adequate if only free oils are present). The Option 2 system
consists of the Option 1 system followed by ultrafiltration, and
the Option 3 treatment system consists of the Option 2 system
with the addition of either carbon adsorption or reverse osmosis.
In addition to these three treatment options, several alternative
technologies are applicable to the treatment of oily wastewater.
These include coalescing, flotation, centrifugation, integrated
adsorption, resin adsorption, ozonation, chemical oxidation,
aerobic decomposition, and thermal emulsion breaking.
II.8.7.4.7 Solvents
Spent degreasing solvents should be segregated from other process
fluids to maximize the value of the solvents, to preclude contam-
ination of other segregated wastes, and to prevent the discharge
of priority pollutants to any wastewaters. This segregation may
be accomplished by providing and identifying the necessary stor-
age containers, establishing clear disposal procedures, training
personnel in the use of these techniques, and checking period-
ically to ensure that proper segregation is occurring. Segre-
gated waste solvents are appropriate for on-site solvent recovery
or may be contract hauled for disposal or reclamation.
Alkaline cleaning is the most feasible substitute for solvent
degreasing. The major advantage of alkaline cleaning over sol-
vent degreasing is the elimination or reduction in the quantity
of priority pollutants being discharged. Major disadvantages
include high energy consumption and the tendency to dilute oils
removed and to discharge these oils as well as the cleaning
additive.
Date: 1/24/83 R Change 2 II.8.7-23
-------
TABLE 8.7-10.
MINIMUM DETECTABLE LIMITS FOR TOXIC AND CLASSICAL
POLLUTANTS IN THE METAL FINISHING INDUSTRY [2-22]
Parameter
M
H
•
00
NJ
*>.
Acenaphthene
Ac ro I e i n
Acrylonitrl le
Benzene
Benz id i ne
Carbon tetrachloride (Tetrachloromethane)
Chlorobenzene
1,2,l»-Trichlorobenzene
HexachIo robenzene
,2-Dichloroethane
,I,l-Trichloroethane
HexachIoroethane
,l-Dichloroethane
,1,2-Trichloroethane
,I,2,2-Tetrachloroethane
Chloroethane
BisfchloromethyI) ether
Bis(2-chloroethyl) ether
2-Chloroethyl vinyl ether (mixed)
2-Chloronaphthalene
2,l|,6-Trichlorophenol
Parachlorometa cresol
Chloroform (Trichloromethane)
2-Chlorophenol
, 2-D i ch I o ro benzene
,3-DiChlorobenzene
, i|-0 i ch I o robenzene
,3'-D i chIo robenz i d i ne
I-D i chIo roethy Iene
2-Trans-dichloroethylene
2,14-Dcch loropheno I
1,2-Oichloropropane
1,2-Dichloropropylene (1,3-Dichloropropene)
2,1-0imethy I phenol
2,i4-Dini tro toluene
2,6-Dinitrotoluene
I,2-DiphenyIhydrazine
Ethyl benzene
Fluoranthene
t-Chlorophenyl phenyl ether
tt-Bromophenyl phenyl ether
Bis(2-chloroisopropyl) ether
Bis(2-chloroethexy) methane
MethyIene chloride (Dichloromethane)
Minimum
Detectable
Limit. mq/L
0. I
0. I
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
Parameter
Methyl chloride (Chloromethane)
Methyl bromide (Bromomethane)
Bromoform (Tribromomethane)
Dichlorobromomethane
T r i chIo ro rIuo rome thane
D i chIo rod i fIuo rome tha ne
ChIo rod i b romome thane
HexachIorobutad iene
HexachIo rocycI opentad i ene
Isophorone
Naphthalene
Nitrobenzene
2-Nitrophenol
4-Ni trophenol
2,U-D i n i t rophenoI
i»,6-Dini trp-o-cresol
N-N i trosod i methyl ami ne
N-Nitrosodiphenylamine
N-Nitrosod i-n-propylamine
PentachIorophenoI
PhenoI
Bis(2-ethyIhexyI) phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Di-n-octyl phthalate
Diethyl phthalate
Dimethyl phthalate
1,2-Benzanthracene (Benzol a{anthracene)
Benzo(a)pyrene (3,i»-Benzo-pyrene)
3,4-Benzofluoranthene (Benzo(b)fluoranthene)
I 1,12-Benzofluoranthene (Benzolk)fluoranthene)
Chrysene
Acenaphthylene
Anthracene
I,12-Benzoperylene (Benzolghi)-perylene)
Fluorene
Phenanthrene
1,2,5,6-D i benza thracene (D i benzo(a,h Janth racene)
IndenolI,2,3-cd)pyrene (2,3-o-Phenylenepyrene)
Pyrene
Tetrachloroethylene
Toluene
Trichloroethylene
Vinyl chloride (Chloroethylene)
Mini mum
Detectable
Limit. mg/L
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
-------
TABLE 8.7-10.
MINIMUM DETECTABLE LIMITS FOR TOXIC AND CLASSICAL
POLLUTANTS IN THE METAL FINISHING INDUSTRY
[2-22] (continued)
CO
I
to
Ul
Parameter
Aldrin
Dieldrin
Chlordane (technical mixture and metabolites)
I4,U'-DDT
II.II'-DDE
1), It1 -ODD
Alpha-endosul fan
Beta-endosu 1 fan
Endosulfan sulfate
Endrin
Endrin aldehyde
Heptachlor
Heptachlor epoxide
Alpha-BHC
Beta-BHC
Gamma -BHC (Lindane)
Delta-BHC
PCB-I2U2 (Arochlor
PCB-I25U (Arochlor
PCB-I22I (Arochlor
PCB-1232 (Arochlor
PCB-I2M8 (Arochlor
PCB-1260 (Arochlor
PCB-IOI6 (Arochlor
Toxaphene
Antimony
Arsenic
Asbestos
Be ry 1 1 i urn
Cadmium
Ch rom i urn
Copper
Cyanide
Lead
Mercury
Nickel
Selenium
Si \ver
Tha 1 1 i urn
Zinc
1242)
I25U)
1221 )
1232)
I2i«8)
1260)
1016)
2,3,7,8-Tetrachlorodibenzo-p-dioxin (TCDO)
1 ron
Minimum
Detectable
Limit. mq/L
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0 . 00.1
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.001
0.0001
0.0001
--
0.001
0.002
0.005
0.006
0.005
0.02
0.0001
0.005
0.0001
0.0001
o.oooi
0.001
0.001
0.005
Parameter
Gold
1 r i d i urn
Osmium
Pa 1 1 ad i urn
Platinum
Rhod i urn
Ruthenium
Tin
Hexavalent Chromium
Phosphorus (total )
Fluoride
Cyanide Amenable to Chlorination
Total Phenols
TSS
Oi 1 and Grease
Mini mum
Detectable
Limit. ma/L
0.01
1.0
0.08
0.006
0.05
0.001)
0.05
0.08
0.005
0.01
0. 1
0.005
0.005
1.0
1.0
-------
-------
Equipment cleaning. Water used to wash mixing tanks, bot-
tles, emulsion cold storage buckets, pumps, coating heads, and
floors in the production and testing areas contains trace quan-
tities of pollutants typical of raw materials used in product
manufacture and should be discharged to treatment. Since some of
these streams contain silver, waste streams in this area can be
divided into silver rich and silver lean streams for separate
treatment.
Product testing. Product testing activities at silver
halide plants include certification of raw materials, determi-
nation of the concentrations of components within emulsions,
physical defect evaluation of coated products, and evaluation of
the sensitometric response of the product to a known standard.
The solutions used in testing include inorganic and organic
analytical reagents and photoprocessing solutions. Wastewaters
from these sources enter the wastewater stream from sinks in the
quality testing laboratory and floor drains in photoprocessing
rooms. These wastewater streams contain a variety of inorganic
and organic compounds present in test reagents, emulsions, and
processing chemicals.
Unused coating solutions. Unused coating solutions contain
high concentrations of pollutants typical of the product manufac-
tured and require treatment prior to disposal. These streams can
be segregated into silver rich, silver lean, and cadmium bearing
streams for separate treatment.
Seven plants were visited in the silver halide subcategory, and a
wastewater sampling program was conducted at four of these plants.
Table 8.8-2 presents information on the concentrations of pollu-
tants found in the total raw waste streams as determined in
screening and additional sampling. The total raw waste stream
represents the combined wastes from incoming plant water, in-
fluent and effluent to silver recovery, influent and effluent to
cadmium recovery, testing wastewater, and final plant effluent.
Table 8.8-3 is a listing of those priority pollutants not detec-
ted in any of the plants sampled.
Diazo Aqueous Subcategory
The major source of water in the diazo aqueous manufacturing
process is from discharge of unused coating solutions and equip-
ment cleaning activities.
Unused coating solutions. Unused coating solutions contain
high concentrations of inorganic and organic pollutants, and they
require treatment prior to discharge. All diazo aqueous manu-
facturers identified hired a contractor to haul away their unused
sensitizer solution rather than treat this solution in-house.
Date: 8/31/82 R Change 1 II.8.8-7
-------
TABLE 8.8-2. SUMMARY OF CLASSICAL AND TOXIC POLLUTANT DATA FOR THE
SILVER HAL IDE SUBCATEGORY RAW WASTEWATER, VERIFICATION
AND SCREENING DATA [2-2H]
Number of
Pol lutant samples
Toxic pollutants, M9/L
Toxic orqanics
Acenaphthene
Benzene
Ch lorobenzene
1 , 2, 4-Tr i ch lorobenzene
Hexach 1 o robenzene
1 , 2-Dich lo roe thane
1,1, l-Trichlo roe thane
2,4,6-Trichlorophenol
Pa rach 1 o rometacreso 1
Ch lo reform
2, 4-D ich 1 oropheno 1
1 , 2-Dich loropropane
Ethyl benzene
Methylene chloride
Tr ich 1 orof 1 uorome thane
1 sophorone
2-Ni trophenol
4-N i tropheno 1
Pentach 1 o ropheno I
Pheno I
Bis-2-ethylhexyl phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Diethyl phthalate
Tet rach lo roe thy 1 ene
Anthracene
Phenanthrene
Vinyl chloride
Toluene
Trichloroethylene
Polvchlorinated biphen.vls
PCB-1242
Metals and inorganics
Antimony
Arsenic
Be ry 1 1 i urn
Cadmi urn
Chromium, total
Copper
Cyanide, total
Cyanide, amn. to chloride
Lead
Me rcu ry
Nickel
Se 1 en i urn
S i 1 ve r
Tha 1 1 i urn
Zinc
Classical pollutants, mg/L
Aluminum
Ammonia
BOD
Ba r i urn
Boron
Ca 1 c i urn
COD
Coba It
Fluoride
1 ron
Magnes i urn
Manganese
Molybdenum
Oil & grease
Phenols, total
Phosphorus
Sod 1 urn
Thyocyanste
Tin
Titanium
Total organic carbon
Total suspended solids
Vanadium
Yttrium
2
5
5
2
2
13
10
12
12
2
12
2
5
13
10
2
2
2
12
12
1 1
7
1 1
1 1
10
2
2
2
5
10
10
14
14
1 1
11
111
14
1 1
7
14
13
14
14
14
14
1 1
1
9
9
9
7
1
8
14
4
1 1
1 1
14
4
1 1
7
4
1
9
1 1
5
10
10
1
1
Number of Range of
detections detections
1
5
1
1
1
12
10
3
5
2
3
1
1
6
1
1
7
9
1 1
6
1 1
8
8
1
1
2
4
6
3
5
2
1 1
13
14
10
1
9
1
10
4
14
6
1
1
9
8
4
2
1
8
3
4
1
1
1
1
6
3
1
5
2
2
10
10
1
1
2.9
BDL - I.I
BDL
BDL
12
BDL - BDL
BDL - 1
BDL - 1,500
BDL - II
3.9 - 4
BDL - 3
37
1
BDL - 13
8. 1
1 . 1
32
57
BDL - 680
BDL - 10
BDL - 21
BDL - 5
BDL - 1,400
BDL - 14
BDL - 42
BDL
BDL
BDL
BDL - 1
BDL - 2
BDL - 1.3
1.9 - 220
BDL - 100
BDL - 1
BDL - 50,000
BDL - 3,000
38 - 2,700
BDL - 720
5. 1
BDL - 400
0.6
BDL - II
1.6 - 42
390 - 37,000
2. 1 - 280
2.7 - 2,000
0.3
0.37 - 160
16 - 820
0.01 - 0.07
0.0095 - 0.024
5
330 - 1, 100
0.005 - 0.086
0.13 - 20
0. 16 - 1.4
0.55 - 7.8
0.001 1 - 0.15
0.005
0.3 - 7.3
0.003 - 0.69
0.075 - 2.3
46
0.027 - 1
0.009 - 0.86
0.02 -I.I
110 - 2,000
20 - 240
0.01
0.02
Mean of
detections
BDL
BDL
BDL
500
3. 1
4
1.4
2.9
150
2.4
4.8
2.7
280
3.6
5.6
BDL
BDL
BDL
140
41
BDL
8,600
590
390
81
170
BDL
24
14,000
130
680
39
290
0.045
0.017
630
0.034
5
0.72
3.7
0.046
3.7
0. 14
0.86
0.3
0.43
0.56
440
68
Median of
detections
BDL
BDL
BDL
BDL
1 .4
1
1 . 1
21
I
1 .7
3. 1
5
BDL
BDL
BDL
BDL
200
22
520
76
140
8.9
120
BDL
23
13,000
140
150
9
210
0.049
570
0.01
0. 16
0.64
1.5
0.048
3.5
0.038
0.20
0.027
190
49
Analytic methods: V.7.3.14, Data sets I,
BDL, below detection limit.
2.
Date: 8/31/82 R Change 1 II.8.8-8
-------
TABLE 8.8-9.
PRIORITY POLLUTANTS NOT DETECTED IN ANY PHOTOGRAPHIC CHEMICAL
FORMULTATION PLANTS [2-24]
Acenaphthene
Acrolein
Acrylonitrile
Benzidine
1,2,4-Trichlorobenzene
Hexachlorobenzene
1,2-Dichloroethane
Hexachloroethane
1,1-Dichloroethane
1,1,2-Trichloroethane
1,1,2,2-Tetrachloroethane
Chloroethane
Bis-chloromethyl ether
Bis-2-chloroethyl ether
2-Chloroethyl vinyl ether
2-Chloronaphthalene
2,4,6-Trichlorophenol
Parachlorometacresol
2-Chlorophenol
3,3-Dichlorobenzidine
1,1-Dichloroethylene
1,2-trans-Dichloroethylene
2,4-Dichlorophenol
1,2-Dichloropropane
1,2-Dichloropropylene
2,4-Dimethylphenol
2,4-Dinitrotoluene
2,6-Dinitrotoluene
1,2-Diphenolhydrazine
4-Chlorophenyl phenyl ether
4-Bromophenyl phenyl ether
Bis-2-chloroisopropyl ether
Bis-2-chloroethoxymethane
Methyl chloride
Methyl bromide
Bromoform
Dichlorobromomethane
Trichlorofluoromethane
Dichlorodifluoromethane
Chlorodibromomethane
Hexachlorobutadiene
Hexachlorocyclopentadiene
Isophorone
Nitrobenzene
2-Nitrophenol
4-Nitrophenol
2,4-Dinitrophenol
4,6-Dinitro-o-cresol
N-nitrosodimethylamine
N-nitrosodiphenylamine
N-nitrosodi-n-propylamine
Pentachlorophenol
Di-n-octyl phthalate
1,2-Benzanthracene
Benzo(a)pyrene
3,4-Benzofluoranthene
Benzo(k)fluoranthene
Chrysene
Acenaphthylene
1,1,2-Benzoperylene
Fluorene
1,2,5,6-Dibenzanthracene
Indeno(l,2,3-cd)pyrene
Vinyl chloride
Aldrin
Dieldrin
Chlordane
4,4-DDT
4,4-DDE
4,4-DDD
Alpha-endosulfan
Beta-endosulfan
Endosulfan sulfate
Endrin
Endrin aldehyde
Heptachlor
Heptachlor epoxide
Alpha-BHC
Beta-BHC
Gamma-BHC
Delta-BHC
PCB-1242
PCB-1254
PCB-1221
PCB-1232
PCB-1248
PCB-1260
PCB-1016
Toxaphene
Chromium, hexavalent
Selenium
TCDD
Date: 8/31/82 R Change 1 II.8.8-17
-------
Solvent recovery. Steam is used to regenerate carbon col-
umns used for air pollution control once the columns become
saturated with organic solvents from thermal product manufacture.
The solvent/steam mixture from the carbon column is condensed and
either separated at the plant for reuse or hauled away by a con-
tractor. Separation of solvent and water is accomplished through
either decantation of immiscible solvent or through distillation.
The water fraction after separation contains trace quantities of
organic solvents and this water is considered as process waste-
water.
Seven plants were visited in this subcategory and a wastewater
sampling program was conducted at three of these sites. Since
the thermal product subcategory includes both aqueous and solvent
processes, the raw wastewater characteristics for this subcate-
gory can be further subdivided based on process type. Table
8.8-10 presents the concentration of pollutants that were found
in the raw wastewater streams of thermal aqueous processes and
thermal solvent recovery processes. Table 8.8-11 is a tabulation
of the pollutants which were not detected in one or both of these
processes.
II.8.8.3 PLANT SPECIFIC DESCRIPTION [2-24]
The effluent characteristics of photographic plants within each
subcategory are presented in this section. Data from plants
19814 and 30927 in the silver halide subcategory are presented in
Table 8.8-12. Plant 19814 uses equalization, silver recovery,
chemical precipitation, clarification, and pH adjustment before
discharging. Plant 30927 uses equalization, silver recovery,
chemical precipitation and clarification, aeration and clarifi-
cation to treat wastes before discharge.
Data from Plant 23004, representing the effluent characteristics
from the diazo aqueous subcategory, are presented in Table 8.8-13.
This plant uses a holding tank for metal bearing streams, and
settling and pH adjustment for non-metal bearing streams before
discharging.
Data are available for five plants in the diazo solvent sub-
category. Four plants (30041, 35032, A, and C) use solvent re-
covery, and one plant, 04046, uses vesicular film. Table 8.8-14
shows the actual performance for the solvent recovery (distilla-
tion) plants. The effluent concentrations represent the sampled
water streams going from the distillation columns to the carbon
adsorption beds. Inclusion of system raw waste concentrations in
Table 8.8-14 would provide a better picture of system performance,
however, these raw waste data are proprietary. Table 8.8-15
shows effluent concentrations from solvent recovery (decantation)
plants. These concentrations represent sampled water going from
decanters to the carbon adsorption bed. Table 8.8-16 shows
effluent concentrations in the vesicular film plant. This plant
Date: 8/31/82 R Change 1 II.8.8-18
-------
TABLE 8 8-10 SUMMARY OF CLASSICAL AND TOXIC POLLUTANT DATA FOR THE THERMAL
TABLE 8.8 10 ^™UCT -SUBCATEGORY RAW WASTEWATER, VERIFICATION AND SCREENING
DATA [2-24]
Number of
Pol lutant samples
Toxic pollutant, ng/L
Toxic orqanics
Benzene
Chlorobenzene
1 ,2-Dichloroethane
2-Chloronaphtha lene
Chloroform
Ethyl benzene
Methylene chloride
Naphthalene
Pheno 1
Bis-2-ethylhexyl phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Di-n-octyl phthalate
Diethyl phthalate
1,2-Benzanthracene
Benzo ( K ) f 1 uo ranthene
Chrysene
Anthracene
Phenanthrene
Pyrene
To 1 uene
Trichloroethylene
Metals and inorganics
Arsenic
Be ry 1 1 i urn
Cadmium
Chromium, total
Copper
Cyanide, total
Cyanide, amn to chlor
Lead
Mercury
Nickel
Si Iver
Zinc
Classical pollutants, mg/L
Aluminum
Ammonia
BOD
Ba r i urn
Ca I c i urn
COD
1 ron
Magnesium
Manganese
Molybdenum
'Oil ft grease
Phenol, total
Phosphorus
Sod i um
Thiocyanate
Tin
Titanium
Total organic carbon
Total suspended solids
Vanadium
9
9
9
9
1
9
9
1
9
9
9
9
9
9
9
1
9
9
9
1
9
9
6
9
9
9
7
6
6
9
7
9
9
9
1
6
5
1
1
6
9
3
9
9
6
6
4
1
6
3
1
6
6
9
Number of
detections
7
2
4
3
1
3
3
1
8
9
7
9
3
3
2
1
2
2
2
1
5
9
1
1
4
4
7
6
3
1
4
2
3
9
1
6
5
1
1
6
9
3
5
I
5
6
4
1
6
1
1
6
6
1
Range of Mean of
detections detections
BDL - 1,800
2-27
BDL - 5,300
BDL - 1
26
1 - 31
BOL - 2
5
BDL - 13
5 - 580
1 - 5
BOL - 5
BDL - 6.2
4.6 - 5
1 - 350
5
1 - 350
BDL - 5
BDL - 5
5
BDL - 8,600
BDL - 80
1,300
13
BOL - 5
16 - 120
1 1 0 - 990
BDL - 20
BDL - BDL
74
9.4 - 890
13 - 19
42 - 620
280 - 54,000
38
0.05 - 7.1
13 - 2, 100
2.9
3.5
50 - 11,000
0.24 - 2.6
9.9 - 12
0.01 1 - 0.057
0.055
0.41 - 1,200
0.29 - 0.79
0.61 - 1.8
9.6
0.004 - 0.05
0.083
0.38
30 - 1,500
6 - 6,000
0.005
260
14
1 , 300
BDL
12
1 . 1
3.9
140
3.2
3.6
4
4.9
170
170
2.6
2.6
1,900
10
3.5
72
440
12
BDL
230
16
280
1 1 , 000
2.4
540
3,300
1.4
1 1
0.029
360
0.54
1. 1
0.027
520
1,300
Median of
detections
BDL
BDL
1
3. 1
1
3
5
4
5
5
5
220
BDL
3.7
76
260
12
BDL
17
ISO
470
0.94
200
1 , 300
1.9
10
0.015
260
0.^1
0.92
0.028
310
170
BDL, below detection limit.
Date: 8/31/82 R Change 1 II.8.8-19
-------
TABLE 8.8-11.
PRIORITY POLLUTANTS NOT DETECTED IN ANY
THERMAL PRODUCT PLANTS [2-24]
Acenaphthene
Acrolein
Acrylonitrile
Benzidine
Carbon tetrachloride
1,2,4-Trichlorobenzene
Hexachlorobenzene
1,1,1-Trichloroethane
Hexachloroethane
1,1-Dichloroethane
1,1,2-Trichloroethane
1,1,2,2-Tetrachloroethane
Chloroethane
Bis chloromethylether
Bis-2-chloroethylether
2-Chloroethylvinylether
2,4,6-Trichlorophenol
Parachlorometacresol
2-Chlorophenol
1,2-Dichlorobenzene
1,3-Dichlorobenzene
1,4-Dichlorobenzene
3,3-Dichlorobenzidine
1,1-Dichloroethylene
1,2-trans-Dichloroethylene
2,4-Dichlorophenol
1,2-Dichloropropane
1,2-Dichloropropylene
2,4-Dimethylphenol
2,4-Dinitrotoluene
2,6-Dinitrotoluene
1,2-Diphenylhydrazine
Fluoranthene
4-Chlorophenyl phenyl ether
4-Bromophenyl phenyl ether
Bis-2-chloroisopropyl ether
Bis-2-chloroethoxymethane
Methyl chloride
Methyl bromide
Bromoform
Dichlorobromomethane
Trichlorofluoromethane
Dichlorodifluoromethane
Chlorodibromomethane
Hexachlorobutadiene
Hexachlorocyclopentadiene
Isophorone
Nitrobenzene
2-Nitrophenol
4-Nitrophenol
2,4-Dinitrophenol
4,6-Dinitro-o-cresol
N-Nitrosodimethylamine
N-Nitrosodiphenylamine
N-Nitrosodi-n-propylamine
Pentachlorophenol
Dimethyl phthalate
Benzo(a)pyrene
3,4-Benzo fluoroanthene
Acenaphthylene
1,1,2-Benzoperylene
Fluorene
1,2,5,6-Dibenzanthracene
Ideno(l,2,3-cd)pyrene
Tetrachloroethylene
Vinyl chloride
Aldrin
Dieldrin
Chlordane
4,4-DDT
4,4-DDE
4,4-DDD
Alpha-endosulfan
Beta-endosulfan
Endosulfan sulfate
Endrin
Endrin aldehyde
Heptachlor
Heptachlor epoxide
Alpha-BHC
Beta-BHC
Gamma-BHC
Delta-BHC
PCB-1242
PCB-1254
PCB-1221
PCB-1232
PCB-1248
PCB-1260
PCB-1016
Toxaphene
Antimony
Chromium, hexavalent
Selenium
Thallium
TCDD
Boron
Cobalt
Fluoride
Gold
Platinum
Yttrium
Date: 8/31/82 R Change 1 II.8.8-20
-------
TABLE 8.8-16. EFFLUENT CHARACTERISTICS FOR ONE PLANT IN THE DIAZO
SOLVENT SUBCATEGORY (VESICULAR FILM), PLANT 04046
[2-24].
Pollutant
Toxic pollutants, yg/L
Toxic organics
Benzene
1 , 2-Dichloroethane
Hexachloroe thane
Ethylbenzene
Methylene chloride
Naphthalene
Phenol
Di-n-butyl phthalate
Benzo (a) anthracene
Toluene
Trichloroethylene
Metals and inorganics
Antimony
Cadmium
Chromium
Copper
Cyanide
Lead
Mercury
Nickel
Silver
Thallium
Zinc
Classical pollutants, mg/L
Ammonia
BOD
COD
Oil & Grease
TOC
TSS
Phenols
Cobalt
Iron
Manganese
Phosphorus
Thiocyanate
Concentration
0.1
ND
ND
ND
ND
ND
ND
10
ND
ND
ND
770
2
42
760
20
ND
ND
ND
ND
ND
17
0.6
35
99
10
65
ND
0.008
ND
0.19
ND
11
2.2
Analytic methods: V.7.3.14, Data sets 1, 2.
ND, not detected.
Date: 9/25/81 II.8.8-25
-------
TABLE 8.8-IT.
EFFLUENT CHARACTERISTICS FOR ONE PLANT
SUBCATEGORY (a) [2-2U]
IN THE PHOTOCHEMICAL
Pollutant
Number of
samples
Number of
detections
Plant 2300k
Range of
detections
Mean of
detect ions
Median or
detect ions
Toxic pollutants, ug/L
Metals and Inorganics
Antimony 3
Arsenic 3
Beryllium 3
Cadmium 3
Chromium 3
Copper 3
Lead 3
Mercury 3
Nickel 3
Silver 3
Tha11i urn 3
Zinc 3
Classical pollutants, mg/L
BOD 3
COO 3
10 * 10
10 - 10
2-2
BDL - BDL
5-50
19 - 27
BOL - 18
If - 6
50 - 50
I - I
5-5
50 - 70
38 - 56
67 - 160
10
10
2
BDL
20
24
12
5
50
I
5
63
100
10
10
2
BDL
5
25
12
5
50
I
5
68
39
77
Analytic methods: V.7.3.IU, Data sets I, 2
BDL, below detection limit.
(a) Also see Plant 30927 on Table 8.8-12.
TABLE 8.8-18.
EFFLUENT CHARACTERISTICS FOR ONE PLANT IN THE THERMAL
PRODUCTS SUBCATEGORY [2-2U]
Pollutant
Number of
samples
Number of
detections
Plant 30QI4
Range of
detections
Mean of
detections
Toxic pollutant, ug/L
Toxic oroanlcs
Benzene
Phenol
Bis(2-ethylhexyl)phthai ate
Butyl benzyl phthai ate
Di-n-butyl phthalate
Diethyl phthalate
To Iuene
T rIchIoroethyIene
inorganics
Metals and
Cadmium
Chromium
Copper
Lead
S iIve r
Zinc
Classical pollutant, mg/L
BDL
I - I
I - 37
I - I
I - 5
60 - 390
BDL - BDL
55
I 10
l»,600 - l»,700
l»0
7-11
1,000
I
19
I
3
230
BDL
l»,600
9
Ammon i a
BOD
COD
TOC
TSS
Pheno 1 s
Iron
Manganese
Phosphorus
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
0.22 - 0.33
16,000 - 18,000
21,000 - 1(14,000
3,900 - 8,200
3-7
0.021 - 0.67
2 - 2.8
0.008 - 0.019
1.2 - 1.9
0.28
17,000
32,000
6, 100
5
0.31*
2.l»
O.OH4
1.6
Analytic methods: V.7.3.14, Data sets I, 2.
BDL, below detection limit.
Date: 8/31/82 R Change 1 II.8.8-26
-------
pressed together between a fixed end and a traveling end. On the
surface of each plate is mounted a filter made of cloth or a
synthetic fiber. The feed stream is pumped into the unit and
passes through holes in the trays along the length of the press
until the cavities or chambers between the trays are completely
filled. The solids are then entrapped, and a cake begins to form
on the surface of the filter material. The water passes through
the fibers, and the solids are retained.
Maintenance consists of periodic cleaning or replacement of the
filter media, drainage grids, drainage piping, filter pans, and
other parts of the system. If the removal of the sludge cake is
not automated, additional time is required for this operation.
Pressure filtration is a commonly used technology that is cur-
rently utilized in a great many commercial applications. It is
used for sludge dewatering in three photographic manufacturing
plants and for purifying process, or non-process, wastewater at
two other plants.
Vacuum filtration. In the wastewater treatment plants,
sludge dewatering by vacuum filtration is an operation that is
generally accomplished on cylindrical drum filters. These drums
have a filter medium which may be cloth made of natural or syn-
thetic fibers, coil springs, or a wire-mesh fabric. The drum is
partially submerged in a vat of sludge. As the drum rotates
slowly, part of its circumference is subject to an internal
vacuum that draws sludge to the filter medium. Water is drawn
through the porous filter cake to a discharge port, and the
dewatered sludge, loosened by compressed air, is scraped from the
filter mesh. Because the dewatering of sludge on vacuum filters
is relatively expensive per kilogram of water removed, the liquid
sludge is frequently thickened prior to processing. Vacuum
filtration is used in photographic manufacturing for dewatering
sludge.
Date: 8/31/82 R Change 1 II.8.8-33
-------
-------
TABLE 8.10-8.
EFFLUENT CONCENTRATIONS (3-DAY AVERAGE) OF
POLLUTANTS FOUND IN STEEL SUBCATEGORY PLANTS,
VERIFICATION DATA [2-55]
Plant Identification
Pollutant, yg/L
Aluminum
Antimony
Arsenic
Cadmium
Chromium
Cobalt
Copper
Fluoride
Iron
Lead
Manganese
Nickel
Phenols, Total
Phosphorus
Selenium
Titanium
Zinc
Oil and grease
TSS
pH, pH units
40053(a)
190
ND
12
22
52
930
250,000
ND
910
2,700
24
11,000
ND
ND
140
51,000
2.1 - 3.2
41062(b)
2,100
ND
75
10
ND
13
2,300
240
ND
BDL
14
36
770
ND
160
230
1,700
11,000
8.1 - 9.1
36030(b)
130,000
9,700
550
630
32,000
3,500
58,000
630,000
3,500
51,000
29,000
3,600
590
660,000
180,000
Analytic methods: V.7.3.16, Data set 2.
Blanks indicate data not available.
ND, not detected.
BDL, below detection limit.
(a) In-place treatment not available.
(b) In-place treatment consists of clarification/settling.
Date: 8/31/82 R Change 1
II.8.10-19
-------
settling, pH adjustment with lime and/or acid, polyelectrolyte
coagulation, clarification, and contractor removal of the result-
ing sludge prior to discharge to a surface stream. Process water
flow for this production consists of 8.12 and 4.37 m3/hr for
surface preparation and coating operations respectively.
Table 8.10-9 gives the water use for each process in the pro-
duction of porcelain enameled aluminum for the above plants.
Pollutant concentrations for treated effluents are presented in
Table 8.10-10.
II.8.10.3.3 Porcelain Enameling on Cast Iron
Plant 15712
This facility produces 9.1 m2/yr of porcelain enameled cast iron.
Primary in-place treatment for process wastewater is clarifica-
tion, settling, and skimming.
Plant 40053
This facility is involved with porcelain enameling on both steel
and cast iron. Data presented in Table 8.10-12 are for the
coating on cast iron subcategory only.
Table 8.10-11 gives the water use for each process in the pro-
duction of porcelain enameled cast iron for the above plants.
Pollutant concentrations in the treated effluent are presented in
Table 8.10-12.
II.8.10.3.4 Porcelain Enameling on Copper
Plant 36030
This facility enamels both copper and steel. It uses 0.042 m3
water/m2 product in all coating operations. Process wastewater
flow is 0.466 m3/hr for metal preparation and 1.69 m3/hr for
coating and ball milling. The production rate for porcelain
enameling on copper is 10 m2/hr for 4,000 hrs/yr. Primary in-
place treatment is clarification and settling.
Table 8.10-13 gives the water use for each process in the pro-
duction of porcelain enameled copper for two plants. Pollutant
concentrations in the treated effluent are given in Table 8.10-14.
II.8.10.4 POLLUTANT REMOVABILITY [2-25]
Treatment technologies used in the Porcelain Enameling Industry
are generally chosen to remove the major wastewater components:
suspended solids and toxic metals. Table 8.10-15 presents a
summary of the treatment and disposal techniques used by this
industry. Usually more than one treatment method is used at each
facility.
Date: 8/31/82 R Change 1 II.8.10-20
-------
D
{a
ft
00
\
OJ
00
S)
TABLE 9.2-5. RAW WASTE CHARACTERISTICS OF TOXIC POLLUTANTS FOUND IN THE FORMULATION
AND PACKAGING OF BLASTING AGENTS, DYNAMITE, AND PYROTECHNICS,
VERIFICATION DATA [2-29]
O
tr
(D
H
Hetalt and, Inorganics
Ant loony
Copper
Cyan Id*
Lead
Hick. I
Silver
Zinc
Oraanfc |
0U(2-ethylhexyl J phthalate
Dl-n-octyl phthalete
Pesticide* and Metabolites
Itophorone
Metals and Inoroa,n1cf
AntlMOny
Copper
Cyanide
Lead
Nickel
Silver
Zinc
Organic.*
ei<(2-ethylhexyl) phthalate
Ol-n-octyl phthalate
Phenol
Pe*tlclde» and •etabolltea
Isophorone
NiMber Huvber Average Had (an HaxlMM
or of or or or
AMFO
1 0
2 Z UTO 9*0
1 1 l«
« 1 110
1 1 100
I 0
II 1 720 7«0 l.tOO
2 2 6> 70
1 0
1 1 10
2 1 20
1 1 2
2 2 70 120
Muobar
of
1
1
2
2
2
1
1
1
1
1
1
1
1
1
Miwbflr Avcng* HedUn
or or or
Slurry
1 J50
1 10
2 1,100 2,600
2 50 >0
2 510 9«0
0
«. .
1 17
1 150
0
0
1 15
1 72
0
1 1$
Hu«b«r MiMbflr Concantritlon
or or or
Dvn»lu
1 1 10
II 10
1 1 1 , *00
HO, not detected.
Blanki Indicate pollutant not analyzed.
-------
rt
(D
to
U1
00
TABLE 9.2-6. RAW WASTE CHARACTERISTICS OF CLASSICAL POLLUTANTS FOUND IN THE
FORMULATION AND PACKAGING OF BLASTING AGENTS, DYNAMITE, AND
PYROTECHNICS, VERIFICATION DATA [2-29]
H
H
VD
1
N>
Pol lutant. mq/L
BODS
COD
TSS
TKN
01 1 and grease
TDS
NH3-N
N03-N
BODS
COD
TSS
TKN
Oi 1 and grease
TDS
NH3-N
N03-N
Number
of
samples
1
1
1
1
1
1
1
1
2
2
1
2
1
2
2
Number
of
detections
1
1
1
1
1
1
1
1
2
2
1
2
1
2
2
ANFO
Average Maximum
of of
detections detections
3, 100
2,700
1, 100
11), 000
1,300
80,000
12,000
20,000
Dynamite
6 8
18 20
8
1)1 1)5
320
33 33
25 27
Number
of
samp les
2
3
3
3
3
3
3
Number
of
detections
2
3
3
3
3
3
3
Slurry
Average
of
detections
6, 100
5,900
940
l),700
19,000
3,500
5,900
Med ian
of
detections
l),000
820
5,800
18,000
4,900
7,800
Max i mum
of
detections
9,900
14,000
2,000
8,200
38,000
5,600
9,200
Ammonium nitrate
1
3
3
3
3
1
3
3
3
3
90
69
250
160
1)80
27
97
83
100
170
580
350
1,200
Analytic nethods:V.7.3.18, Data set 2.
Blanks indicate pollutant not analyzed.
-------
areas. Dilution may be necessary for wastewaters with very high
nitrogen content.
Biological Treatment
Biological treatment is used at one plant to handle wastewater
from several sources. Slurry plant wastewater is combined with
explosives manufacturing plant wastewater for a combined flow of
approximately 150 m3/day (40,000 gpd). The water is treated in a
diffused-air, extended aeration, activated sludge treatment
system. Based on verification data from this plant, cyanide and
ammonia nitrogen levels were reduced more than 90% and nitrate
nitrogen increased from 900 mg/L to 1,400 mg/L.
Other combined wastewater treatment systems include septic tanks
and facultative ponds.
Solids Separation
Suspended solids are found at various levels in wastewater from
slurry and dynamite plants. Dynamite wastewater has very small
particles which originate from the airborne dust collected by the
wet scrubbers. Slurry wastewater generally contains larger
particles, such as granular aluminum or glass microspheres.
Small settling ponds, air flotation, and continuous paper belt
filter are three methods used to remove these solids from the
wastewater. Another method uses caustic to dissolve the aluminum
present, then neutralizes the treated wastewater to convert the
paint grade aluminum in the raw wastewater to a settleable sludge.
The sludge is then recovered and reused.
Alternative Technologies
Several potential technologies for treating industrial wastewater
containing high levels of ammonium and nitrate nitrogen have been
studied. These technologies include biological processes in-
volving a variety of process configurations, and physical/chemical
unit processes, such as reverse osmosis, ammonia stripping, and
ion exchange. Break point chlorination and electrodialysis have
also been suggested.
Date: 8/31/82 R Change 1 II.9.2-17
-------
-------
II.9.3 GUM AND WOOD CHEMICALS
II.9.3.1 INDUSTRY DESCRIPTION
II.9.3.1.1 General Description [2-30]
The Gum and Wood Chemicals Industry in the United States (SIC
Code 2861) consists of establishments primarily engaged in manu-
facturing hardwood and softwood distillation products, wood and
gum naval stores, charcoal, natural dyestuffs, and natural tanning
materials. It does not include establishments primarily engaged
in manufacturing synthetic 'tanning materials and synthetic organic
chemicals, or those engaged in the production of synthetic organic
dyes; rather, these establishments are included within SIC Codes
2869 and 2865, respectively.
Some materials produced by this industry, such as rosins, may be
further processed into materials classified under different SIC
codes. Those cases in which materials change classifications
within the same plant are included in this description. Excluded
are those cases where materials are purchased from one plant for
processing at a different plant into a product with a different
SIC code.
Table 9.3-1 summarizes pertinent information regarding the number
of subcategories, the number of subcategories studied by Effluent
Guidelines Division, and the number and type of dischargers in
the Gum and Wood Chemicals Industry.
TABLE 9.3-1. INDUSTRY SUMMARY [2-1,30]
Industry: Gum and Wood Chemicals
Total Number of Subcategories: 7
Number of Subcategories Studied: 4
Number of Dischargers in Industry: 23
• Direct: 14
• Indirect: 6
• Zero: 3
Date: 8/31/82 R Change 1 II.9.3-1
-------
Best Practicable Technology (BPT) limitations currently promul-
gated for each subcategory are presented in Table 9.3-2. Limita-
tions on the sulfate turpentine subcategory have been proposed
but not promulgated.
TABLE 9.3-2. BPT LIMITATIONS FOR THE GUM AND WOOD CHEMICALS
MANUFACTURING INDUSTRY [2-31]
Concentration. kq/Mq of product
BOD5 . TSS
Daily 30-day Daily 30-day
Subcategory maximum average(a) maximum average(a) pH
Char and charcoal briquets No discharge of process wastewater pollutants
to navigable waters
Gum rosin and turpentine
Wood rosin, turpentine, and pine oil
Tall oil rosin, pitch, and fatty acids
Essent ia 1 oils
Rosin-based derivatives
1.1
2. 1
0.99
23
1 .4
0.76
1 . 1
0.53
12
0.75
0.08
1.4
0.70
9
0.04
0.03
0.48
0.24
3. 1
0.02
6.0-9.0
6.0-9.0
6.0-9.0
6.0-9.0
6.0-9.0
(a)Computed from average daily values taken over 30 consecutive days.
II.9.3.1.2 Subcategory Descriptions
The modern Gum and Wood Chemicals Industry is grouped into the
following major areas:
(1) Char and charcoal briquets
(2) Gum rosin and turpentine
(3) Wood rosin, turpentine, and pine oil
(4) Tall oil rosin, fatty acids, and pitch
(5) Essential oils
(6) Rosin derivatives
(7) Sulfate turpentine
Three of the seven Gum and Wood Chemicals subcategories (char and
charcoal briquets, gum rosin and turpentine, and essential oils)
have been submitted for exclusion of BAT, NSPS, and pretreatment
standards for all specific toxic pollutants on the basis of Para-
graph 8 of the NRDC Consent Decree. These subcategories are
described herein; however, no wastewater characterizations are
presented.
Char and Charcoal Briquets
Eighty plants, primarily concentrated in the eastern section of
the country, have been identified in the char and charcoal indus-
try. Char is produced from the destructive distillations of
Date: 8/31/82 R Change 1 11.9.3-2
-------
Exclusion of BAT, NSPS, and pretreatment standards has been
recommended for all specific toxic pollutants on the basis of
Paragraph 8. The subcategory includes seven plants, none of
which is a direct discharger; one is an indirect discharger and
the remaining six have no discharge. Flows of process wastewater
in this subcategory are low (a maximum flow of 57 m3/d from the
indirect discharger under full-scale production). The only toxic
pollutants detected during screening of the indirect discharger
were benzene and metals, and all were at low levels.
Rosin Derivatives
Rosin derivatives are not included in SIC 2861, Gum and Wood
Chemicals, but in SIC 2821, Plastics and Synthetic Materials.
Derivatives production is a natural extension of processing in
gum and wood chemicals plants since the rosin is available in the
plants. This industry description is applicable only to those
derivative operations which are located within, and in conjunc-
tion with, gum and wood chemicals facilities. Another deriva-
tives operation that occurs in gum and wood chemicals plants is
terpene derivatives. Derivative products include ink resins,
paint additives, paper size, oil additives, adhesives, wetting
agents, chewing gum base, and chemical-resistant resins.
Sixteen gum and wood chemicals plants currently are producing
rosin or terpene derivatives. These plants are located within
all four types of rosin-producing plants.
Process operating conditions in the reaction kettle are dependent
on product specifications, raw materials, and other variables. A
simple ester is produced under high temperature vacuum conditions.
A steam sparge is used to remove excess water of esterification,
and the condensable impurities are condensed in a noncontact
condenser on the vacuum leg and stored in a receiver. Noncon-
densables escape to the atmosphere through the reflux vent and
steam vacuum jets.
Wastewater is developed from the chemical reaction and separation
of product.
Sulfate Turpentine
Sulfate turpentine was originally considered to be a waste product
in the kraft pulp and paper process. However, modern technology
allows it to be profitably recovered by a distillation process to
such an extent that sulfate turpentine is the major source of
turpentines in the Gum and Wood Chemicals Industry.
During the distillation of sulfate turpentine, the first tower is
usually used to strip odor-causing mercaptans from the turpen-
tine. Subsequent fractionation breaks the turpentine into its
major components: a-pinene, B-pinene, dipentene, camphene, and
Date: 9/25/81 II.9.3-5
-------
sulfated pine oil.
The distillation of sulfate turpentine is an intermediate produc-
tion step. The operations are usually batch reactions that take
place in reaction kettles in the presence of some organic solvent
and metal catalyst. The catalyst and solvent used depend on the
type of products required. There are approximately 200 products
produced in this area.
Wastewater usually is generated from the condensation in the
distillation tower and from washdown of reactors.
II.9.3.1.3 Wastewater Flow Characterization [2-30]
The volume of Wastewater produced by the plants in the Gum and
Wood Chemicals Industry ranges from 19 to 7,310 m3/d. Discharge
flow rates for each subcategory are difficult to quantify because
most plants have combined processes' that fall under several dif-
ferent subcategories, and all process wastewater typically is
discharged to a common sewer. Although total plant flow can be
determined from this discharge pipe, a breakdown into components
from each process is not possible. Wastewater flows have been
tabulated in Table 9.3-3 for each plant, and grouped according to
the processes within the plant.
TABLE 9.3-3. TABULATED WASTEWATER FLOWS BY PLANT [2-30]
Subcate-
qories(a )
G
G,F
G,C,F
G,D,F
B,F
C
C,F
D,F
D
Plant
No.
009
885
159
571
222
743
993
485
934
242
334
244
714
660
454
040
049
759
436
590
Di scharge
type
Ind i rect
1 nd i rect
Di rect
1 nd i rect
1 nd i rect
Di rect
(b)
1 nd i rect
Di rect
Di rect
Di rect
Di rect
(b)
1 nd i rect
(b)
(b)
(b)
Di rect
Di rect
(b)
Production,
kq/d
57,600
86,300
45,300
218,000
464,000
209,000
467,000
45,400
48, 100
336,000
199,000
139,000
192,000
69,000
306,000
227,000
270,000
163,000
152,000
193,000
Wastewater
flow, cu.m/d
273
1,230
4,470
2,200
1,750
682
3,830
19
587
7,310
3,030
636
2,020
186
447
3,410
1,330
158
2,270
984
(a)B = gum rosin and turpentine; C = wood rosin, turpentine,
and pine oil; D = tall oil rosin, pitch, and fatty acid;
F = rosin- and terpene-based derivatives; G = sulfate
turpent i ne.
(b)Plant discharges into the waste treatment system of another
plant.
Date: 8/31/82 R Change 1 II.9.3-6
-------
II.9.3.2 WASTEWATER CHARACTERIZATION [2-30]
Wastewater characteristics for the Gum and Wood Chemicals Indus-
try demonstrate that,organic solvents are generally the most
prevalent pollutants. These solvents are used in the extraction
processes across all subcategories. Some heavy metals have been
listed as natural components of the raw materials (e.g., tree
stumps) that are utilized in this industry.
Due to the nature of the Gum and Wood Chemicals Industry, there
is a great deal of overlap among the various subcategories. Al-
though the subcategories were defined according to the principal
product(s) peculiar to a set group, most of the plants within a
subcategory secondarily produce products which are primary to
another subcategory. The resulting overlap makes separation of
available data relative to specific pollutants difficult to
achieve.
Wastewater sampling of screening protocol was conducted to
determine the presence of the 129 priority pollutants. Those
pollutants detected were further analyzed in a verification
program. The following tables present the results of the veri-
fication program. The minimum detection limit for toxic pollut-
ants is 10 yg/L and any value below 10 yg/L is presented in the
following tables as BDL, below detection limit.
II.9.3.2.1 Wood Rosin, Turpentine, and Pine Oil
Principal toxic pollutants observed were some organic solvents
(particularly toluene), chromium, and zinc. Benzene and ethyl-
benzene, which were frequently observed in sampling, are not used
directly in the production of gum and wood chemicals, but are
major contaminants of the two solvents - toluene and xylene,
respectively -that are commonly used in the industry. Chloroform
and methylene chloride were found in raw and treated wastewaters
in each subcategory. These compounds were not used in the indus-
try processes, but are common solvents found in laboratories.
Although methylene chloride was found at relatively high levels,
it is unclear what the actual waste stream concentrations are due
to possible contamination from outside sources. Classical pollut-
ants of concern are BOD and COD.
Of the five plants that process wood stumps for their extractable
components, only one has segregated wood rosin waste streams (the
remaining plants have multiprocess wastestreams). The multi-
process streams could not be used to characterize the wastewater
from this subcategory; thus, Tables 9.3-4 and 9.3-5 present con-
centrations of toxic and classical pollutants for the wood rosin,
turpentine, and pine oil subcategory based on sampling conducted
at one plant.
Date: 9/25/81 II.9.3-7
-------
TABLE 9.3-4.
CONCENTRATIONS OF TOXIC POLLUTANTS FOUND IN
VERIFICATION SAMPLING OF WOOD ROSIN, TURPENTINE,
AND PINE OIL SUBCATEGORY WASTEWATER [2-30]
Toxic pollutant, yg/L Intake(a)
Raw Treated
wastewater(b) effluent(c)
Metals and inorganics
Arsenic
Chromium
Copper
Lead
Zinc
Monocyclic aromatics
Ethylbenzene
Toluene
1,500
33
15
160(e)
50
(d)
17(e)
110
16(f)
27
10(f)
Halogenated aliphatics
Chloroform 20
Methylene chloride(g) 910
190
340
Analytic method: V.7.3.19, Data set 2.
(a)Process makeup water—well water.
(b)Influent to equalization basin; one sample.
(c)From aerated and settling lagoon; average of three samples.
(d)Indeterminate because of high organic compound loading.
(e)Average of two samples.
(f)One sample.
(g)Concentrations presented are suspect due to possible contam-
ination.
TABLE 9.3-5.
CONCENTRATIONS OF CLASSICAL POLLUTANTS
FOUND IN WOOD ROSIN, TURPENTINE, AND PINE
OIL SUBCATEGORY WASTEWATER [2-30]
Pollutant,mg/L Intake(a)
Raw
wastewater(b)
Treated
effluent(c)
BOD 5
COD 11
Suspended solids
Total phenols 0.12
Oil and grease
1,500
1,200
240
0.46
22
230
55
0.09(d)
12(e)
Analytic methods: V.7.3.19, Data set 2.
(a)Process makeup water—well water.
(b)Influent to equalization basin; one sample.
(c)From aerated and settling lagoon; average of three
samples.
(d)Average of two samples.
(e)One sample.
Date: 8/31/82 R Change 1 II.9.3-8
-------
TABLE 9.3-9. CONCENTRATIONS OF CLASSICAL POLLUTANTS
FOUND IN ROSIN DERIVATIVES SUBCATEGORY RAW
WASTEWATER, VERIFICATION DATA [2-30]
Pollutant, mg/L
Raw Treated
Intake wastewater effluent
BOD 5
COD
Suspended solids
Total phenols
Oil and grease
450
40,000
87
46
150
1,300
31,000
71
41
92
38,000
70
53
62
Analytic method: V.7.3.19, Data set 2.
Values not blank adjusted.
II.9.3.2.4 Sulfate Turpentine
Three plants that fractionate sulfate turpentine were sampled.
Mean concentrations of two of the three plants' wastewaters were
used to determine the values in Tables 9.3-10 and 9.3-11, since
the waste stream from one plant is very different from those of
the other two. Waste streams differ based on the types of end
products manufactured by the various plants. The varying product
lines of the sulfate turpentine fractionators make this subcate-
gory very difficult to characterize.
II.9.3.3 PLANT SPECIFIC DESCRIPTION [2-30]
Tables 9.3-12 through 9.3-15 present toxic and classical pollut-
ant data for gum and wood chemical process plants. The data in
this section are based on the most current representative infor-
mation available from two of the plants contacted. Verification
sampling data are used to supplement historical data obtained
from the plants for the classical pollutants, and in most cases
are the sole source of quantitative information for toxic pollut-
ant raw waste concentrations.
II.9.3.4 POLLUTANT REMOVABILITY [2-30]
II.9.3.4.1 Industry Application
A matrix of the current in-place treatment technology in the Gum
and Wood Chemicals Industry is shown in Table 9.3-16. Many of
the direct dischargers have primary treatment in place at this
time. Pretreatment processes used by indirect dischargers depend
on the requirements of the receiving treatment works. Six in-
direct dischargers discharge their wastewater to POTW's. Six
plants discharge their wastewater to the waste streams of other
industries such as pulp and paper mills. The plants that dis-
charge to POTW's have treatment equipment to meet POTW require-
Date: 8/31/82 R Change 1 II.9.3-11
-------
TABLE 9.3-10.
CONCENTRATIONS OF TOXIC POLLUTANTS FOUND IN SULFATE
TURPENTINE SUBCATEGORY WASTEWATER( a) [2-30]
Toxic pollutants. uq/L
I ntake
Raw wastewater
Treated effluent
Arsenic
Chromium
Copper
Lead
Nickel
Se len ium
Zinc
Bi s(2-ethylhexy 1 ) phthalate
Phenol
Benzene
To 1 uene
Ch lo reform
Methylene chloride
I20(b)
250(b)
36(b)
7<4(b)
480
62
540
2,800
15
1,300
280
450(b)
I40(b)
1,600
1, I00(b)
3,600
76(b)
U50
2,800
15
U50
I9(b)
310
l,900(b)
850(b)
200
9UO
1, I00(b)
1,600
Analytic methods: V.7.3.19, Data set 2.
Values not blank adjusted.
(a)Data compiled from two plants whose
sulfate turpentine. Values are the
(b)Data available for one plant only.
major processing effort was fractionating
mean of the averages for each plant.
TABLE 9.3-11.
CONCENTRATIONS OF CLASSICAL POLLUTANTS FOUND IN SULFATE
TURPENTINE SUBCATEGORY WASTEWATER [2-30]
Classical pollutants. mg/L
BOD5
COD
Suspended So 1 ids
Total phenols
Oil and grease
1 ntakef a )
17
0.023
Raw
wastewaterfa )
2,200
8,200
160
1 .7
260
Treated
effluentf
2, 100
5,600
220
3.8
3 10
a)
Analytic method: V.7.3.19, Data set 2.
(a)Data compiled from two plants whose major processing effort was frac-
tionating sulfate turpentine. Values are the mean of the averages
for each plant.
Date: 8/31/82 R Change 1 II.9.3-12
-------
•TABLE 9.3-17.
SECONDARY TREATMENT FEED AND EFFLUENT ANALYSIS
AND PERFORMANCE DATA FOR PLANT 102 GRANULAR
ACTIVATED CARBON SYSTEM [2-30]
Item
Design
12,300 m3/d (3.24 MGD)
COD
TOC
BOD
Startup period
9,810 m3/d (2.59 MGD)
COD
TOC
Typical operation
9,810 m3/d (2.59 MGD)
COD
TOC
Selected samples
9,810 m3/d (2.59 MGD)
BOD
Phenols
Ni
Zn
Cd
Cu
Cr
TS
SS
DS
Chlorides
NO 2
Oil and grease
Concentration
, mg/L
Influent Effluent
600
160
250
980
220
750
200
300
4.7
1.0
1.1
0.9
1.3
1.1
1,200
81
1,100
1.8
5.2
28
130
30
50
150
46
160
42
82
0.58
0.33
0.29
0.22
0.36
0.26
970
13
950
0.84
4.3
2.2
Percent
reduction
78
81
80
85
79
79
79
73
88
67
74
76
72
76
19
84
14
53
17
92
Removal,
kg/ day
5,800
1,600
2,400
8,100
1,600
5,800
1,600
2,100
40
6.8
8.2
6.8
9.1
8.6
2,400
680
1,700
8.6
8.6
250
Date: 8/31/82 R Change 1 II.9.3-19
-------
As indicated in Table 9.3-19, the toxic pollutants found at plant
102 were benzene, toluene, phenol, and bis(2-ethylhexyl) phthalate
The bis(2-ethylhexyl) phthalate was found only in the effluent of
the carbon adsorption unit.
Evaporation
Due to the significant volumes of plant wastewater generated,
evaporation is not a feasible or widely used technology in the
Gum and Wood Chemicals Industry for achieving no-discharge status.
However, it may be applicable for disposal of specific, high
strength, low volume, process waste streams.
TABLE 9.3-18. TYPICAL TOTAL TREATMENT SYSTEM PERFORMANCE
DATA(a) [2-30]
Parameter
COD
TOC
BOD
TSS
Oil and grease
Raw waste-
water,
mg/L
3,200
1,200
1,600
320
500
Primary
treated
effluent,
mg/L
670
200
270
72
25
Secondary
treated
effluent,
mg/L
140
37
73
12
2
Overall
reduction,
%
96
97
95
96
99
(a)Data represent the total performance of an oil-water separation,
neutralization, dissolved air flotation, filtration, and granular
activated carbon(see Table 9.3-17) system at 9,810 m3/d (2.5 MOD).
TABLE 9.3-19. REMOVAL OF ORGANIC PRIORITY POLLUTANTS FOR
PLANT 102 ACROSS ACTIVATED CARBON COLUMN
[2-30]
Sample prior toSample after carbon column
Pollutant, yg/L carbon column Day 1 Day 2 Day 3
Benzene 590 130 200 300
Toluene 2,500 180 400 1,300
Phenol 120 49
Bis(2-ethylhexyl)
phthalate 400 260
Blanks indicate data not available.
Date: 8/31/82 R Change 1 11.9.3-20
-------
o
fl)
ft
(D
oo
\
U)
oo
rO
O
TABLE 9.5-13.
CLASSICAL POLLUTANT REMOVABILITY AT
AND VERIFICATION DATA [2-32]
SELECTED PHARMACEUTICAL PLANTS(a), SCREENING
Subca-
teqory
A
C
C
AC
BC
BD
BCD
ACD
CD
AD
BOD
Concent ral
Raw
Plant wastewater
I2162(b)
I2026(b)
12236(0)
I2l32(b)
I22l0(b)
1 24201 b)
121 ll(c)
I2l6l(b)
I2097(c)
I2036(b)
1,000
1,1400
1, 100
2, 100
27
3,200
1,500
1,000
2,500
1,900
tion. aa/L
Treated
effluent
160
350
140
250
1 10
200
290
61
210
35
Percent
remova 1
81
75
87
88
NM
914
81
91
92
98
COD
Concent rat
Raw
wastewater
1,700
2,100
2,300
1,600
360
5, 100
3,000
3,200
1,200
ion. mq/L
Treated
effluent
1,300
160
630
1,700
610
3. 100
780
110
260
Percent
remova 1
72
93
73
63
NM
39
71
87
91
TSS
Concentrat
Raw
wastewater
960
620
620
30
NO
100
97
810
:lon. mq/L
Treated
effluent
1,000
120
120
90
190
88
10
19
Percent
remova 1
NM
81
81
NM
NM
78
90
91
Blanks Indicate data not available.
NO, not detected.
NM, not meaningful.
(a)See Table 9.5-lk for treatment operations at these plants.
(b{screening data.
(c)Verification data.
TABLE 9.5-14. TREATMENT OPERATIONS AT SELECTED PLANTS [2-32]
H
Plant
12162
12026
12236
12132
12210
12120
1211 1
1 2 1 6 1
Wastewater
conditionino
Equa 1 izat Ion,
neutra 1 izat ion
Equa 1 izat ion,
neutral izat ion
Equa 1 izat ion,
neutra 1 izat ion
Equa 1 izat ion,
neutra 1 ization
neutra 1 izatton
Treatment system
Act ivated sludge,
aerated lagoon
Act ivated sludge,
aerated lagoon,
pol i shing pond
primary sedimentation,
activated sludge
wi th pure oxygen
Coarse settleable solids
removal, primary sedi-
mentation, activated sludge
Aerated lagoon
Activated sludge
Ae ra ted lagoon
removal, primary sedimenta-
tion, activated sludge,
pol i shing pond
Sludge
t re a tment
Anaerobic digestion
Flotation thickening,
chemica 1 conditioning,
vacuum f i 1 trat Ion
Aerobic digestion,
phys./chem. : evapo-
ration, drying beds
Chem i ca 1 cond i t i on i ng ,
centri fuga 1 dewatering
Grav i ty dewa te r i ng
thickening
Disoosal
Sludge haul ing
Landf i 1 1
Sludge haul ing
Landfill
Incineration
La nd f i 1 1 ,
cropland use,
composting
12036
Coarse settleable solids
removal, secondary chemical
flocculation/clarii fication,
activated sludge with powdered
activated carbon
Activated sludge,
trickl ing f i I ter,
aerated lagoon,
waste stabilization
pond, polishing pond
ChemicaI cond i tioning,
chemical stabiIization,
vacuum fiItration,
phys./chem. evaporation
Aerobic digestion
Cropland use
-------
Table 9.5-13 presents classical pollutant removability and re-
spective treatment for 10 plants grouped according to manufac-
turing subcategory combinations. These data are from screening
and verification studies. Table 9.5-14 presents the respective
treatment operations for these selected plants.
Date: 8/31/82 R Change 1 II.9.5-20
-------
There are several potential treatment technologies that may be
applicable, but are more expensive than the methods currently
used. These potential treatments are: sulfide precipitation,
ultrafiltration, reverse osmosis, deep-well disposal, activated
carbon adsorption or activated alumina adsorption, solidifica-
tion, or ion exchange.
Pollutant removal data for toxic organic pollutants in the sub-
categories studied are presented in Tables 10-32 through 10-41.
The average removal percentage was determined by comparing the
average raw wastewater concentrations found in the Wastewater
Characterization section with the average treated wastewater
concentrations presented in these tables. In some instances,
insufficient data were available to determine accurately an
average concentration. Removal data for toxic and classical
pollutants are presented on an individual facility basis in the
plant specific section.
Date: 8/31/82 R Change 1 11.10-35
-------
TABLE 10-32. REMOVABILITY OF TOXIC ORGANIC POLLUTANTS FROM RAW WASTEWATER
IN THE PRIMARY ALUMINUM SUBCATEGORY [2-35]
Toxic DOI lutant
Phtha lates
Bis(2-ethylhexyl ) phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Diethyl phthalate
Dimethyl phthalate
Di-n-octyl phthalate
Phenols
Phenol
Aromat ics
Benzene
2, M-D i n i t roto 1 uene
2,6-Dini trotoluene
Ethyl benzene
Toluene
Polycyolic aromatic hydrocarbons
Acenaphthene
Aconaph thy lene
Anthracene
Benzfa (anthracene
Benzol a )pyrene
Benzoj b )fl uoranthene
Benzojghi )perylene
Bonzoj k)f 1 uoranthene
Chrysene
D i be nz( ah) anthracene
FKioranthene
F 1 uorene
1 ndeno( 1 , 2, 3-cd Jpyrene
Naphtha lene
Phenanthrene
Pyrene
Haloqenated aliphatics
Chloroform
1 ,2-Dichloroethane
1 , l-Dichloroethylene
Methylene chloride
1, 1 ,2,2-Tetrachloroethane
Tet rach 1 oroethy 1 ene
Trichloroethy lene
Pesticides and metabolites
Aldrin
Del ta -BUG
Gamma-BHC
Ch 1 ordane
U,i4'-DDT
Dieldrin
Endrin a Idehyde
Heptach 1 o r
Heptachlor epoxide
1 sophorone
PCB I2i|8
PCB I25H
Number of
samo les
9
9
9
9
9
9
l»
lit
9
9
14
IU
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
9
14
114
in
m
IU
111
lit
8
8
8
8
8
8
8
8
8
9
8
8
Number of
detections
>IO ua/L
2
1
3
0
0
1
0
2
0
0
1
0
1»
0
2
0
0
0
1
0
1
0
5
0
0
0
2
3
2
0
1
6
0
1
1
0
0
0
0
0
0
0
0
0
0
0
0
Treated effluent
Concentration. ua/L
Range
ND - 120
ND - 75
ND - 30
ND
ND - 5
NO - 13
ND
ND - 33
ND - 7
ND - 1
ND - 12
ND - 6.8
ND - 13
ND - 7
ND - 1 1
ND - 6
ND - 8
ND - 6
ND - 1 1
ND - 6
ND - UtO
ND
ND - 79
ND - 1
ND - 1
ND - 1
ND - 1 1
ND - 80
ND - 320
ND - 5.5
ND - It, 100
ND - 4,200
ND - 1
NO - 61
ND - 120
ND - 0. 1
NO - 0. 1
ND - 0.01
ND - 0. 1
ND - 0.01
ND - 0. 1
ND - 0.2
ND - 0.2
ND - 0.2
ND
ND - O.U
ND - 0.2
Median
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
2.6
(b)
(b)
(b)
(b)
(b)
(b)
1 1
(b)
(b)
(b)
(b)
9
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
(b)
Mean
17
9.6
5
1
1.8
It
0.9
0. 1
0.8
0.5
5
1.9
l».7
0.7
2. 1
0.7
0. 1
1 . 1
17
22
0.2
0. 1
0. 1
(a)
20
23
0.14
290
360
0. 1
1*1»
8.5
(c)
(c)
(0)
(c)
(c)
(c)
(c)
(c)
(c)
(c)
(c)
(c)
Average
percent
remova 1
79
56
74
>99
NM
NM
>99
NM
NM
NM
NM
NM
HO
66
88
98
98
98
>99
97
58
>99
77
97
>99
97
NM
71
NM
NM
NM
NM
NM
NM
NM
NM
NM
Old)
NM
NM
NM
NM
NM
NM
>99
NM
NM
Analytic methods: V.7.3.22, Data sets 1,2.
Blanks indicate insufficient or conflicting data.
ND, not detected.
NM, not meaningful.
(a)Insufficient data to report concentration.
(bJNo median concentration was available in reference.
(c)No mean concentration was available in reference.
(d)Percent removal derived from the maximum raw and treated waste concentrations.
Date: 8/31/82 R Change 1 11.10-36
-------
11.11 ORE MINING AND DRESSING
II.11.1 INDUSTRY DESCRIPTION [2-37]
II.11.1.1 General Description
The Ore Mining and Dressing Industry is both large and diverse.
It includes the ores of 23 separate metals and is segregated by
the U.S. Bureau of the Census Standard Industrial Classification
(SIC) into nine major codes. This industry category includes
establishments engaged in mining ores for the production of
metals, and includes all ore dressing and beneficiating opera-
tions, whether performed at mills operating in conjunction with
the mines served or at mills operated separately. These include
mills which crush, grind, wash, dry, sinter, or leach ore, or
perform gravity separation or flotation operations.
As mined, most ores contain valuable metals, whose recovery is
sought, disseminated in a matrix of less valuable rock called
gangue. The purpose of ore beneficiation is the separation of
the metal-bearing minerals from the gangue to yield a product
that is higher in metal content. To accomplish this, the ore
must generally be crushed and/or ground small enough for each
particle to contain either the mineral to be recovered or mostly
gangue. Separation of the particles on the basis of some dif-
ference between the ore mineral and the gangue can then yield a
concentrate high in metal value, as well as waste rock (tailings)
containing very little metal. The separation is never perfect,
and the degree of success attained is generally described by two
parameters: (1) percent recovery, and (2) grade of the concen-
trate. Widely varying results are obtained in beneficiating
different ores; recoveries may range from 60% or less to greater
than 95%. Similarly, concentrates may contain less than 60% or
more than 95% of the primary ore mineral. In general, for a
given ore and process, concentrate grade and recovery are in-
versely related. (Higher recovery is achieved only by including
more gangue, yielding a lower grade concentrate.)
Many properties are used as the basis for separating valuable
minerals from gangue, including specific gravity, conductivity,
magnetic permeability, affinity for certain chemicals, solu-
bility, and the tendency to form chemical complexes. Separation
processes in general use are gravity concentration, magnetic
separation, electrostatic separation, flotation, and leaching.
Amalgamation and cyanidation, which are variants of leaching,
deserve special mention. Solvent extraction and ion exchange are
Date: 1/24/83 R Change 2 II.11-1
-------
widely applied techniques for concentrating metals from leaching
solutions, and for separating them from dissolved contaminants.
All of these processes are discussed in general terms in the
paragraphs that follow. This discussion is not meant to be all-
inclusive; rather, its purpose is to discuss the primary process-
es in current use in the ore mining and milling industry.
Gravity-concentration processes utilize the differences in den-
sity to separate valuable ore minerals (values) from gangue.
Several techniques (e.g., jigging, tabling, spirals, and sink/
float separation) are used to achieve the separation. Each is
effective over a somewhat limited range of particle sizes, the
upper bound of which is set by the size of the apparatus and the
need to transport ore within it, and the lower bound by the point
at which viscosity forces predominate over gravity and render the
separation ineffective. Selection of a particular gravity-based
process for a given ore will be strongly influenced by the size
to which the ore must be crushed or ground to separate values
from gangue, as well as by the density difference and other
factors.
Magnetic separation is widely applied in the ore milling indus-
try, both for the extraction of values from ore and for the
separation of different valuable minerals recovered from complex
ores. Extensive use of magnetic separation is made in the pro-
cessing of ores of iron, columbium, and tungsten. The separation
is based on differences in magnetic permeability (which, although
small, is measurable for almost all materials). This method is
effective in handling materials not normally considered magnetic.
The basic process involves the transport of ore through a region
of high magnetic field gradient. The most magnetically permeable
particles are attracted to a moving surface by a large electro-
magnet. The particles are carried out of the main stream of ore
by the moving surface and as it leaves the high field region the
particles drop off into a hopper or onto a conveyor leading to
further processing.
Electrostatic separation is used to separate minerals on the
basis of their conductivity. It is an inherently dry process
using very high voltages (typically 20,000 to 40,000 volts). In
a typical implementation, ore is charged to 20,000 to 40,000
volts, and the charged particles are dropped onto a conductive
rotating drum. The conductive particles discharge very rapidly,
are thrown off, and collected. The nonconductive particles keep
their charge and adhere by electrostatic attraction to be removed
from the drum separately.
Flotation is a process where particles of one mineral or group of
minerals are made by addition of chemicals to adhere preferen-
tially to air bubbles. When air is forced through a slurry of
mixed minerals, the rising bubbles carry with them the particles
of the mineral(s) to be separated from the matrix. If a foaming
Date: 1/24/83 R Change 2 II.11-2
-------
agent is added which prevents the bubbles from bursting when they
reach the surface, a layer of mineral laden foam is built up at
the surface of the flotation cell which may be removed to recover
the mineral. Requirements for the success of the operation are
that particle size be small, that reagents be compatible with the
mineral, and that water conditions in the cell not interfere with
attachment of reagents to the mineral or to air bubbles. Flota-
tion concentration has become a mainstay of the ore milling
industry. Because it is adaptable to very fine particle sizes
(less than 0.001 cm), it allows high rates of recovery from
slimes, which are inevitably generated in crushing and grinding
and which are not generally amenable to physical processing.
Ores can be leached by dissolving away either gangue or values in
aqueous acids or bases, liquid metals, or other special solu-
tions. The examples below illustrate various leaching possibil-
ities.
(1) Water-soluble compounds of sodium, potassium, and boron
can be mined, concentrated, and separated by leaching
with water and recrystallizing the resulting brines.
(2) Vanadium and some other metals form anionic species
that occur as insoluble ores. Roasting of such insolu-
ble ores with sodium compounds converts the values to
soluble sodium salts. After cooling, the water-soluble
sodium salts are removed from the gangue by leaching in
water.
(3) Uranium ores are only mildly soluble in water, but they
dissolve quickly in acid or alkaline solutions.
(4) Native, finely divided gold is soluble in mercury and
can be extracted by amalgamation (i.e., leaching with a
liquid metal). One process for nickel concentration
involves reduction of the nickel using ferrosilicon at
a high temperature and extraction of the nickel metal
into molten iron. This process, called skip-lading, is
related to liquid-metal leaching.
(5) Certain solutions (e.g., potassium cyanide) dissolve
specific metals (e.g., gold) or their compounds, and
leaching with such solutions immediately concentrates
the values.
In the amalgamation process, mercury is alloyed with some other
metal to produce an amalgam. The process is applicable to free
milling precious-metal ores, which are those in which the gold is
free, relatively coarse, and has clean surfaces. Lode or placer
gold/silver that is partly or completely filmed with iron oxides,
greases, tellurium, or sulfide minerals cannot be effectively
amalgamated. Hence, prior to amalgamation, auriferrous ore is
Date: 1/24/83 R Change 2 II.11-3
-------
typically washed and ground to remove any films on the precious-
metal particles. Although the amalgamation process has, in the
past, been used extensively for the extraction of gold and silver
from pulverized ores, it has, due to environmental considera-
tions, largely been superseded, in recent years, by the cyanida-
tion process.
In the cyanidation process, gold and/or silver are extracted from
finely crushed ores, concentrates, tailings, and low-grade mine-
run rock in dilute, weakly alkaline solutions of potassium or
sodium cyanide. The gold is dissolved by the solution and sub-
sequently adsorbed onto activated carbon ("carbon-in-pulp"
process) or precipitated with metallic zinc. The gold particles
are recovered by filtering, and the filtrate is returned to the
leaching operation.
Ion exchange and solvent extraction processes are used on preg-
nant leach solutions to concentrate values and to separate them
from impurities. Ion exchange and solvent extraction are based
on the same principle: polar organic molecules tend to exchange
a mobile ion in their structure [typically, Cl~ , N03 , HSOJ , or
COf (anions) or H+ or Na+ (cations)] for an ion with a greater
charge or a smaller ionic radius.
Table 11-1 presents industry summary data for the Ore Mining and
Dressing point source category in terms of the total number of
subcategories, the number of subcategories studied by EGD, and
the number and types of dischargers.
TABLE 11-1. INDUSTRY SUMMARY [2-1,37,38,39]
Industry: Ore Mining and Dressing
Total Number of Subcategories*: 11
Number of Subcategories Studied*: 11
Number of Dischargers in Industry: Over 500
• Direct: Over 500
• Indirect: None
• Zero: No definition for this industry
*Based on revised BAT subcategorization.
II.11.1.2 Subcategory Descriptions [2-37,38]
Based on similarities in types of processing, technology, waste-
water, end products, and other factors, eleven subcategories have
been established for the Ore Mining and Dressing Industry. This
subcategorization constitutes a revision from the seven subcate-
gories established for the BPT regulations. The BPT subcategor-
ies are retained under proposed BAT with several modifications.
Date: 1/24/83 R Change 2 II.11-4
-------
The Ferroalloy ores subcategory which included tungsten and
molybdenum ore mines and mills has been eliminated. Molybdenum
ore mines and mills are now categorized with copper, lead, zinc,
gold, and silver ore mines and mills. Tungsten ore mines and
mills are placed in a new and separate subcategory. All subcate-
gories, with the exceptions of iron ore, aluminum ore, mercury ore,
and uranium ore, have been changed since the BPT rules were promul-
gated. Table 11-2 presents the seven BPT categories and identi-
fies the subcategory changes promulgated for BAT. Unless other-
wise noted, the subcategorization referenced below is that pro-
posed for BAT.
TABLE 11-2.
REVISIONS TO THE SUBCATEGORIZATION OF THE
ORE MINING AND DRESSING INDUSTRY
BPT Subcateqories
I ron Ore
Base and Precious Metals
(includes copper, lead,
zinc, gold, and silver)
Aluminum Ore
FerroaIloy Ores
(includes chromium, cobalt,
columbium, tantalum, man-
ganese, molybdenum, nickel,
tungsten, and vanadium recovered
alone and not as a by-product of
uranium mining and mills)
Mercury Ore
Uranium, Radium, and Vanadium
Ores (only vanadium by-product
production from uranium ores)
Proposed BAT Subcateqories
Iron Ore
Copper, Lead, Zinc, Gold,
Silver, Platinum, and
Molybdenum Ores
Aluminum Ore
Titanium Ore
Mercury Ore
Uranium, Radium, and Vanadium
Ores (only vanadium by-pro-
duct production from uranium
ores)
Titanium Ores
Nickel Ore
Vanadium (mined alone and not
as a by-product of uranium
mini ng and mills)
Antimony Ore
Platinum Ores
These subcategories are discussed briefly in the following sec-
tion.
Date: 1/24/83 R Change 2
II.11-5
-------
Iron Ore
The iron ore subcategory covers mining and/or milling operations
associated with the excavation and extraction of iron ore and is
classified as SIC 1011. Of the iron ore operations currently
active, over 50% use milling operations which result in no dis-
charge. Over 30% of the operations discharge to surface waters
and the remaining are unknown. The general trend in the industry
is to produce increasing amounts of pellets and less "run of
mine" quantities (coarse, fines, and sinter). For pelletizing
operations, 56% of total production is represented by operations
with no discharge of process wastewater while approximately 35%
of the operations discharge to surface waters. Unlike the mill-
ing segment, the mining segment of the industry does discharge
either as the primary source of process water or as makeup water.
The primary water treatment used in this subcategory is removal
of suspended solids by settling.
Aluminum (Bauxite)
In both BPT and BAT effluent guidelines, the aluminum ore sub-
category applies only to the mining of bauxite for the eventual
metallurgical production of aluminum. The bauxite mining indus-
try is classified as SIC 1051 and includes establishments engaged
in mining and milling bauxite and other aluminum ores. No other
aluminum ores are being commercially exploited on a full-scale
basis at present. Domestic bauxite ore operations require dis-
charge of large volumes of mine water, but there is no process
water for crushing or grinding of the ore.
Copper, Lead, Zinc, Gold, Silver, and Molybdenum Ores
Because of the similarity of the wastewater discharge from mills
and mine drainage, a large subcategory has been established for
ores mined or milled for the recovery of copper, lead, zinc,
gold, and silver. Molybdenum is also included in this group be-
cause of the similarity in mill processes. The mine drainage of
this subcategory was identified as being of similar pH with
relatively high concentrations of heavy metals regardless of the
ore mined. The most commonly used mill process in the subcate-
gory is the froth flotation process.
Uranium
This category includes facilities which mine primarily for the
recovery of uranium, but vanadium and radium are frequently found
in the same ore body. Uranium is mined chiefly for use in gener-
ating energy and isotopes in nuclear reactors. Where vanadium
does not occur in conjunction with uranium/radium (nonradio-
active), it is discussed as a separate subcategory. Within the
past 20 years, the demand for radium (a decay product of uranium)
has vanished due to the availability of radioactive isotopes with
Date: 1/24/83 R Change 2 II.11-6
-------
specific characteristics. As a result, radium is now treated by
the industry as a pollutant rather than as a product.
The milling processes of this industry involve complex hydro-
metallurgy. Such point discharges, as might occur in milling
processes (i.e., the production of concentrate), are expected to
contain a variety of pollutants that need to be limited. Mining
for the ores is expected to lead to a smaller set of contami-
nants. While mining or milling uranium ores produces particularly
noxious radioactive pollutants, these are largely absent in an
operation recovering vanadium only.
Tungsten Ore
Tungsten mining and milling is conducted by numerous facilities
(probably more than 50), the majority of which are very small and
operate intermittently. Almost all are underground mines, and
many have no discharge of mine water. Most of the active mills
do not discharge primarily because they are in arid regions and
need the water. Wastewater treatment methods vary, but may
include settling and recycle and/or evaporation.
Nickel Ore
A relatively small amount of nickel is mined domestically, all
from one mine in Oregon. This mine is open-pit, and there is a
mill at the site, but it only employs physical processing methods.
The ore is washed and transmitted to an on-site smelter. Depend-
ing on the outcome of on-going exploration, nickel production may
increase in the next 5 to 10 years, and the Bureau of Mines
predicts a significant increase in production by 1985. Nickel
production is possible both from the Minnesota sulfide ores and
from West Coast laterite deposits.
Water used in beneficiation and smelting of nickel ore is exten-
sively recycled, both within the mill and from external waste-
water treatment processes. Most of the plant water is used in
the smelting operation since wet-beneficiation processes are not
practiced. Water is used for ore belt washing, for cooling, and
for slag granulation in scubbers or ore driers. Water recycled
within the process is treated in two settling ponds. A sizeable
discharge results from runoff inputs to the ponds during the
rainy season (winter).
Vanadium Ore (Mined Alone, Not as a By-Product)
This subcategory includes facilities which are engaged in the
primary recovery of vanadium from non-radioactive ore; however,
there is only one active facility in this subcategory. At the
facility, vanadium pentoxide, V205, is obtained from an open-pit
mine by a complex hydrometallurgical process involving roasting,
leaching, solvent extraction, and precipitation. Water used in
Date: 1/24/83 R Change 2 11.11-7
-------
the mill includes scrubber and cooling wastes and domestic use.
The most significant effluent streams are from leaching and
solvent extraction, wet scrubbers or roasters, and ore dryers.
Together, these sources account for nearly 70% of the effluent
stream, and essentially all of its pollutant content.
Mercury
The mercury industry in the United States currently is at a re-
duced level of activity due to depressed market prices. Two
facilities were found to be operating at present, although it is
thought that activity will increase with increasing demand and
rising market prices. The decreased use of mercury due to strin-
gent air and water pollution regulations in the industrial sector
may be offset in the future by increased demand in dental, elec-
trical, and other uses. Historically, little beneficiating of
mercury ores has been known in the industry. Common practice for
most producers (since relatively low production characterizes
most operators) has been to feed the cinnabar-rich ore directly
to a kiln or furnace without beneficiation. Water use in most of
the operations is at a minimum.
The majority of U.S.-produced mercury is recovered by a flotation
process at one mill in Nevada. Ore processed in that mill is
mined from a nearby open pit. The flotation concentrate produced
is furnaced on site to recover elemental mercury. Wastewater
treatment consists of impoundment in a multiple pond system with
no resulting discharge. The majority of impounded wastewater
evaporates, although a small volume of clarified decant is occa-
sionally recycled.
Antimony
Antimony is recovered from antimony ore (stibnite) and as a
byproduct of silver and lead concentrates. This industry is
concentrated in two states: Idaho and Wyoming. Currently, only
one operation recovers only antimony ore. The ore is mined
underground and concentrates are obtained by the froth flotation
process. There is no discharge from the mine, but wastewater
from the mill flows to an impoundment. No discharge of process
wastewater to surface waters occurs. A second facility recovers
antimony as a byproduct from tetrahedrite, a complex silver-
copper-antimony sulfide mineral. The antimony is recovered from
tetrahedrite concentrates in an electrolytic extraction plant
operated by one of the silver mining companies in the Coeur
d'Alene district of Idaho. Antimony is also contained in lead
concentrates and is recovered as a byproduct at lead smelters
usually as antimonial lead. This source may represent about 30%
.to 50% of domestic production in recent years.
Date: 1/24/83 R Change 2 II.11-8
-------
Titanium
The principal mineral sources of titanium are ilmenite (FeTi03)
and rutile (Ti02). Rutile associated with ilmenite in domestic
sand deposits is not separately concentrated typically. The
majority of all ilmenite concentrates (includes a mixed product
containing ilmenite, rutile, leucoxine, and altered ilmenite)
produced domestically are from titanium dredging operations. The
remainder of the domestic production comes from a mine in New
York mining an ilmenite ore. However, domestic production of
ilmenite concentrates has substantially declined during recent
years, dropping approximately 40% between 1968 and 1978.
Most of the active titanium mine/mill operations employ floating
dredges to mine beach-sand placer deposits of ilmenite in New
Jersey and Florida. At these operations, concentration of the
heavy titanium minerals is accomplished by wet gravity and dry
electrostatic and magnetic methods. Ilmenite can also be mined
from a hardrock, lode deposit by open-pit methods. A flotation
process is employed to concentrate the ore materials.
Wastewater treatment practices employed at titanium mine/mill
operations are designed primarily for removal of suspended solids
and adjustment of pH. In addition, peculiar to the beach sand
dredging operations in Florida is the presence of silts and
organic substances (humic acids, tannic acids, etc.) in these
placer deposits. During dredging operations, this colloidal
material becomes suspended. Methods employed for the removal of
this material from water are coagulation with either sulfuric
acid or alum, followed by multiple pond settling. Adjustment of
pH is accomplished by addition of either lime or caustic prior to
final discharge.
Platinum
One placer mine in Alaska was operated to recover platinum as the
primary product, but in 1982 that mine was temporarily closed. A
potentially new mine was identified that will use .a different
metal recovery process from the currently existing placer mine.
Therefore, BAT was promulgated for a new subcategory, Platinum
Ores. However, new source performance standards for Platinum
Ores is reserved for future use.
II.11.2 WASTEWATER CHARACTERIZATION [2-37]
The wastewater situation evident in the mining segment of the Ore
Mining and Dressing Industry is unlike that encountered in most
other industries. Usually, industries (such as the milling
segment of this industry) utilize water in the specific processes
they employ. This water frequently becomes contaminated in the
process and must be treated prior to discharge. In the mining
segment, process water is not normally utilized in the actual
Date: 1/24/83 R Change 2 II.11-9
-------
mining of ores, except where it is used in placer mining opera-
tions (hydraulic mining and dredging) and in dust control.
Water is a natural feature that interferes with mining activ-
ities. It enters mines by groundwater infiltration and surface
runoff and comes into contact with materials in the host rock,
ore, and overburden. An additional source of water in deep
underground mines is the water that results from the backfilling
of slopes with the coarse fraction of the mill tailings. Trans-
portation of these sands underground is typically accomplished by
sluicing. Mill wastewater is usually the source of the sluice
water. The mine water then requires treatment depending on its
quality before it can be safely discharged into the surface
drainage network. Generally, mining operations control surface
runoff through the use of diversion ditching and grading to
prevent, as much as possible, excess water from entering the
working area. The quantity of water from an ore mine thus is
unrelated, or only indirectly related, to production quantities.
The principal uses of water in the Ore Mining and Dressing Indus-
try can be grouped in three major categories:
(1) Noncontact cooling water
(2) Process water: wash water
transport water
scrubber water
process and product consumed water
(3) Miscellaneous water: dust control
domestic/sanitary uses
washing and cleaning
drilling fluids
Noncontact cooling water is defined as cooling water that does
not come into direct contact with any raw material, intermediate
product, by-product, or product used in or resulting from the
process. Process water is defined as that water which, during
the beneficiation process, comes into direct contact with any raw
material, intermediate product, by-product, or product used in,
or resulting from, the process.
Wastewater characteristics for the Ore Mining and Dressing. Indus-
try in general reflect the diversity of the mining and milling
operations associated with the various ores mined and processed.
Each ore exhibits its own set of waste characteristics and these
peculiarities were used, in part, as criteria to determine the
various subcategories.
Date: 1/24/83 R Change 2 11.11-10
-------
The wastewater of the Ore Mining and Dressing Industry was
analyzed in screening and verification sampling programs to
determine the presence or absence of the 129 priority pollutants
and to quantify the concentrations of those pollutants detected.
An extensive sampling and analysis effort was undertaken by USEPA
in 1977 and extends to the present. The purpose of this effort
is to establish the quantities of toxic, conventional, and non-
conventional pollutants in ore mine drainage and mill processing
effluents. USEPA visited 20 and 14 facilities respectively for
screening and verification sampling.
USEPA selected at least one facility in each major BPT subcate-
gory. The sites selected were representative of the operations
and wastewater characteristics present in particular subcate-
gories. These facilities were visited from April through Novem-
ber 1977. To determine these sites, the agency reviewed the BPT
data base and industry as a whole, with consideration to:
• those using reagents or reagent constituents on the
toxic pollutants list;
• those using effective treatment for BPT regulated
pollutants;
• those for which historical data were available as a
means of verifying results obtained during screening;
and
• those suspected of producing wastewater streams that
contain pollutants not traditionally monitored.
After reviewing the screen sampling analytical results, USEPA
selected 14 sites for verification sampling visits. Because most
of the organic toxic pollutants were either not detected or
detected only at low concentrations in the screen samples, the
Agency emphasized verification sampling for total phenolics
(4AAP), total cyanide, asbestos (chrysotile), and toxic metals.
Table 11-3 lists the minimum detection limits for toxic pollut-
ants appropriate to the studies described above. Any value below
the quantifiable limit is referred to in this section as BDL,
below detection limit.
Toxic metals are naturally associated with metal ores and all -of
the 13 toxic metals were found in wastewater from the Ore Mining
and Dressing Industry. The concentrations of each metal varied
greatly, as expected in such a diverse industry. Organic com-
pounds are not found naturally with metal ores and only 27 toxic
organics were detected in the industry's treated wastewater.
The conventional parameters observed were primarily those regu-
lated by BPT effluent guidelines, namely TSS and pH. The TSS
values are very high in many raw wastewater samples because these
samples include tailings which typically contain tens of thousands
Date: 1/24/83 R Change 2 11.11-11
-------
TABLE 11-3. MINIMUM DETECTION LIMITS FOR
TOXIC POLLUTANTS [2-38]
Pollutant Concentration, yg/L
Antimony 200
Arsenic 2
Beryllium 5
Cadmium 2
Chromium 20
Copper 10
Lead 50
Mercury 0.5
Nickel 20
Selenium 2
Silver 10
Thallium 100
Zinc 5
Asbestos, fibers/L 2.2 x 105
Cyanide . 20
Phenol (total) 2
Benzene 0.04
Diethyl phthalate 0.2
Bis (2-ethylhexyl) phthalate 0.2
Butyl benzyl phthalate 0.25
Di-n-butyl phthalate 0.3
Dimethyl phthalate 0.35
Methylene chloride 0.08
Toluene 0.35
Chloroform 0.05
Trichlorofluoromethane 0.1
Carbon tetrachloride 0.35
Ethylbenzene 0.1
Tetrachloroethylene 1.1
1,1,1-Trichlorethane 0.15
g-BHC 0.1
2C-BHC 0.1
Dichlorobromomethane 0.05
COD, mg/L 2
TSS, mg/L 1
TOC, mg/L 1
VSS, mg/L 1
Date: 1/24/83 R Change 2 11.11-12
-------
of mg TSS/L. Effluent TSS values vary, but are generally low
indicating good solids settling characteristics.
Values of pH vary, but are often in the alkaline range (7 to 14)
because several mill processes operate at elevated pH levels.
The levels of pH, TSS, and metal are often closely associated.
The solubility of many metals varies greatly with pH, and the
status of the metals (dissolved versus solubilized) affects the
concentration of TSS. This relationship is used by the industry
for ore beneficiation and for wastewater treatment.
Table 11-4 presents available screening and verification data, by
subcategory, for wastewater pollutant concentrations. Verifica-
tion data for the nickel subcategory are not available.
II.11.3 PLANT SPECIFIC DESCRIPTION [2-37,38]
Copper Mine/Mill 2120
This copper mine/mill facility is located in southwest Montana.
The ore body consists primarily of chalcocite and enargite, mined
only by open-pit methods at present. Underground mines at this
facility are inactive, but mine water is continuously pumped.
The mill employs the froth flotation process to produce copper
concentration, while cement copper is produced by dump leaching
of low grade ore. In 1976, ore production was 15,000,000 metric
tons (17,000,000 short tons), and 327,000 metric tons (360,000
short tons) of copper concentrate were produced. Approximately
16,000 metric tons (17,600 short tons) of cement copper are pro-
duced annually.
Table 11-5 summarizes the verification pollutant data for mine/
mill 2120. The barrel pond system characterized by the data
consists of a three celled settling pond where the influent
wastewater is limed and polymer is added to enhance flocculation
and settling. A relatively high pH is maintained through this
treatment system, but a final pH adjustment is made when nec-
essary by addition of sulfuric acid. Average discharge volume
from this treatment system is approximately 25,000 m3 (6.5
million gallons) per day.
Date: 1/24/83 R Change 2 II.11-13
-------
TABLE II-U. WASTEWATER POLLUTANT CHARACTERISTICS BY SUBCATEGORY,
SCREENING AND VERIFICATION DATA [2-37]
Number of Number of
samples/number Mean of Maximum of samples/number
Pollutant of detections detections detections of detections
pH, pH units
COD
TSS
TOC
VSS
Phenols (total )
1 ron
Ant i mony
Arsenic
Be ry 1 1 i urn
Cadm 1 urn
Chromium
Copper
Cyanide ( tota 1 )
Lead
Mercury
Nickel
Se 1 en i um
Si 1 ve r
Tha 1 1 i um
Zinc
Asbestos (chrysot 1 le).
fibers/L
Asbestos (total fibers).
fibers/L
Classical pollutants, mg/L
pH, pH units
COD
TSS
TOC
VSS
Phenols (total )
1 ron
Toxic metals and inorganics.
Antimony
Arsenic
Be ry 1 1 i um
Cadmium
Chromium
Copper
Cyanide ( tota 1 )
Lead
Mercury
Nickel
Se ten i um
Si Iver
Thai 1 ium
Zinc
Asbestos (chrysot i le).
fibers/L
Asbestos (total fibers).
fibers/L
Mean of Maximum of
detections detections
Subcateaorv - Iron Ore: Mine drainaae
2/2
I/I
2/2
I/I
I/I
I/O
I/O
2/0
I/O
2/0
2/0
I/O
2/1
I/O
2/0
2/0
2/0
2/0
2/0
2/0
2/1
I/I
I/I
2/2
I/I
2/2
I/I
I/I
I/O
I/I
ug/L
2/0
2/1
2/1
2/1
2/2
2/2
I/O
2/2
2/0
2/2
2/1
2/2
2/0
2/2
I/I
I/I
Raw wastewater
8.1 8.2
10
1.6 5
25
2
90
18
3.5XIOE6
I.7XIOE7
Subcateaorv - Iron Ore:
Raw wastewater
7.8 7.9
96
65,000 110,000
22
80
73
890
920
31
280 500
230 320
51 80
2,200 2,700
20
17 20
3.200 5,800
3.8XIOEIO
2.3XIOEI 1
Treated
I/I
I/I
I/I
I/I
I/I
I/O
I/I
I/O
I/O
I/O
I/I
I/O
I/O
I/O
I/O
I/O
I/O
I/O
I/I
I/I
I/I
Phvsica 1 /chemica 1 mi
Treated
2/2
I/I
2/2
I/I
I/I
I/O
2/0
2/1
2/0
2/0
2/2
2/1
I/O
2/0
2/0
2/0
2/0
2/0
2/0
2/2
I/I
I/I
wastewater
8
6
U
19
3
5
120
30
3.8XIOE6
I4.2XIOE7
1 1 orocess
wastewater
7.7 8.1
14
2 1
1 1
BOL
5
BDL BDL
100
19 30
1. IXIOE6
U.3XIOE7
Date: 1/24/83 R Change 2 11.11-14
-------
TABLE 11-4. WASTEWATER POLLUTANT CHARACTERISTICS BY SUBCATEGORY,
SCREENING AND VERIFICATION DATA [2-37] (continued)
Po 1 1 utant
Number of Number of
samples/number Mean of Median of Maximum samples/number Mean of Median of Maximum of
Subcategory -
Copper, Lead, Zinc, Gold, Silver, Platinum,
Molvbdenum: Mine Drainaae
Classical pollutants, atg/L
pH, pH units
COD
TSS
TOC
VSS
Phenols (total )
1 ron
Toxic metals and inorganics.
Antimony
Arsenic
Be ry 1 1 i urn
Cadmium
Ch rom i urn
Copper
Cyanide (total )
Lead
Mercury
Nickel
Selenium
Si Iver
Tha Ilium
Zinc
Asbestos (chrysoti le).
f ibers/L)
Asbestos (total fibers).
fibers/I.
12/12
12/12
13/13
10/10
6/5
13/9
7/7
ng/L
15/3
15/11
15/1
15/9
15/7
15/11
11/2
15/10
!5/"»
15/N
15/1
15/5
15/U
15/15
6/6
6/5
7. 1
24
200
7.6
16
0.008
20
BDL
37
9
28
22
760
12
1, 100
3
71
I |
100
5,300
9.2XIOEI5
2.1XIOEIO
7. 1
7.9
20
3.8
3.2
0.008
I.U
BOL
18
7
5
BDL
15
290
2
59
12
BDL
310
3. IXIOE9
I.OXIOE8
Subcategory
Raw Wastevater
Classical pollutants, mg/L
pH, pH units
COD
TSS
TOC
VSS
Phenols (total )
Toxic metals and inorganics.
Antimony
Arsenic
Be ry 1 1 i urn
Cadmium
Chromium
Copper
Cyan ide
Lead
Mercury
Nickel
Se lenium
SI Iver
Tha 1 1 i urn
Zinc
Asbestos (chrysoti le).
f ibers/L
Asbestos (total fibers).
f ibers/L
2/2
2/2
2/2
2/2
2/2
2/0
wg/L
2/1
2/2
2/1
2/0
2/2
2/2
2/2
2/2
2/2
2/0
2/2
2/1
2/0
2/2
2/2
2/2
8.8
350
30,000
12
650
100,000
830
1,1400
3,800
200
280
78
2,200
1 . 1XIOE9
5.5XIOEIO
8.3
150
1,500
23
70
0.016
130
BDL
200
22
120
65
7,300
20
5,900
6
200
12
20
870
28,000
5.5XIOEI6
1 .2XIOEI 1
- Copper, Lead, Zinc,
Molvbdenum: Cvanidi
9.9
700
60,000
18
1,300
BDL
200,000
30
1,600
2,600
6,800
370
510
150
100
3,900
2.7XIOE9
1 . IXIOEI 1
1/1 8.3
U/1 27
5/5 II
2/2 3.5
2/2 2.5
1/2 0.0075
3/3 9.1
5/0
5/2 10
5/1
5/2 II
5/0
5/5 56
I/I
5/1 63
5/1
5/2 320
5/0
5/1
5/2 300
5/5 3,800
2/2 U.6XIOE6
2/2 6.1XIOE7
Gold, Silver, Platinum,
ition Mil 1 Process
8.2 9
It 77
10 20
6
3
0.01
0.65 27
10
6
13
10 120
35
66 99
19
600
BDL
180
530 11,000
8.2XIOE6
7.2XIOE7
Date: 1/24/83 R Change 2 11.11-15
-------
TABLE 11-4. WASTEWATER POLLUTANT CHARACTERISTICS BY SUBCATEGORY,
SCREENING AND VERIFICATION DATA (continued)
Pol lutant
Number of
samples/number
of detections
Mean of
detect io
Median
ns detect
of Maximum of
ions detections
Subcategory - Copper, Lead,
Raw wastewater
Classical pollutants, mg/L
pH, pH units
COD
TSS
TOC
VSS
Phenols (total )
1 ron
Toxic metals and inorganics.
Antimony
Arsenic
Beryl 1 ium
Cadmium
Chromium
Copper
cyanide
Lead
Mercury
Nickel
Se 1 en i urn
Si Iver
Tha 1 1 1 urn
Zinc
Asbestos (chrysot i le).
f ibers/L
Asbestos (total fibers)
f ibers/L
22/22
22/22
22/22
22/22
9/9
73/65
9/9
U9/L
78/13 1
78/78
78/55
78/11
78/63
78/78
71/31
78/69
72/18
78/72
77/50
78/13
78/7
78/78
15/15 2.
13/13 1.
8.8
1,100
200,000
15
10,000
220
58
l,700(b)
2,900
75
610
1,600
99,000
280
20,000
52(b)
3,700
210
110
BOL
71,000
3XIOEII
8XIOEI2
8.1
530
160,000
9.5
3,800
36
29
BDL
800
75
170
1,900
63,000
180
2,800
1. 1
2,000
200
250
BDL
5,600
1.8XIOEIO
5.4XIOEI 1
Subcategory -
Classical pollutants, mg/L
pH, pH units
TSS
1 ron
Toxic metals and inorganics.
Ant imony
Arsenic
Beryl 1 ium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Tha 1 1 i urn
Zinc
I/I
I/I
I/I
W9/L
I/O
I/I
I/I
I/I
I/I
I/I
I/I
I/O
I/I
I/O
I/O
I/I
I/I
Raw wast6'
at
Molybdenum:
12
3,000
110,000
29
15,000
100
160
l,100(b)
8, 100
150
1, 100
1 1,000
290,000
590
27,000
22(b)
9,200
530
800
200
270,000
4.2XIOEI 1
3.5XIOEI2
Copper, Lead, Zinc
Molybdenum: Heap/
3
320
1,900
27
BDL
260
1,300
88,000
BDL
11,000
BDL
1 10,000
Number of
samples/number
of detections
Zinc, Gold, Si
Froth Flotation
21/21
22/22
21/20
15/15
8/7
52/18
6/6
59/3
59/13
59/7
59/6
59/20
59/55
51/12
59/27
58/16
59/35
58/23
59/8
59/0
59/18
11/11 2
11/11 6
, Cold, Si Iver,
Vat/Dumo Leach i
I/I
I/I
I/O
I/O
I/I
I/I
I/I
I/O
I/I
I/I
I/I
I/O
I/O
I/I
I/I
Mean of
detections
Median of
detect ions
Maximum of
detect ions
Iver, Platinum.
Mill Process
7.8
16
1 1
12
1.7
75
0.57
BDL
75
5.7
7.3
160
310
160
100
27
91
23
31
260
.2XIOE8
. IXIOE8
Plat inum.
na Process
W t t
7.8
12
1.6
9.5
1.5
19
0. 15
BDL
13
BDL
5
30
70
120
BOL
0.8
60
12
20
70
I.7XIOE6 3.
I.9XIOE7 1
8.8
27
17
21
3.2
220
1.3
BDL
290
12
12
320
610
250
230
68
190
31
16
560
.2XIOE8
.9XIOE9
7.9
50
2
BDL
3
23
BOL
28
BDL
. 13
Date: 1/24/83 R Change 2 11.11-16
-------
TABLE 11-4. WASTEWATER POLLUTANT CHARACTERISTICS BY SUBCATEGORY,
SCREENING AND VERIFICATION DATA (continued)
Number of Number of
Pollutant of detections detections detections detections of
Classical pollutants, mg/L
pH, pH units
TSS
Toxic metals and inorganics.
Arsenic
Mercury
Classical pollutants, mg/L
pH, pH units
COO
TSS
TOC
VSS
Phenols (total )
Toxic metals and inorganics.
Antimony
Arsenic
Beryl 1 ium
Cadmium
Chromium
Coppe r
Cyanide
Lead
Mercury
Nickel
Selenium
Si Iver
Thai 1 ium
Zinc
Asbestos (chrysot i le) ,
f ibers/L
Asbestos (total fibers).
f ibers/L
6/6
1 I/I 1
Mg/L
1 I/I 1
1 I/I 1
I/I
I/O
I/I
I/I
I/I
2/1
ug/L
I/O
I/O
I/O
I/O
I/I
I/I
I/O
I/O
I/I
I/I
I/O
I/O
I/O
I/I
2/8
I/I
Subcategory - Copper, Lead, Zinc
Molybdenum: Gravi
Raw wastewater
7.2 7.2 7.9
19 12 64
1,200 200 5,000
BDL BDL l.<4
Subcateaory - Aluminum:
Raw wastewater
3. 1
2.8
2
1.6
0.005
30
60
37
60
570
5.5XIOE6 5.5XIOE6
3.5XIOE7
detections detections detections detections
, Gold, silver. Platinum,
ty Separation
Treated Wa;
10/10 0.17
10/10 I.U
10/10 170
10/10 BDL
Mine Dra inane
Treated wa
I/I
I/I
I/I
I/I
3/2 0.025
I/I
I/I
I/I
I/O
I/O
I/O
• I/O
I/O
2/2 I.OXIOE8
2/2 7.5XIOE8
itewater
0.05 1.2
BDL 5.7
50 1 , 200
BDL BDL
8.6
6
K
5
0.041
25
50
81
2.0XIOE8
I.14XIOE9
Date: 1/24/83 R Change 2 11.11-17
-------
TABLE 11-4. WASTEWATER POLLUTANT CHARACTERISTICS BY SUBCATEGORY,
SCREENING AND VERIFICATION DATA (continued)
pollutant
Number of
samples/number
of detections
Mean of Maximum of
detections detections
Number of
samples/number
of detections
Mean of Maximum of
detections detections
Subcateqorv - Tungsten: Mill Process
Classical pollutants, mg/L
pH. pH units
COO
TSS
TOC
VSS
Phenols (Total)
1 ron
Toxic metals and Inorganics,
Ant Imony
Arsenic
Beryl 1 ium
Cadmium
Chromium
Copper
Cyanide
Lead
Mercury
Nickel
Selenium
Silver
Tha 1 1 1 urn
Zinc
Asbestos ( chrysot 1 1 e ) ,
flbers/L
Asbestos (total fibers).
flbers/L
Classical pollutants, mg/L
pH, pH units
COO
TSS
TOC
VSS
Phenols (total)
Toxic metals and Inorganics,
Antimony
Arsenic
Beryl 1 lum
Cadm i urn
Ch rom i urn
Copper
Cyanide
Lead
Mercury
Nickel
Selenium
Si Iver
Thai 1 ium
Zinc
Asbestos (chrysot! le),
fibers/L
Asbestos (total fibers).
fibers/L
2/2
I/I
2/2
I/I
I/I
2/1
I/I
tig/u
2/1
2/1
2/2
2/2
2/2
2/2
I/O
2/2
2/1
2/2
2/2
2/2
2/0
2/2
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
ng/L
I/I
I/I
I/I
I/I
I/I
I/I
I/O
I/I
I/I
I/I
I/O
I/I
I/I
I/I
I/I
I/I
Raw wastewater
Treated wastewater
9.9
260,000
1420
260
910
22,000
3, 100
1,300
31
300
17,000
9.9
300
390,000
220
1,1*00
63
660
BOL
370
620
320
1, 100
21,000
1, 100
2
1,600
142
350
21,000
I.3XIOEI2
3.7XIOEI 1
Subcateoorv - Mercury:
Raw wastewater
8
60
1 10,000
21
11,300
0.92
53,000
1, 100
90
560
160
850
1,000
230,000
1,600
10
200
2,100
1 .5XIOEI 1
1 .3XIOE<2
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/O
I/O
I/O
I/I
I/O
I/I
Froth Flotation Process
Treated wastewater
I/I
I/I
I/I
I/I
I/O
I/I
I/I
I/I
I/O
I/I
I/I
I/I
I/O
I/O
I/I
I/O
I/O
I/O
I/O
I/I
I/I 5,
I/I 7
9.2
160
15
BOL
15
BDL
36
BDL
11,000
220
35
1,100
8.3
22
16
13
0.22
200
110
6
BDL
50
50
1)0
.7XIOE7
.7XIOE8
Date: 1/24/83 R Change 2 11.11-18
-------
TABLE II-U. WASTEWATER POLLUTANT CHARACTERISTICS BY SUBCATEGORY,
SCREENING AND VERIFICATION DATA (continued)
Pol lutant
Classical pollutants,. mg/L
pH, pH units
COD
TSS
TOC
VSS
Phenol s ( tota 1 )
1 ron
Toxic metals and inorganics.
Antimony
Arsenic
Be ry 1 1 i um
Cadmium
Ch rom i um
Copper
Cyanide
Lead
Me rcu ry
Nickel
Se 1 en i um
Si Iver
Tha 1 1 i um
Zinc
Asbestos (chrysoti le).
f ibers/L
Asbestos (total fibers).
fibers, L
Classical pollutants, mg/L
pH, pH units
COD
TSS
TOC
VSS
Phenols (total )
1 ron
Toxic metals and inorganics.
Ant imony
Arsen ic
Be ry 1 1 i um
Cadmium
Chromium
Copper
Cyanide
Lead
Mercury
Nickel
Se 1 en i urn
S i 1 ve r
Thai 1 ium
Zinc
Asbestos (chrysoti le),
f ibers/L
Asbestos (total fibers),
f ibers/L
Number of
samples/numbe
of detections
13/13
15/15
18/18
2/2
2/2
3/1
I/I
M9/L
3/1
17/16
3/0
16/13
1/3
11/11
3/0
1/3
3/1
VI
5/3
3/0
3/0
17/17
3/3
2/2
6/6
5/5
5/5
I/I
I/I
2/2
7/5
ng/L
1/2
10/9
6/2
12/1 1
8/8
12/10
2/1
8/5
I/I
8/8
6/6
6/3
1/2
12/12
I/I
I/I
r Mean of
detections
Raw wastewater
7.7
22
110
8.5
21
20
1
13
17
90
23
13
1 . IXIOE8 1 .
2.0XIOE9
Raw wastewater
6.1
95
19,000
0.009
1,500
520
1,300
270
150
1,700
1,000
1,900
2,300
170
70
1,200
26,000
Median of
detections
Subcateaorv
8. 1
7
21
7
3
15
BDL
50
28
20
IXIOE8 1
Maximum of
detections
- Uranium:
8.8
110
1,600
9
28
0.01
0.32
BDL
170
10
50
1 10
180
1 «,
60
37
190
.9X108
2.3XIOE9
Subcateaory
7.5
26
61
1,700
210
100
1,500
190
1,300
2,800
150
56
22,000
2.
2.
- Uranium:
8.3
390
95,000
21
20
0.01
2,000
1,000
1 1 , 000
300
120
3,700
3,100
16
1,200
36
3,700
190
100
1,200
61,000
3X1 OE7
9X1 OE8
Number of
samples/number
of detections
Mine dra i nage
Mean of
detections
Median of
detections
Maximum of
detections
Treated wastewater
9/9
12/12
13/13
2/1
2/2
3/1
I/I
3/0
13/11
3/0
13/10
3/2
1 1/8
3/0
3/1
3/1
3/0
5/3
3/0
3/0
13/12
2/2 1.
2/2 5.
Mil 1 Process Arid
7.9
10
33
1.5
a
1
13
BDL
36
20
OXIOE7
OXIOE8
Locations
7.9
8.9
27
6
3
BDL
18
11
5,
5,
8.5
38
83
10
2
0.01
0.051
21
7
60
II
50
9
51
78
.3XIOE7
.7XIOE8
Treated wastewater
9/9
7/6
9/9
2/2
2/2
3/2
7/5
5/3
12/11
7/3
13/11
10/5
11/1 1
3/0
10/5
5/1
10/8
7/6
7/1
5/2
11/13
2/2 1.
2/2 1.
6.7
60
56
22
6
0.01
1.1
300
120
7
35
11
190
390
830
61
16
790
1,700
8XIOE8
8X1 OE9
7.7
1 1
26
0.1
BDL
29
10
29
28
100
200
950
22
20
2,500
8.5
280
160
27
10
0.01
3.9
900
750 **
1 1
77
100
900
960
11
1,300
210
23
810
1 1,000
2.0XIOE8
2
. 3XIOE9
Date: 1/24/83 R Change 2 11.11-19
-------
TABLE II-U. WASTEWATER POLLUTANT CHARACTERISTICS BY SUBCATEGORY,
SCREENING AND VERIFICATION DATA (continued) .
PO Mutant
Number of
samples/number
of detections
Mean of Median of
detect ions detect ions
Maximum of
detections
Number of
samples/number Mean of Median of Maximum of
of detect ions detect ions detect Ions detect ions
Subcateoorv - Titanium: Mine drainage
r
-------
TABLE II-U. WASTEWATER POLLUTANT CHARACTERISTICS BY SUBCATEGORY,
SCREENING AND VERIFICATION DATA (continued)
Pol lutant
Number of
samples/number
of detections
Mean or
detections
Median or
detections
Maximum or
detections
Subcateaorv - Vanadium:
Raw wa&tevater
Classical pollutants, mg/L
Phenols (total )
Iron (total)
Toxic metals and Inorganics,
Ant i mony
Arsenic
Beryl 1 lun
Cadmium
Ch rom 1 urn
Copper
Cyanide
Lead
Mercury
Nickel
Se 1 en 1 urn
SI Iver
Thall lum
Zinc
I/O
I/I
"9/L
I/I
I/I
I/I
I/I
I/I
I/I
I/O
I/I
I/I
I/I
I/I
I/I
I/I
I/I
Subcateaorv
69
BDL
130
16
17
120
1(2
320
1
150
6.3
BOL
BDL
1,500
- Vanadium:
Raw wastewater
Classical pollutants, mg/L
Phenols (total )
1 ron ( tota 1 )
Toxic metals and inorganics.
Antimony
Arsenic
Be ry 1 1 1 urn
Cadmium
Ch rom 1 urn
Copper
Cyanide
Lead
Mercury
Nickel
Se 1 en 1 urn
silver
Tha 1 1 1 urn
Zinc
Analytic methods: V.7.3.23,
3/0
3/3
Mg/L
3/3
3/3
3/3
3/3
3/3
3/3
3/1
3/3
3/2
3/3
3/3
3/3
3/3
3/3
Data sets 1,2,3
110
BDL
300
III
180
1,600
"4,200
5.800
mo
790
870
31
290
314,000
69
BDL
370
38
25
170
65
320
150
mo
27
BDL
1,500
330
BDL
390
69
510
1.100
13,000
290
17,000
280
1,800
2,500
63
870
100,000
Number or
samples/number
or detections
: Mine drainaae
jre
I/O
I/I
I/I
I/I
I/I
I/I
I/I
I/I
I/O
I/I
I/O
I/I
I/I
I/O
I/I
I/I
Froth F|ot|tf9n
Mean or Median or
detections detections
Maximum of
detections
0.66
BDL
5
BDL
8.2
29
21
170
59
12
BDL
160
Treated wastewater
3/0
3/3
3/3
3/3
3/3
3/3
3/3
3/3
3/0
3/3
3/0
3/3
3/3
3/2
3/3
3/3
0.56 0.56
BDL BDL
110 IM
53 36
21 25
IliO 61
37 12
560 330
110 95
810 79
BDL
120 BDL
120 110
0.86
BOL
300
120
38
330
17
1,200
250
160
16
350
160
BDL, below detection limit
(a) Data not available.
(b) As reported in source.
Date: 1/24/83 R Change 2 11.11-21
-------
TABLE 11-5. PLANT SPECIFIC DATA FOR COPPER MINE/MILL
2120, VERIFICATION DATA [2-70]
PoI Iutant
Barrel pond
influent
Barrel pond
effluent
Percent
removaI
Classical pollutants, mg/L
TSS
COD
TOG
pH, pH units
Toxic pollutants, u.g/L
14
10
19
I 1.8
Analytic methods: V.7.3.23, Data set 2.
NM, not meaningful.
4
18
12
3.4
71
NM
37
Ant imony
Arsen ic
Beryl 1 ium
Cadmium
Chromi urn
Copper
Cyan ide
Lead
Mercury
Nickel
Se 1 en ium
Si 1 ve r
Tha 1 1 i urn
Zinc
Asbestos, fibers/L
88
88
Copper Mine/Mill/Smelter Refinery 2122
The wastewater treatment plant at this facility treats the com-
bined waste streams from two mills, a refinery (including a
refinery acid waste stream), a smelter, and the facility sanitary
wastewater. Existing treatment includes lime addition, polymer
addition, flocculation, and settling. Table 11-6 summarizes the
pollutant verification data for this mine.
Date: 1/24/83 R Change 2 11.11-22
-------
TABLE 11-6.
PLANT SPECIFIC DATA(a) FOR COPPER MINE/MILL
2122, VERIFICATION DATA [2-70]
Pol lutant
Treatment
infIuent
Treatment
effluent
Percent
removaI
Classical pollutants, mg/L
TSS
COD
TOC
pH, pH units
Toxic pollutants, u,g/L
76
25
9.5
3.4
Analytic methods: V.7.3.23, Data set 2
ND, not detected.
NM, not mean ingfuI.
(a)Average of two 24-hour composites.
3
14
10
8.0
96
46
NM
Ant imony
Arsen ic
Be ry 1 1 i urn
Cadmium
Chrom i urn
Copper
Cyan ide
Lead
Mercury
Nickel
Se len ium
Si Iver
Tha 1 1 ium
Zi nc
Asbestos, fibers/L
88
>50
33
7
>88
NM
74
NM
Lead/Zinc/Copper Mine/Mill 3103
This facility is located in Missouri and has an underground mine.
The minerals of principal value are galena, sphalerite, and
chalcopyrite. Zinc, lead, and copper concentrates are produced
by the flotation process in the mill. In 1976, mine production
totalled 972,000 metric tons (1,070,000 short tons), while 92,000
metric tons (102., 000 short tons) of lead concentrate, and 9,800
metric tons (11,000 short tons) of copper concentrate were pro-
duced at the mill.
Mine and mill wastewater streams are combined for treatment at
this facility. Wastewater treatment consists of alkaline sedi-
mentation in a multiple pond settling system. Table 11-7 sum-
marizes pollutant verification data for mine/mill 3103.
Lead/Zinc Mine/Mill/Smelter/Refinery 3107
Wastewater streams generated from mining, milling, smelting, and
refining activities at this lead/zinc complex are combined in a
common impoundment pond, and the effluent from this pond is
subsequently treated in a physical/chemical treatment plant by
lime precipitation, aeration, flocculation, and clarification, in
Date: 1/24/83 R Change 2 11.11-23
-------
conjunction with high-density sludge recycle. Table 11-8 sum-
marizes pollutant verification data for mine 3107.
II.11.4 POLLUTANT REMOVABILITY [2-37,38]
Pollutants in the Ore Mining and Dressing Industry originate from
two distinct sources: particles from raw ores, and beneficiation
(dressing) reagents. Pollutants from various ores generally con-
sist of heavy metals contained in the ore. These pollutants are
normally in a natural state as dissolved or suspended particles
resulting from contact with rainwater and seepage water. The
beneficiation or dressing process generally contributes cyanide
or phenols and may result in high volumes of waste loads when
combined with the natural pollutants.
In-process recycle of waste streams after thickening or filtering
is used at several plants within the industry. Water also may be
recovered by dewatering tailings prior to final discharge. The
recovered water may be reused as makeup or as a process control
measure for additional metal recovery. In-process recycle may
reduce the volume of wastewater discharged by 5% to 17%; when
tailing wastewater is recovered, the wastewater volume may be
reduced by up to 50%. This reduction allows for a smaller waste-
water treatment system. Mine drainage also has been used as mill
makeup water, which has a similar effect on the treatment system.
Several treatment methods are currently being used by the Ore
Mining and Dressing Industry. Settling, chemical treatment, and
filtration, are techniques commonly employed. Other methods for
wastewater treatment also are used but on a less frequent basis.
Ponds are used in the industry for settling. Tailings ponds
receive relatively high solids loadings and thus require frequent
cleaning or enlargement. Chemical treatment involves the addi-
tion of a chemical compound, usually lime or alum, to precipi-
tate dissolved metals. Preliminary settling may be used to
remove larger particles prior to chemical treatment, which is
generally followed by sedimentation. Large quantities of sludge
may be produced that may be disposed of in an abandoned mine.
Filtration is accomplished by the passage of water through a
physically restrictive medium with the resulting deposition of
suspended particulate matter.
Settling is used at mine/mill 1108, where the tailing-pond efflu-
ent is treated with alum, followed by polymer addition and secon-
dary settling to reduce suspended solids from approximately 200
mg/L to an average of 6 mg/L. At mine/mill 3121, initiation of
the practice of polymer addition to the tailings has greatly
improved the treatment system capabilities. Mean concentrations
of total suspended solids, lead, and zinc in the tailing-pond
effluent were reduced by 64%, 43%, and 17%, respectively, over
those previously attained as shown in Table 11-9.
Date: 1/24/83 R Change 2 11.11-24
-------
TABLE 11-7. PLANT SPECIFIC DATA FOR LEAD/ZINC/COPPER
MINE 3103, VERIFICATION DATA [2-70]
Pollutant Tailings pond Tailings pond Percent
. influent effluent remova I
Classical pollutants, mg/L
TSS 120,000 3 >99
COD 2,100 14 99
TOG 22 15 32
pH, pH units 6.4 7.4
Toxic pollutants, u.g/L
Ant imony
Arsen ic
Be ry 1 1 i urn
Cadmium
Ch rom i urn
Copper
Cyan ide
Lead
Me rcu ry
Nickel
Selenium
Si 1 ve r
Tha 1 1 i urn
Zinc
Asbestos, fibers/L
< 1,000
500
70
350
200
21,000
HO
120,000
<2
4,400
<200
150
99
>86
>97
>95
>99
25
>99
NM
96
NM
>93
NM
98
Analytic methods: V.7.3.23, Data set 2.
NA, not analyzed.
NM, not meaningful.
TABLE 11-8. PLANT SPECIFIC DATA (a) FOR LEAD/ZINC
MINE 3107, VERIFICATION DATA [2-70]
Pollutant Treatment plant Treatment plant Percent
influent effluent remova I
Classical pollutants, mg/L
TSS 12 19 NM
COD II 3 73
TOC I 2 NM
pH, pH units 2.7 6.6
Iron, total 58 2,400 NM
Toxic pollutants, u.g/L
Ant imony
Arsenic
Be ry 1 1 i urn
Cadmium
Chromi urn
Copper
Cyanide
Lead
Mercury
Nickel
Selen ium
S i 1 ve r
Z inc
Bi s(2-ethylhexyl ) phthalate
Di-n-butyl phthalate
<500
28
<5
3,000
75
700
180
2,800
30
280
<5
<20
86,000
NA
NA
<500
4
<5
220
25
60
35
220
1.6
75
<5
<20
5,500
16
0.3
NM
86
NM
93
67
91
81
92
95
73
NM
NM
94
Analytic methods: V.7.3.23, Data set 2.
NA, not analyzed.
NM, not meaningful.
(a)Average of two 24-hour composites-.
Date: 1/24/83 R Change 2 11.11-25
-------
TABLE 11-9,
IMPROVEMENT IN TREATMENT SYSTEM CAPABILITY
RESULTING FROM POLYMER ADDITION TO EFFLUENT
AT MINE/MILL 3121 [2-38]
Effluent levels
attained prior to
use of polymer, mg/L
Effluent levels
attained subsequent
to use of polymer, mg/L
Parameter
TSS
Pb
Zn
Mean
0.
0.
39
51
46
0
0
Range
15 -
.24 -
.23 -
Mean
80
0
0
.80
.86
0
0
14
.29
.38
0.
0.
Range
4 -
14 -
06 -
34
0.
0.
67
69
Similarly, the use of a polymer at mine 3130 reduced mean concen-
trations of total suspended solids, lead and zinc in treated ef-
fluent by 89%, 76%, and 29%, respectively, over those attained
prior, to use of polymer and sedimentation as shown in Table
11-10.
TABLE.11-10.
IMPROVEMENT IN TREATMENT SYSTEM CAPABILITY
RESULTING FROM POLYMER ADDITION AND SEDIMEN-
TATION TO EFFLUENT AT MINE 3130 [2-38]
Effluent levels
attained prior to use
of polymer and
secondary settling
pond(a), mg/L
Effluent levels
attained subsequent to
use of polymer and
secondary settling
pond(a), mg/L
Parameter
Mean
Range
Mean
Range
TSS
Pb
Zn
0.
/- o.
19
34
45
0.
0.
4 -
11 -
23 -
67
1.1
1.1
0
0
2
.08
.32
0.
-------
solids concentrations have been reduced by approximately 66%,
from an average 35 mg/L to less than 12 mg/L. Zinc removals from
0.2 mg/L (influent) to 0.05 mg/L (effluent) and iron removals
from 0.2 mg/L (influent) to 0.09 mg/L (effluent) have also been
achieved.
Depressing agents are commonly used in the flotation of metal
ores to assist in the separation of minerals with similar float-
abilities. Cyanide is widely used as a depressant and thus often
is present in mill tailings and wastewater. Because of its
toxicity, treatment methods are needed to reduce cyanide concen-
tration. Alkaline chlorination and ozonation are two methods
being used to achieve cyanide destruction.
A fullscale system has been implemented at mill 6102 for cyanide
reduction. The unit is an integral part of a total treatment
system employing lime precipitation, electrocoagulation-flotation,
ion exchange, alkaline chlorination, and multimedia filtration,
followed by final pH adjustment. The alkaline-chlorination
system involves onsite generation of sodium hypochlorite by
electrolysis of sodium chloride. The hypochlorite is injected
into the wastewater following the electrocoagulation-flotation
process and immediately preceding the filtration unit. At this
point in the system, some cyanide removal has already been real-
ized incidental to the lime precipitation-electrocoagulation
treatment. Operating data from the first four months show the
concentration of cyanide at 0.09 mg/L prior to the electrocoagu-
lation unit. Concentrations of cyanide progressively decrease
from 0.04 mg/L (electrocoagulation effluent) to 0.01 mg/L or less
after filtration and less than 0.01 mg/L after the final reten-
tion pond. Mill personnel expect this removal efficiency to
continue throughout the optimization period of the system. The
problem of elevated chlorine residual levels has not yet been
resolved.
Ozonation tests in the laboratory showed substantial destruction
of cyanide. Although the target level of less than 0.025 mg/L of
cyanide was not achieved and the tests under pilot-plant condi-
tions showed less favorable results, ozonation did result in sub-
stantial removal of manganese as well as cyanide.
Phenolic compounds are also used to dress the raw ores. The low-
concentration, high-volume phenolic wastes generated lend .them-
selves most readily to treatment by chemical oxidation or aera-
tion. Aeration is the only treatment currently in use although
phenols may be incidentally reduced by treatment of traditional
parameters such as TSS. At Mill 2120, phenol concentrations in
the tailing-pond influent and effluent average 0.031 mg/L and
0.021 mg/L, respectively. Similar results are noted at Mill
2122, where phenol concentrations in the tailing-pond influent
and effluent average 0.26 mg/L and 0.25 mg/L respectively. Data
from samples collected at Mill 2117 show phenol reductions from
Date: 1/24/83 R Change 2 11.11-27
-------
5.1 mg/L of phenol in raw tailings to 0.25 mg/L of phenol in the
tailing-pond overflow.
Radium 226, a product of the radioactive decay of uranium, occurs
in both dissolved and insoluble forms and is found in wastewater
resulting from uranium mining and milling. Coprecipitation of
radium with a barium salt is typically used for waste stream re-
moval of radium. Dosages vary from 10 mg/L to 300 mg/L depending
on the characteristics of the wastestream.
At uranium mine/mill 9452, a unique minewater treatment system
exists that employs radium 226 ion exchange, in addition to floc-
culation, barium chloride coprecipitation, settling, and uranium
ion exchange. The mine water to be treated is pumped from an
underground mine to a mixing tank where flocculant is added. The
water is then settled in two ponds, in series, before barium
chloride is added. After barium chloride addition, the water is
mixed and flows to two additional settling ponds (also in series).
The decant from the final pond is acidified before it proceeds to
the uranium ion-exchange system. The effluent from the uranium
ion exchange column is pumped to the radium 226 system. After
treatment for removal of radium 226, the final effluent is pumped
to a holding tank for either recycle to the mill or discharge.
The unique feature of this treatment approach is the radium 226
ion exchange system, which consists of two up-flow ion exchange
columns operated in parallel. Each column is constructed of
fiber-reinforced plastic (FRP) and contains approximately 11.3 m3
(400 ft3) of resin, supported on a FRP distribution plate. Min-
ing personnel have estimated that the theoretical life of the
resin at the present loading is 50,000 years. The total treat-
ment system at mine/mill 9452 is capable of reducing radium 226
from levels of 955 picocuries/L (total) and 93.4 picocuries/L
(dissolved) to 7.18 picocuries/L (total) and less than 1
picocurie/L (dissolved). This performance represents 99.2%
removal of total radium 226 and greater than 98.9% removal of
dissolved radium 226.
Asbestos is often found in the ores from this industry. Although
several bench-scale and pilot-scale plants have been proposed,
only settling ponds are currently in use. For mill treatment
systems consisting primarily of tailing ponds and settling, or
polishing ponds, some facilities have demonstrated reductions of
104 and 105 fibers/L. Examination of these treatment systems
indicates several factors in common: high initial suspended
solids loading, effective removal of suspended solids, large
systems or systems with long residence times, and/or the presence
of additional settling or polishing ponds.
Other methods, which are used to a lesser extent and normally in
the pilot plant stage, include: flocculation, centrifugation,
oxidation, adsorption, and solvent extraction.
Date: 1/24/83 R Change 2 11.11-28
-------
a
n>
••
GO
OJ
CO
to
o
tr
0)
iQ
n>
TABLE 12-1. WASTE STREAM AND PRIORITY POLLUTANTS EXPECTED FOR
ORGANIC CHEMICAL INDUSTRY PRODUCT-PROCESSES. (CONTINUED)
Product-Process
Waste Streams
Potential Priority
PoI Iutants
2. Wastewater from the aftercondenser of
the steam jet ejector at the phenol
still may contain residual phenol.
3. Wastewater from the aftercondenser of
the steam jet ejector at the isomers
still may contain BPA isomers and other
organ ics.
U. Wastewater from the aftercondenser of
the steam jet ejector at the BPA still
may contain a trace of BPA.
5. Bottoms from the BPA still discharged
as waste contain residual BPA and tars.
to
I
to
u>
17. BUTADIENE
Butadiene by Extractive
DistiI I at ion of C(U)
Pyrolyzates
Isobutylene
from
by Extraction
Pyrolyzates
Isobutylene by Dehydration
of tert-Butyl Alcohol
Butenes by Extractive Dis-
til lation of C(U) Pyroly-
zates
Butadiene by Dehydrogenation
of Butane and/or Butenes
No liquid waste streams are
generated in the production of
butadiene by solvent extraction
of C(H) pyrolyzates.
An aqueous acidic purge withdrawn
intermittently from the recycle
stream contains 45-65% sulfuric acid,
residual tertbutyl alcohol and C(U) hy-
drocarbons.
Waste stream and potential pollutants
will be similar to that of the process
above.
No liquid waste streams are generated
in the solvent extraction of butenes,
unless the solvent carries over into
the raffinate or into the butenes dis-
tilled from the extract.
The condensate from the steam jet
cyclically evacuating the reactors
contains various light hydrocarbons.
Copper
None identified
Copper
Chromium
18. n-BUTYL ACRYLATE
n-Butyl Acrylate by Esteri-
ficat ion of Acrylic Acid
with n-Butanol
Similar to production of acrylic acid
esters, under ACRYLIC ACID.
-------
ti-
ro
oo
00
O
(D
TABLE 12-1. WASTE STREAM AND PRIORITY POLLUTANTS EXPECTED FOR
ORGANIC CHEMICAL INDUSTRY PRODUCT-PROCESSES. (CONTINUED)
Product-Process
Waste Streams
Potential Priority
PoI Iutants
19. n-BUTYL ALCOHOL
Butyl Alcohols by the Oxo
Process: n-Butyl Alcohol
by Hydrogenation of
n-ButyraIdehyde,
Isobutanol by Hydrogenation
of IsobutyraIdehyde
The bottoms stream from the aldehyde-
refining distillation column may con-
tain unreacted propylene, aldehydes,
catalyst residues, and various high-
boiling organic byproducts.
The product fractionator bottoms stream
consists mainly of heavy ends, with
small amounts of the product. These
heavy ends are mainly high-boiling by-
product oxygenated compounds formed
from condensation of the aldehydes
and aIcohols.
Zinc, nickel
20. SECONDARY BUTYL ALCOHOL
sec-Butyl Alcohol by Hy-
drolysis of Mixed Butylenes
Methyl Ethyl Ketone by Dehy-
drogenation of sec-Butyl
AlcohoI
Methyl Ethyl Ketone as a
Byproduct of n-Butane Oxi-
dation for the Production
of Acetic Acid
I. The water effluent from the sulfuric-
acid reconcentrat ion evaporators con-
tains sulfuric acid and soluble sul-
fates.
2. Spent caustic from the caustic scrubber
could be contaminated with sodium sul-
fate, butylenes, and sec-butyl alcohol.
3. The overhead liquid stream from the
light-ends column is essentiaIly water
with traces of sec-butyl alcohol and
other light organics.
4. The bottoms stream from the heavy-ends
column contains organic byproducts and
traces of sec-butyl alcohol.
I. The wastewater discharged from the
alcohol cleanup step (as a consequence
of scrubbing the off-gas) could be con-
taminated with SBA and MEK.
I. The wastewater stream from the formic-
acid separation tower contains formic
acid.
2. The wastewater stream from the MEK
separator may contain MEK and formic
acid.
None identified
Copper, zinc, benzene
None identified
-------
TABLE 12-6. POLLUTANT REMOVABILITY FOR THE ORGANIC CHEMICALS AND
ft-
CD
CO
OJ
•i^"
DO
to
»
0
Eif
3
CD
M
PLASTICS/SYNTHETICS FIBERS INDUSTRIES [2-66]
BOD Removal by Type of Treatment
Treatment
Activated Sludge With
Tertiary Treatment) a)
Activated Sludge Without
Tertiary Treatment
Aerated Lagoon With
Tertiary Treatment) a)
Aerated Lagoon Without
Tertiary Treatment
No. Plants
26
59
5
•5
Cumu lat
70
100.0
98.3
100.0
100.0
ive Percent of
80
96.2
93.2
80.0
1.00.0
M TSS Remova 1 by Type
H
•
to
1
-J
Treatment
Activated Sludge With
Tertiary Treatment(a)
Activated Sludge Without
Tertiary Treatment
Aerated Lagoon With
Tertiary Treatment) a)
Aerated Lagoon Without
Tertiary Treatment
No. Plants
15
39
4
7
Cumu lat
5_0
73.3
48.7
75.0
57. 1
ive Percent of
60
73.3
43.6
50.0
57. 1
Plants
2Q
92.3
83. 1
40.0
60.0
with %
25_
61.5
54.2
20.0
60.0
BOD Re/nova 1
22
15.4
10.2
0.0
0.0
>
of Treatment
Plants
80
33.3
25.6
50.0
42.9
»
with %
2Q
26.7
20.5
50.0
28.6
TSS Remova 1
25
20.0
15.4
25.0
28.6
>
22
6.7
5. 1
0.0
0.0
Analytic methods: V.7.3.24, Data set 5
(a)The tertiary treatment following the biological treatment system
includes polishing ponds, filtration, or both polishing ponds and filtration.
-------
D
ft)
rt
(D
00
U)
00
M
n
tr
ft)
5
CD
M
H
H
to
1
VD
00
TABLE 12-7. EFFLUENT POLLUTANT CONCENTRATION FOR THE ORGANIC CHEMICALS
AND PLASTICS/SYNTHETIC FIBERS INDUSTRIES [2-66]
BOD Effluent Concentration
Treatment No.
Activated Sludge
With Tertiary Treatment (a)
Activated Sludge
Without Tertiary Treatment
Aerated Lagoon
With Tertiary Treatment (a )
Aerated Lagoon
Without Tertiary Treatment
Plants
34
67
10
1 1
Cumu lat i ve
20
47. 1
40.3
60.0
45.5
% of
30
58.8
55.2
60.0
54.5
Plants with
40
73.5
67.5
60.0
54.5
TSS Effluent Concentration
Treatment No.
Activated Sludge With
Tertiary Treatment(a )
Activated Sludge
Without Tertiary Treatment
Aerated Lagoon With
Tertiary Treatment(a)
Aerated Lagoon Without
Tertiary Treatment
Plants
32
58
8
14
Cumu lat ive
20
28. 1
13.8
50.0
42.9
% of
1Q
56.3
25.9
50.0
42.9
Plants with
40
65.6
36.2
87.5
57. 1
by Type of
Treatment
BOD Concentrations <
50.
79.4
71.6
70.0
72.7
by Type of
100
91 .2
85. 1
90.0
81 .8
Treatment
COD Concentrations <
5Q
75.0
44.8
87.5
57. 1
100
100.0
70.7
100.0
71.4
mq/L
200
100.0
92.5
90.0
90.9
mq/L
200
100.0
96.6
100.0
85.7
400
100.0
97.0
100.0
100.0
400
100.0
98.3
1 00 . 0.
100.0
800
100.0
100.0
100.0
100.0
800
100.0
98.3
100.0
100.0
Analytic methods: v.7.3.24, Data set 5
(a)The tertiary treatment following the
polishing ponds, filtration, or both
biological treatment system includes
polishing ponds and filtration.
-------
o
o
ft
oo
\
CO
00
JO
O
y
OJ
3
ifl
(D
H
•
h-1
to
H
O
TABLE 12-9. POLLUTANT REMOVAL BY PURE OXYGEN ACTIVATED SLUDGE (UNOX)
PROCESS FOR THE ORGANIC CHEMICAL INDUSTRY [2-67]
Po 1 1 utant
Acenaptnene
Ac ro 1 e i n
Benzene
Carbon tetrach loride
1 ,2-Dichloroethane
1,1, 1 -Trich lo roe thane
1, 1 -D i ch 1 oroethane
1 , 1 , 2, 2- Tet rach 1 oroethane
Ch f oroethane
2, it, 6-Tr ich loropheno 1
Chloroform
1 , l-Dich loroethylene
2,i)-Dichlorophenol
1 ,2-Dichloropropane
1 , 3-Dich loropropy tene
2, '1-Di methyl phenol
Ethyl benzene
Fluoranthene
Methylene chloride
D i ch 1 o rob romome thane
Trichlorof luorome thane
Naptha lene
N i t robenzene
2-Nitrophenol
t-Ni trophenol
Pentach 1 o ropheno 1
Pheno 1
Bis-(2-ethlhexyl )ph thai ate
Di-n-butyl phthaiate
Diethyl phthaiate
Acenapthylene
Anthracene
Fluorene
Phenanthrene
Pyrene
Tet rach loroethylene
Toluene
Trichloroethylene
Chrom i urn
Copper
Cyan ide
Lead
Mercury
Nickel
Se t en i urn
Si Iver
Thai 1 ium
Z. inc
Trans- 1 , 3-Dich loropropene
Number
of Plants
1
1
3
2
3
2
1
1
1
1
2
1
1
2
2
1
2
1
2
1
1
2
1
1
1
1
3
3
2
1
3
2
2
3
1
1
3
2
3
3
2
1
1
1
2
1
1
1
1
Average
Flow, cu.m/d
30,600
16,1(00
19,700
23,500
19,700
23,500
30,600
30,600
16,1400
30,600
23,500
30,600
30,600
23,500
23,500
30,600
23,500
30,600
23,500
30,600
30,600
23,500
16,1(00
30,600
16,1(00
16,1*00
19,700
20,600
23,500
30,600
19,700
23,500
21,500
19,700
30,600
16,400
19,700
23,500
19,700
19,700
IU,300
30,600
30,600
16,1(00
2 1 , 1(00
12,300
30,600
16, '(00
I6,UOO
Averaqe Concent n
Influent I
16
ND
U80
6.5
1 1
8.8
10
10
3.3
10
16
10
10
8.3
1 10
180
1(1
10
8.6
10
10
780
ND
1(00
ND
ND
8. It
35
330
10
6.1(
6.5
9.6
13
10
2.5
130
8.3
1 10
1 10
5.9
51
1
250
10
5
60
53
230
Ition. liq/L
:f fluent
10
ND
5. 1
6.5
8.9
7.7
10
10
ND
350
9.7
10
12
8.3
26
17
6.5
10
7.7
10
10
33
ND
1(9
ND
ND
7.2
2140
180
10
8.0
6.5
7.2
5.2
10
ND
1(6
8.3
31
1(0
13
20
1
270
1 1
6
33
67
28
Percent
Reduct i on
38
99
0
19
12
0
0
>99
NM
39
0
NM
0
76
91
8U
0
10
0
0
96
88
|1(
NM
1(5
0
NM
0
25
60
0
>99
65
0
72
6i(
NM
61
0
NM
NM
NM
'(5
NM
88
Analyt ic methods:
ND, not detected
NM, not mean IngfuI
V.7.3.24, Data set 3.
-------
D
0)
rl-
(D
oo
\
oo
00
NJ
O
(D
TABLE 12-10. PRIORITY POLLUTANT REMOVAL BY ACTIVATED SLUDGE PROCESS
FOR THE ORGANIC CHEMICAL INDUSTRY [2-67]
I
M
O
Pol lutant
Acenapthene
Aery Ion it ri le
Benzene
Carbon tetrachloride
Chlorobenzene
Hexach lorobenzene
2-Dichloroethane
1 , 1 -Tr ich loroethane
Hexachlo roe thane
1 , -Dich loroethane
1 ,2-Tr ich loroethane
1 , 2,2-Tetrach loroethane
Ch loroethane
Bi s(2-ch loroethy 1 Jether
2,4,6-Trich lorophenol
4-ch 1 oro-m-creso 1
Chloroform
2-Ch loropheno 1
, 2-D i ch 1 o robenzene
, 3-D ich lorobenzene
, 1 -Dich loroethylene
,2-Trans d ich loroethy lene
2,4- Dich loropheno 1
,2- Dich loropropane
, 3-Di ch 1 oropropy 1 ene
2 , 4-D i methy 1 pheno 1
2, 4-Di ni troto 1 uene
2, 6-D i n i troto 1 uene
Ethyl benzene
F 1 uoranthene
Bi s-( 2-ch loro i sop ropy 1 ) ether
B i s-( 2-ch 1 o roe thoxy) me thane
Methylene chloride
Methyl chloride
Bromoform
Dich lo rob romoe thane
Tr ich 1 orof 1 uoromethane
Ch lorod ibromomethane
Hexachlorobutad iene
Naptha lene
N i t robenzene
?-Ni tropheno 1
'-Ni tropheno 1
Number
of Plants
2
1
8
5
5
1
3
3
1
2
2
2
2
1
3
1
7
4
3
1
3
3
3
2
2
2
1
1
6
1
2
1
5
1
1
1
2
2
1
3
1
3
3
Average
Flow. m(3)/d
58,700
4, 160
19,900
28,400
23, 100
87, 100
34,300
42,800
87, 100
58,700
58,700
20,700
58,700
87, 100
31,600
87, 100
22,700
32,600
34,800
87, 100
42,800
34,300
31,600
17,000
45,800
58,300
9,230
9,230
24,000
7,680
45,800
87, 100
28,200
87, 100
4, 160
4, 160
7,830
17,000
87, 100
42,400
9,080
36,000
36,000
Average Concentration. ug/L
Influent
3.4
ND
4,900
210
1,500
ND
590
200
ND
190
170
9.9
38
1,700
100
ND
510
900
570
ND
450
1 . 1
1 10
1 ,300
10,000
7
15,000
3,800
840
150
810
ND
1,200
ND
ND
ND
7.3
27
ND
190
1 10,000
430
290
Effluent
2.5
ND
36
3.6
1 10
ND
5.9
3.2
ND
14
5.3
12
2.5
710
91
ND
3.6
58
66
ND
6. 1
1 . 1
44
39
190
8.7
1,800
1,800
3. 1
33
320
ND
140
ND
ND
ND
7.3
8.7
ND
3.6
9,700
60
31
Percent
Reduct ion
26
99
98
93
99
98
93
97
NM
93
58
9
99
94
88
99
0
60
97
98
NM
78
53
>99
78
60
88
0
68
98
91
86
89
-------
the existence or absence of floor drains. Where no troughs or
floor drains exist, equipment is often cleaned by hand with rags;
when wastewater drains are present, there is a greater tendency
to use hoses.
II.13.2.1 Solvent-Wash (Solvent-Base Solvent-Wash) Subcategory
Batches of solvent-base paint or ink that are rinsed with solvent
ordinarily generate no wastewater. The used solvent is generally
(1) used in the next compatible batch of paint (or ink) as part
of the formulation, or (2) collected and redistilled, either by
the plant or by an outside company, for subsequent reuse or
resale, or (3) reused with or without settling to clean tanks and
equipment until spent, and then drummed for disposal. If sludge
settles out, it is also drummed for disposal, but as a solid
waste. Because Effluent Guidelines for the solvent-base solvent
wash have been promulgated, solvent-base wash operations are not
considered further in this manual.
II.13.2.2 Water-Wash and/or Caustic-Wash Subcategory
Batch mixing tanks for water-base paint (or ink) that are rinsed
with water generate considerable quantities of wastewater. The
spent tank and equipment rinse water is usually handled in one of
four ways: (1) reuse in the next compatible batch of paint (or
ink) as part of the formulation, (2) reuse either with or without
treatment, to clean tanks and equipment until spent (if sludge
settles out, it is disposed of as a solid waste), (3) discharge
with or without treatment as wastewater, and (4) disposal as a
solid waste.
Plants that use caustic-rinse systems usually rinse the residue
with water, although a few plants allow the caustic to evaporate
from the tanks. Evaporation of caustic solution, however, can
leave a residue that will interfere with some types of paint
formulas. There are two major types of caustic systems commonly
used by the paint and ink industries. In one type of system,
caustic is maintained in a holding tank (usually heated) and is
pumped into the tank to be cleaned. The caustic drains to a
floor drain or sump where it is returned to the holding tank. In
the second type of system, a caustic solution is prepared in the
tank to be cleaned, and the tank is soaked until clean. Most
plants using caustic, reuse the solution until it loses some of
its cleaning ability. At that time, the caustic is disposed of
either as a solid waste or wastewater, with or without treatment.
The water rinse following a caustic wash is rarely reused in a
subsequent batch of paints (or ink). Generally, any generated
wastewater is combined with the regular clean-up water, and
disposed of by one of the same methods.
Date: 9/25/81 II.13-7
-------
In addition to process wastewater generated as a result of tank
and equipment cleaning, there are other sources of pollutants
within the typical paint or ink plant and these include: (1) bad
or spoiled batches that are not reused in other products or
discharged as a solid waste, and (2) residue from spills that is
discharged to the sewer or combined with other wastewater.
Tables 13-2 and 13-3 present information on the toxic and classi-
cal pollutants found in detectable concentrations for the plant
water supply, raw wastewater, and treated effluents for the
"water-wash and/or caustic-wash" subcategory of the paint indus-
try. Similar data are presented in Tables 13-4 and 13-5 for the
ink industry. Values for both the paint and ink industries were
generated from verification and field sampling results repre-
senting 22 paint plants and 6 ink plants.
II.13.3 PLANT SPECIFIC DESCRIPTION [2-40,41]
Production characterization and statistics concerning wastewater
generation and treatment for each of the 22 paint plants and 6
ink plants are presented in Table 13-6.
Tables 13-7 through 13-10 present toxic pollutant and classical
pollutant data for four of the 22 paint plants representing the
"water-wash and/or caustic-wash" subcategory of the paint indus-
try. Tables 13-11 through 13-14 present similar data for four of
the six plants representative of the ink industry. Unless other-
wise noted, all values are generated from screening data and
averaged from two or more batches based upon batch sampling. The
detection limit for toxic organic pollutants is 10 yg/L and
samples below that value are identified as BDL, below detection
limit. Due to convention in the reference, the full value of the
detection limit is used in computing the mean concentration where
there are one or more BDL samples.
II.13.4 POLLUTANT REMOVABILITY [2-40,41]
Paint and ink plants treat wastewater in several ways. Generally
the plants can reduce or reuse the wastewater, or release it with
or without treatment. Because a majority of the plants release
the wastewater into municipal sewage systems, treatment is often
a function of the municipal restrictions on the plant.
II.13.4.1 Reduction or Reuse of Wastewater
There are two widely used general strategies for reducing the
amount of wastewater that paint and ink plants discharge to the
environment. The first is to reduce the amount of wastewater
generated; the second is to reuse as much wastewater as possible
within plant processes. The amount of wastewater generated is
influenced by the water pressure used for tank and equipment
Date: 8/31/82 R Change 1 II.13-8
-------
TABLE 13-2. CONCENTRATIONS OF TOXIC POLLUTANTS DETECTED IN PAINT PLANT
WASTEWATER AND INTAKE, VERIFICATION DATA [2-UO]
Untreated Wastewater
Toxic pollutants. ua/L
Metals and inorganics
Ant imony
Arsen ic
Bery 1 1 i um
Cadm i um
Chrom i um
Copper
Cyanide
Lead
Me rcury
Nickel
So 1 en i um
Si 1 ver
Tha 1 1 i um
Z i nc
Toxic orqanics
Bis(2-ethylhexy 1 ) phthalate
Di-n-butyl phthalate
Pentachlorophenol
Phenol
Benzene
Ethy 1 benzene
N i t robenzene
To 1 uene
Naphtha lene
Carbon tet rach 1 or ide
Ch 1 o rod i b romome thane
Ch 1 o roform
D i ch t o rob romome thane
1 , l-Dichloroethane
1 , 2-D i ch 1 o roe thane
1, l-Dichloroethytene
1 ,2-trans-Dichlo roe thy 1 ene
1 ,2-Dichloro propane
Methylene chloride
Tet rach 1 o roe thy 1 ene
1,1, I-T rich lo roe thane
1,1,2-Trichlo roe thane
Trichloroethylene
Aero 1 e t n
2-Chloronaptha lene
3, 3-Dichlorobenzidene
2,4-Dichlorophenol
F 1 uoranthene
B i s( 2-ch 1 o roe thoxy) me thane
4,6-Dinitro-o-cresol
Diethyl phthalate
3, 4-Benzopy rene
Anthracene
Ch 1 orobenzene
D i { 2-ch 1 oro i sopropy 1 ) ether
2-4 D i n i t ropheno 1
Butyl benzyl phthalate
Pesticides and metabolites
1 sophorone
A 1 d r i n
Dieldrin
4,4-DDE
Beta-endosul fan
Mcptachlor epoxide
Alpha-BHC
Beta-BIIC
Gamma-BIIC
Del ta-BMC
Number
of
samples
ana 1 vzed
49
41
51
51
51
51
54
51
50
51
(b)
51
51
51
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
27
(a)
a)
a)
a)
a)
a)
(a)
(a)
a)
(a)
(b)
(b)
(b)
(b)
27
(a)
(a)
(a)
(a)
(a)
(a)
(a)
a)
(a)
Number
of
times
detected
49
41
51
51
51
51
54
51
50
51
51
51
51
9
18
6
8
17
21
3
23
9
8
0
14
1
1
5
5
2
3
17
17
15
5
15
Average
of
detected
va lues
72
120
< 1 3
80
2,900
2,300
73
6,300
10,000
1,000
< 1 6
< | 7
84,000
490
8,000
6,000
1,000
2,000
2,600
100
20,000
3,000
3,800
200
27
BDL
120
140
130
330
34,000
600
150
570
90
BDL
BDL
BDL
BOL
BDL
BDL
BDL
BDL
BDL
BDL
BDL
BDL
BDL
BDL
BDL
BDL
BDL
BDL
BDL
BDL
Median
of
detected
va 1 ues
25
52
< 1 0
20
200
500
20
800
1, 100
50
< 1 0
< | o
10,000
140
260
750
1 10
440
1,200
1 10
2,500
54
14
1 10
33
23
12
790
230
82
BDL
52
Max i mum
of
detected
va lues
1,000
800
100
810
40,000
40,000
310
80,000
120,000
40,000
100
200
900,000
2,800
69,000
27,000
3,800
9,900
15,000
180
260,000
18,000
30,000
900
420
620
260
970
210,000
4,900
930
2,800
250
Date: 8/31/82 R Change 1 II.13-9
-------
TABLE 13-2. CONCENTRATIONS OF TOXIC POLLUTANTS DETECTED IN PAINT PLANT
WASTEWATER AND INTAKE (continued)
Treated wastewater(b)
Toxic DO! lutant
Metals and inorganics
Antimony
Arsenic
Be ry 1 1 i urn
Cadmium
Ch rom i urn
Copper
Cyanide
Lead
Mercury
Nickel
Selenium
Si Iver
Thai 1 ium
Zinc
Toxic organ ics
Bis(2-ethylhexyl ) phthalate
Di-n-butyl phthalate
Pentach 1 o ropheno 1
Pheno 1
Benzene
Ethyl benzene
Nitrobenzene
Toluene
Naphtha lene
Carbon tetrach loride
Chlorodibromomethane
Chloroform
D i ch 1 o rob romome tha ne
, l-Dichloroethane
,2-Dichloroethane
, 1 -Dichloroethy lene
,2-Trans-dichloroethylene
,2-Dichloropropane
Me thy lene chloride
etrachloroethylene
, 1, l-Trichloroethane
, 1 ,2-Trichloroethane
Trichloroethylene
Acrolein
1 , 2-Dichlorop ropy lene
Bis(2-Chloroethoxy)ether
2 , 4-D i n i t ropheno 1
Di-n-octyl phthalate
Butyl benzyl phthalate
Dimethyl phthalate
Chlorobenzene
Chloroethane
1 ,2-Diphenylhydrazine
Diethyl phthalate
Acenapthy lene
Anthracene
Phenanthrene
Pesticides and metabolites
4,4-DDD
Isophorone
Beta-endosulfan
Endrin aldehyde
Beta-BHC
Number
of
samples
ana Ivzed
U3
39
45
45
45
45
48
45
45
45
. (a)
45
45
45
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
23
0
(a)
(a)
(a)
(a)
(a)
(a)
(a)
(a)
(a)
(a)
(a)
(a)
(a)
(a)
23
(a)
(a)
(a)
Number
of
times
detected
43
39
45
45
45
45
48
45
45
45
45
45
45
7
9
6
13
14
15
1
17
7
3
0
15
0
2
4
4
6
2
19
8
14
4
10
2
Average
of
detected
va 1 ues
28
34
9
29
1,300
2,000
51
1, 100
830
3,500
>IO
9
12
8,500
33
310
120
140
680
5,800
35
1,800
380
640
390
95
71
19
51
210
5,600
190
89
930
78
>IO
>IO
>IO
>IO
>IO
>IO
BDL
BDL
BDL
BDL
BDL
BDL
BDL
BDL
1 10
BDL
BDL
BDL
Median
of
detected
va lues
25
25
BDL
20
50
120
20
200
200
50
BDL
BDL
1,000
BDL
BDL
1 1
16
310
370
960
16
120
34
53
1 1
27
1,700
35
29
810
15
Maximum
of
detected
va 1 ues
180
400
20
200
30,000
60,000
530
40,000
4,400
80,000
20
100
100,000
160
1,300
490
1,200
3,800
74,000
7,200
1,800
1,800
4,700
180
170
44
190
400
31,000
700
560
2, 100
300
200
Date: 9/25/81
11.13-10
-------
TABLE 13-3. CONCENTRATIONS OF CLASSICAL POLLUTANTS DETECTED
IN PAINT PLANT WASTEWATER AND INTAKE, VERIFICATION
DATA [2-40]
Untreated Wastewater
Po 1 1 utant, mq/L
Number
of
samp les
ana lyzed
Number
of
t imes
detected
Average
of
detected
va lues
Med ian
of
detected
va 1 ues
Maximum
of
detected
va 1 ues
BOD5
COD
TOG
TSS
Total phenols
Oil and grease
pH, pH units
6005
COD
TOG
TSS
Total phenols
Oil and grease
pH, pH units
54
54
49
51
54
50
53
54
54
49
51
54
50
53
9,900
56,000
10,000
20,000
0.29
1,200
Sludge
4,900
40,000
8,500
13,000
0. 14
980
7
66,000
350,000
34,000
150,000
1.9
3,400
12
31
32
31
31
32
30
29
31
32
31
31
32
30
29
26,000 12,000
190,000 140,000
37,000 30,000
100,000 70,000
0.63 0.20
8,600 2,900
7
Treated Wastewaterfa)
150,000
950,000
1 10,000
470,000
6.0
130,000
12
BOD5
COD
TOG
TSS
Total phenols
Oil and grease
pH, pH units
48
47
44
48
49
43
46
48
47
44
48
49
43
46
5,300
21,000
4,000
2,000
0.23
230
Intake Water
3,500
I 1,000
2,800
240
0.09
24
7
32,000
260,000
25,000
22,000
1.9
1,700
I I
BODS
COD
TOG
TSS
Tota 1 pheno 1 s
Oil and grease
pH, pH units
21
22
20
20
22
18
20
21
22
20
20
22
18
20
3
10
8
3
0.01
1
2
6
8
3
0.01
1
7
6
40
20
1 1
0.04
5
9
Analytic methods: V.7.3.25, Data set I.
(a) Includes both direct and indirect dischargers.
Date: 8/31/82 R Change 1 11.13-13
-------
TABLE 13-t. CONCENTRATIONS OF TOXIC POLLUTANTS DETECTED IN INK PLANT
WASTEWATER AND INTAKE AS REPORTED IN SOURCE, VERIFICATION
DATA [2-41 ]
Untreated Wastewater
Toxic DOllutents. uo/L
Metals and Inorganics (b)
Antimony
Arsenic
Be ry 1 1 i urn
Cadmium
Chromium
Copper
Cyanide
Lead
Mercury
Nickel
Se 1 en i urn
S i 1 ve r
Thai 1 lum
Zinc
Toxic oroanics
Bi s(2-ethylhexyl ) phthalate
Di-n-butyl phthalate
Pentach 1 oropheno 1
Phenol
Benzene
Ethyl benzene
Toluene
Naphtha lene
Carbon tetrach loride
Ch 1 o rod 1 b romomethane
Chloroform
, l-Dichloroethane
,2-Dich lo roe thane
, 1 -Dich loroethy lene
,2-Trans-di chlo roe thy lene
,2-Dichloropropane
Me thy lene chloride
Tetrach loroethy lene
, 1, l-Trichloroethane
, 1 ,2-Tri chlo roe thane
Trich loroethy lene
Acenapthene
1 , 2, 1-Tri chlo robenzene
2,1,6-Trichloropnenol
Parachlorometa cresol
1 , 2-D i ch 1 o robenzene
2,1-Dimethylphenol
2 , 14-0 i n i t ro to 1 uene
2, 6-Di n i t roto 1 uene
T 1 uoranthene
Bi s(2-chloroi sopropyl (ether
Chlo robenzene
1 , 2-D iphenyl hydra zine
Tr i ch lo rof luoro methane
1 sophorone
N-N i t rosod i pheny 1 am i ne
Butyl benzyl phthalate
Di-n-octyl Phthalate
Dlethyl phthalate
Dimethyl phthalate
Ch rysene
Anthracene
F 1 uo rene
Phenanthrene
Pyrene
T r i ch 1 o roe thy 1 ene
Dieldrin
Number
of
samples
1
1
1
!
i
i
0
1
9
1
1
1
1
1
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
e
B
8
8
8
8
8
8
B
8
8
8
8
8
8
B
6
8
8
8
8
8
8
8
B
8
8
8
8
Number of
detections
above detec-
tion limit
3
0
0
5
1 1
1 1
7
1 1
3
2
0
1
0
8
3
3
1
2
5
3
6
3
1
1
2
2
1
1
0
1
5
0
2
0
14
0
0
0
0
0
0
0
0
0
0
2
1
0
1
0
0
1
1
0
0
1
0
0
0
Ll
0
Mini mum
of
detections
(a)
<25
<25
-------
TABLE 13-4. CONCENTRATIONS OF TOXIC POLLUTANTS DETECTED IN INK PLANT
WASTEWATER AND INTAKE AS REPORTED IN SOURCE, VERIFICATION
DATA (continued)
Treated Wastewater
Toxic pollutants. uq/L
Number of Minimum Mean Maximum
Number detections of of of
• of above detec- detections detections detections
samples t ion limit (a 1 I a ) la 1
Metals and inorganics (b)
Ant i mony
Arsen i c
Be ry 1 1 i urn
Cadmium
Chromium
Copper
Cyanide
Lead
Mercury
Nickel
Selenium
Si Iver
Thai 1 ium
Zinc
Toxic orqanics
Acenaphthene
Benzene
3,3'-Oichlorobenzidine
2,i|-Dichlorophenol
2,it-Dini trotoluene
Ethy 1 benzene
Di (2-chloroethoxy) methane
Methylene chloride
Isophorone
Naptha lene
Phenol
Bis (2-ethylhexyl ) phthalate
Di-n-butyl phthalate
Di-n-octyl phthalate
1 ,2-Benzanthracene
Anthracene
Phenanthrene
Toluene
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
1
2
2
2
1
2
1
2
2
2
2
2
2
2
2
2
1
0
0
0
0
1
1
2
1
0
0
0
0
0
2
0
1
0
0
0
1
0
1
1
1
1
1
1
0
0
0
1
1
<25
<25
-------
-------
TABLE 13-4. CONCENTRATIONS OF TOXIC POLLUTANTS DETECTED IN INK PLANT
WASTEWATER AND INTAKE AS REPORTED IN SOURCE, VERIFICATION
DATA (continued)
Intake water
Toxic pollutants. ug/L
Number of Minimum Mean Maximum
Number detections of of of
of above detec- detections detections detections
samples tlon limit (al (al (al
Metals and Inorganics (b)
Antimony
Arsenic
Be ry II 1 urn
Cadmium
Ch rom I urn
Copper
Cyanide
Lead
Me rcu ry
Nickel
Selenium
Silver
Tha II 1 urn
Zinc
Toxic organlcs
Acenaphthene
Benzene
1 ,2,14-Trlchlorobenzene
1,2-Dlchlo roe thane
1,1, l-Trlchlo roe thane
1 , 1,2,2-Tetrachloroethane
Chloroform
1 ,2-Dichlorobenzene
i»-Chlorophenyl phenyl ether
Methylene chloride
Dichlorobromomethane
Trf chlorofl uorome thane
Ch 1 o rod 1 b romomethane
Isophorone
Naphtha lene
Bis (2-ethylhexyl ) phthalate
Butyl benzyl phthlate
Oi-n-butyl phthalate
Diethyl phthalate
3,i|-Benzof luoranthene
Anthracene
Fluorene
Phenanthrene
Toluene
Trichloroethylene
Alpha-BHC
Gamma -BHC
7
7
8
8
8
8
7
8
6
8
7
8
7
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
1
0
0
1
6
6
0
6
2
1
0
1
0
2
0
14
0
0
0
0
-------
TABLE 13-5. CONCENTRATIONS OF CLASSICAL POLLUTANTS DETECTED IN INK PLANT
WASTEWATER AND INTAKE AS REPORTED IN SOURCE, VERIFICATION
DATA [2-41]
Treated wastewater
Pol lutant. ma/L
BOOS
COD
TOC
TSS
Tota 1 pheno 1 s
Or 1 and grease
pH, pH units
Tota 1 sol ids
TDS
TVS
VDS
TVSS
Aluminum
Barium
1 ron
Manganese
Ca 1 c i um
Magnes ium
Boron
Coba f t
Mo lybdenum
Tin
T r tan i um
Vanad i um
Yttrium
Sod i um
Number
of
samples
1
2
1
2
2
2
2
2
1
1
1
1
2
2
2
2
2
2
1
2
2
2
2
2
2
2
Number of
detect ions
above detec
t ion limit
1
2
1
2
2
2
2
2
1
1
1
(
2
2
1
1
0
2
0
1
1
0
2
0
0
2
Mini mum
:- of
detections
4,800
1 10
30
260
13
5,600
600
100
<2,000
50
<5
1
<5D
<50
<50
450
-------
cleaning, the degree of cleaning required, and the use of dry
cleaning techniques.
Several methods in use by some plants reduce the water usage.
Cleaning a tank with a squeegee prior to a water rinse reduces
the quantity of water needed to clean the tank. High pressure
hoses can also clean a tank in less time using less water.
Wastewater volume can also be reduced by eliminating or sealing
floor drains, assuring that water will not be used to clean the
floors. The use of these methods can significantly reduce the
wastewater volume of a paint or ink plant.
Reuse of wash or rinse water is common in the paint and ink
industry. Wash water can be transferred directly to a second tub
or can be reused as makeup water. The paint industry often uses
wash water for makeup in a batch of similar color paint. Ink
plants reuse the rinse water from a caustic rinse as makeup for a
caustic wash. These techniques can reduce raw material costs as
well as treatment costs. Generally, reuse of wastewater is more
prevalent in small plants than in larger ones.
II.13.4.2 Treatment Systems
Less than 26 percent of all paint plants and 15 percent of all
ink plants practice any type of wastewater treatment. The major-
ity of the plants that release wastewater, discharge it to munic-
ipal sewage systems. Of the plants that discharge their waste-
water to a municipal sewer, less than 40 percent of the paint
plants and 33 percent of the ink plants pretreated the wastewater
prior to discharge.
The most common methods used by paint and ink plants for treating
or pretreating wastewater prior to disposal are gravity oil
separation and neutralization. The paint industry also uses
physical/chemical treatment. Few plants from either industry use
biological treatment, and those that do usually have a combined
treatment plant for wastes from other plant processes. No paint
or ink plants use advanced wastewater treatment methods such as
activated carbon or ultrafiltration.
Gravity Separation or Settling
Gravity separation or settling of paint and ink wastewater re-
moves many of the suspended solids but leaves a supernatant layer
that is high in solids and other pollutants. This treatment
usually requires large areas to achieve a reasonable removal of
solids.
Neutralization
Neutralization is used to adjust the pH of the wastewater stream
to levels necessary for other treatment steps. The pH adjustment
Date: 9/25/81 11.13-27
-------
can be made with the addition of either alkalies or acids depend-
ing on what pH is required. This technique can often signif-
icantly reduce the dissolved metals by precipitation.
Physical/Chemical Treatment
%
Physical/chemical (P/C) treatment systems take advantage of the
natural tendency of paint wastewater to settle. Most plants
operate the treatment on a batch basis, collecting the wastewater
in a holding tank. If necessary, the pH is adjusted to an opti-
mal level, a coagulant (lime, alum, ferric chloride, or iron
salts) and/or a coagulant aid is added and mixed, and the batch
is allowed to settle (1 to 48 hours). The supernatant is dis-
charged and the sludge is treated as a solid waste. P/C removes
some metals and some organic priority pollutants, and achieves a
reduction in conventional pollutants.
Biological Treatment
Biological treatment has been used as a secondary treatment
(usually following P/C) at several paint plants. Most of the
plants pretreat the raw wastewater and then combine it with other
plant wastewater. Data from this treatment indicate that bio-
logical treatment in an aerated lagoon can reduce conventional,
metal, and organic pollutant concentrations to low levels. Use
of this technique can be practical for paint plants in rural
areas that wish to further treat P/C effluent for both conven-
tional and toxic pollutants.
Potential Wastewater Treatment Systems
Other treatment systems which have been suggested for use in the
paint and ink industry, but for which no data were available,
include ultrafiltration, carbon adsorption, reverse osmosis,
steam stripping, dissolved air flotation, and sand filtration.
The following tables present data on several treatment processes.
Table 13-15 shows the average effluent characteristics and re-
moval efficiencies for batch physical/chemical treatment at
several paint plants. Table 13-16 presents data from one paint
plant that uses an aerated lagoon as a secondary treatment.
Table 13-17 presents data from an ink plant that practices grav-
ity oil separation, and clarification, and neutralization and
shows average effluent concentrations and removal efficiencies.
Date: 8/31/82 R Change 1 11.13-28
-------
D
P>
rt
0>
TABLE IU-3. CONCENTRATION OF TOXIC POLLUTANT IN PETROLEUM REFINING WASTEWATER (continued)
00
00
to
O
n>
i
en
Intake
Toxic pollutants. uq/L
Number
of
samples
Ranqe
Median
API separator effluent
Number
of
samples
Ranae
Median
DAF effluent
Number
of
samples
Ranae
Median
Polvcycllc aromatic hydrocarbons
Acenapthene
Acenapthylene
Anthracene
Anth racene/phenanth rene
Benzo(a) pyrene/pery lene
Benzoj a )py re ne/pery lene
Chrysene
Chrysene/benzo(a (anthracene
Fluoranthene
F 1 uo ranthene/py rene
Fluorene
Naphthalene
Phenanthrene
Pyrene
Polychlorlnated blphenvls and
related compounds
Aroclor 1016
Aroclor 1221
Aroclor 1232
Aroclor 1239
Aroclor I2M2
Aroclor I2t8
Aroclor I25M
Aroclor 1260
Halogenated allphatics
Carbon tetrachlorlde
Chloroform
D 1 chlo rob romome thane
1,2-DI chlo roe thane
1 ,2-Trans-dlchloroethy lene
He thy lene chloride
1, 1,2,2-Tetrachloroethane
Tetrachloroe thy lene
1,1, l-Trl chlo roe thane
Trlchloroethylene
pesticides and metabolites
Aldrin
Alpha-BHC
Beta-BHC
Delta-BHC
Gamma-BHC
Chlordane
u!l»'-DDD
Alpha-Endosul ran
Beta-Endosulfan
Endosulfan sulfate
Heptachlor
Heptachlor epoxlde
Isophorone
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
17
16
16
16
16
9(c)
16
16
16
16
17
17
17
17
17
17
17
17
17
17
17
17
17
17
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
NO
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
- 29
- 0.2
- ND
- 160
- NO
- 33
- M9
- ND
- 29
- ND
- 1
- 2
- ND
- IUO
- ND
- ND
- 1(9
- ND
- 0.2
- ND
- ND
- ND
- >50
- 70
- ND
- ND
- 1 1
- 130
- < 10
- 50
- >50
- 20
- ND
- ND
- ND
- ND
- ND
- 2.8
- ND
- ND
- ND
- ND
- ND
- ND
- ND
- ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
NO
ND
NO
ND
85
ND
ND
50
ND
ND
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
1 1
1 1
1 1
1 1
1 1
9(c)
1 1
II
II
II
12
12
12
12
12
12
12
12
12
12
12
12
12
12
ND - 520
ND - 660
ND - 660
NO - 1, 100
NO - ND
ND - ND
ND - MO
ND - t)0
ND - 8
ND - l»0
ND - 270
ND - 3,200
ND - 660
NO - 16
ND - 50
ND - ND
ND - NO
ND - 12
ND - ND
ND - <5
ND - 12
ND - ND
ND - NO
ND - 7
ND - ND
ND - ND
ND - 13
ND - ND
ND - <5
ND - <5
ND - 3,600
ND
ND
ND
19
ND
ND
ND
ND
ND
21(0
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
6
ND
ND
ND
>IOO
ND
ND
ND
ND
ND
ND
ND
ND
NO
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
2
3(c)
5
5
5
3(c)
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
5
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
ND -
390
530
1,800
600
ND
ND
0.3
ND
ND
ND
500
3,700
1,800
5
-------
rt
(D
N)
Ul
00
TABLE 14-3. CONCENTRATION OF TOXIC POLLUTANTS IN PETROLEUM REFINING WASTEWATER
SCREENING AND VERIFICATION DATA (continued)
Second API
separator effluent
Third API
separator effluent
Fourth API
separator effluent
Toxic DO) lutant. uq/L
Metals and inorganics
Ant imony(b)
Arsenic
Beryl 1 ium
Cadmium
Chromium
Copper
Cyanide
Lead
Mercury
Nickel
Selenium(b)
Si Iver
Thai 1 ium(b)
Zinc
Phthalates
Bis(2-ethylhexy 1 ) phthalate
Di-n-butyl phthalate
Diethyl phthalate
Dimethyl phthalate
Phenols
2-Ch loropheno 1
2, 4-Dich loropheno 1
2, 4-Din itrophenol
2, 4-Di methyl phenol
2-N itrophenol
4-N itrophenol
Pentach 1 o ropheno 1
Pheno 1
Aromatics
Benzene
1 , 2-D i ch 1 o ro benzene
I , II-D i ch 1 o robenzene
Ethyl benzene
Toluene
Number
of
samples
2
2
6
6
6
6
6
6
6
6
2
6
2
6
2
2
2
2
2
2
2
2
2
2
1
1
1
1
1
Ranqe
<,
5
<2
<20
41(0
<4
10
<60
0.3
<50
8
<25
3
300
ND
ND
ND
ND
ND
ND
ND
ND
ND
>IOO
- <25
- <20
- <2
- <20
- 1, 100
- 230
- 210
- 2, 100
- 2.8
- 69
- <20
- <25
- < 1 5
- 1,400
- 300
- ND
- ND
- ND
- ND
- ND
- ND
- >IOO
- ND
- 160
Number
of
Median samples
50(d)
>!30(d)
1
1
3
3
3
3
3
3
3
3
1
3
1
3
1
1
1
1
1
1
1
1
1
Ranqe
<2
<20
350
14
10
<6
0.2
<50
<25
190
<(
3
- <2
- <20
- 1,000
- 16
- 10
- 120
- 0.9
- 120
6
- <25
<2
- 280
50
ND
ND
ND
ND
ND
ND
ND
ND
Med ian
<2
<20
550
16
10
<60
0.6
<50
<25
250
Number
of
samples
1
1
3
3
3
3
3
3
3
3
3
1
3
1
1
1
1
1
1
1
1
1
Range
1
3
<2 - <2
<20 - <20
840 - 1,900
21 - 77
50 - 60
<60 - 80
0.2 - 1.6
<50 - <50
1 1
<25 - <25
<2
260 - 580
600
NO
ND
ND
ND
650
850
16,000
Med ian
<2
20
1,200
38
60
<60
1 .3
<50
<25
410
>IOO
ND
ND
>IOO
>IOO
-------
D
(D
rt
n>
oo
\
u>
TABLE \H-1. CONCENTRATIONS OF CLASSICAL POLLUTANTS FOUND DURING A VERIFICATION
STUDY IN PETROLEUM REFINING WASTEWATER (continued)
CO
n
(D
I
M
LO
Fifth API separator
effluent
Pol lutant. raq/L
BOD5(a)
B005(b)
B005(c)
COO
TOC
TSS
Ammon i a
Cr+6
S-2
Oi 1 and grease
pH, pH uni ts
Cyanides
Phenol s
Flow, ML/d
BOD5(a)
BOD5(b)
B005(c)
COO
TOC
TSS
Ammon ia
Cr+6
S-2
Oil and grease
pH, pH units
Cyanides
Phenols
Flow, ML/d
Number
of
samples
2 10
3 10
3 75
3 22
3 16
3
-------
as nitrogen, phenolic compounds/ sulfide, chromium, and TSS are
the significant pollutant parameters.
Table 14-6 presents the number of plants, ranges, and median
concentrations in wastewater for classical pollutants for
indirect discharges from the topping and cracking subcategories
of petroleum refining. The available data were not sufficient
for the other subcategories. These data tend to confirm that
there are no significant differences in raw wastewater character-
istics (flow and classical pollutants) for indirect dischargers
and for the Petroleum Refining Industry as a whole, and further
analysis confirmed this.
Table 14-7 presents ranges and median loadings in raw wastewater
of classical pollutants for the Petroleum Refining Industry
subcategories.
Wastewater Flows
Table 14-8 presents the median flows for the Petroleum Refining
Industry subcategories.
II.14.3 PLANT SPECIFIC DESCRIPTIONS [2-47]
Verification and screening studies were undertaken in the
Petroleum Refining Industry to: (a) analyze for the presence
of the 129 toxic pollutants in the plants' intake water sources;
(b) analyze the plants' raw wastewaters to determine the net
production of toxic pollutants as a result of refinery process
operations; and (c) analyze the plants' final effluents for the
presence of toxic pollutants and to determine an indication of
the removal efficiencies of BPT-type wastewater treatment systems
for these pollutants.
The verification and screening studies were conducted by
the Robert S. Kerr Environmental Research Laboratory (RSKERL)
and Burns and Roe (B <& R) . The details of how the plants were
selected in both studies are available in Reference 2-47. The
combined studies sampled 17 refineries, at which intake water,
raw wastewater, and final effluent samples were collected for
three consecutive 24-hr periods.
Date: 8/31/82 R Change 1 11.14-14
-------
a
rt
(D
00
\
U)
CO
N)
n
(D
M
H
H
•
H
I
Ul
TABLE 14-5. RAW WASTEWATER CHARACTERIZATION BY SUBCATEGORY IN
PETROLEUM REFINING, SCREENING AND VERIFICATION DATA [2-44]
Parameter. mq/L
BODS
COO
TOC
TSS
Nitrogen
Phenol ic
Suicides
Oi 1 and
, ammon i a
compounds
grease
Total chromium
BOD5
COO
TOC
TSS
Nitrogen
Phenol ic
Sulf ides
Oi 1 and
, ammonia
compounds
grease
Total chromium
Topping
subcategory
Range
10
50
10
10
0.05
NO
NO
10
ND
s
100
MOO
100
80
1
0. 1
ND
UO
ND
- 50
- 150
- 50
- UO
- 20
- 200
- 5
- 50
- 3
Lube
ubcategory
- 700
- 700
- MOO
- 300
- 120
- 25
- 140
- UOO
- 2
Med i an
23
1 10
20
NA
2.7
0.80
0.211
25
NO
NA
NA
NA
NA
NA
NA
NA
NA
NA
Cracki ng
subcategory
Pet rochem ica 1
subcategorv
Range Median
30
150
50
10
0.5
ND
ND
15
ND
100
300
50
20
1
0.5
ND
20
ND
- 600
- UOO
- 500
- 100
- 200
- too
- UOO
- 700
- 6
1 nteg rated
subcategory
- 800
- 600
- 500
- 200
- 250
- 50
- 60
- 500
- 2
HiO
380
66
NA
29
6.0
1.2
53
0. 1 1
1 10
260
52
NA
IU
2.2
1.2
UU
0.27
Range
50 -
300 -
100 -
50 -
U -
0.5 -
NO -
20 -
NO -
800
600
250
200
300
50
200
250
5
Med i an
IUO
U20
130
NA
U2
10
180
15
O.U7
Analytic methods:
ND, not detected.
NA, not aval(able.
V.7.3.26, Data sets 1,2.
TABLE 14-6. RAW WASTEWATER CHARACTERIZATION BY SUBCATEGORY IN
PETROLEUM REFINING FOR INDIRECT DISCHARGERS [2-44]
Topp i ng
subcategorv
Parameter. mg/L
Flow, ML/d
BOD5
COD
Ammonia
Pheno 1 tcs
Sulf ides
Oi 1 and grease
Tota 1 chromi urn
Number
of
plants
6
1
6
5
6
6
6
6
Range
0.023
200
71
0.62
<0.05
-------
o
Sa
rt
(D
oo
\
CO
00
to
O
tr
0)
(D
M
H
H
•
I-1
I
Ol
TABLE 14-7. RAW WASTEWATER LOADINGS IN NET KlLOGRAMS/I,000 cu.m Of FEEDSTOCK
THROUGHOUT BY SUBCATEGORY IN PETROLEUM REFINING (a) SCREENING
AND VERIFICATION DATA [2-44]
Topp ing
subcateqory
Pa ra meter
Flow(c)
BODS
COD
TOC
TSS
Su If ides
Oil and grease
Phenol s
Ammon ia-N
Ch rom i urn
Ranqe(b)
8.00 -
1.3 -
3.1 -
1 . 1 -
0.7 -
0.002 -
1.0 -
0.001 -
0.077 -
0.0002 -
558
220
490
66
290
1.5
89
1 . 1
20
0.29
Med fan
66.6
3.4
37
8.0
12
0.054
8.3
0.034
1 .2
0.007
Cracking
subcateqory
Ranqe(b) Median
3.29
14
28
5.4
0.94
0.01
2.9
0. 19
2.4
0.0008
Lube
subcateqory
Flow(c)
BODS
COD
TOC
TSS
Ammon ia-N
Phenol s
Su If ides
Oil and g rea se
Ch rom i urn
68.6 -
63 -
170 -
32 -
17 -
6 -
4.6 -
0.00001 -
24 -
0.002 -
772
760
2,300
3 It)
310
96
53
20
600
1.2
1 17
220
540
1 10
72
24
8.3
0.014
120
0.046
40
64
73
29
15
0.61
0.52
21
0. 12
- 2,750
- 470
- 2,500
- 320
- 360
- 40{d)
- 360
- 80
- 170
- 4.2
1 nteg rated
subcateqory
- 1370
- 620
- 1,500
- 680
- 230
- 23
- 7.9(d)
- 270
- 1.9 0
93
73
220
42
18
0.94(d)
31
4.0
28
0.25
235
200
330
140
59
3.8
2.0(d)
75
.49
Petrochemica 1
subcateqory
Ranqef b)
26.6
41
200
49
6.3
0.009
12
2.6
5.4
0.014
- 443
- 720
- 1,100
- 400
- 370
- 92
- 240
- 24
- 210
- 3.9
Med fan
109
170
460
150
49
0.86
53
7.7
34
0.23
Analytic methods: V.7.3.26, Data sets 1,2.
(a)After refinery API separator.
(b)ProbabiIity of occurrence less than or equal to
(c)l,000 cu.m/1,000 cu.m of feedstock throughput.
(d)Sulfur.
or 90% respectively.
-------
D
V
ft
(D
oo
\
U)
TABLE 14-18. SCREENING AND VERIFICATION STUDY WASTEWATER
CHARACTERIZATION BY PLANT, REFINERY J (continued)
oo
NJ
n
i
U)
Separator 1 effluent
Pol lutane
Classical pollutants, mg/L(b)
Ammon i a
BOD-I
BOD- 3
COO
Oi 1 and grease
pH
Phenols, total (d)
Sul fide
TOC
TSS
Flow. HL/d
Toxic pollutants, |ig/L
Metals and inorganics
Antimony
Arsenic
Be ry 1 1 i un
Cadmium
Chromium
Chromium! +6)
Copper
Cyanide
Lead
Mercury
Nickel
Se t en i urn
Si Iver
Tha 1 1 i urn
Zinc
Day
1
2.0
51
39
210
71
8.9
1,000
0.7
60
51
<2
<20
36
20
<1
10
<60
0. 1
<50
<25
-------
rt
(D
TABLE IU-18. SCREENING AND VERIFICATION STUDY WASTEWATER
CHARACTERIZATION BY PLANT, REFINERY J (continued)
ro
en
oo
I
tt*
O
Pol lutant
Classical pollutants, as/Mb)
AMionla
BOD-I
BOD-3
COD
Ol 1 and grease
Phenols, total(d)
Suicide
TOC
TSS
Flow, ML/d
Toxic pollutants, u.g/L
Metals and Inorganics
Ant 1 Hony
Arsenic
Be ry 1 1 i UK
Cadmium
Chroaiun
Chro«lmn(+6)
Copper
Cyanide
Lead
Mercury
Nickel
Set en lull
Silver
Tna 1 1 1 ux
Zinc
Phthalates
Bls(Z-ethylhexyl) ph thai ate
Pheno 1 s
Phenol
Polvcvcllc arontic hydro-
carbons
Anthracene/phenanthrene
Chrysene benzo(a)anthracene
Fluoranthene/pyrene
Naptha lene
Polvchlorinated blphenvls and
related compounds
Aroclor 1016
Aroclor 1232
Aroclor 1212
Seoarator 3 effluent
Day
3.0
15
58
160
25
7.1*
6001 e)
1.8
52
62
<2
<20
550
20
It
10
120
0.2
120
<25
190
Day
2
6.2
20
22
180
23
7.3
1,300
5.3
45
38
<2
<20
1,000
20
16
10
<60
0.6
<50
<25
240
Day
3
1.5
32
220
51
7.3
1.5
1.5
63
314
<2
<20
350
>IO
16
10
<60
0.9
<50
<25
280
COHD.Ial
<2
<20
630
25
71
1 .0
63
<25
210
Cono.(c)
80
100
310
65
7.7
9,500
6.8
66
36
<2
<20
810
<20
38
60
80
0.2
<50
25
<25
-------
II.14.4.2 Classical Pollutants
End-of-pipe control technology in the Petroleum Refining Industry
relies heavily upon the use of biological treatment methods.
These are supplemented by appropriate pretreatment to insure that
proper conditions, especially sufficient oil removal and pH
adjustment, are present in the feed to the biological system.
When used, initial treatment most often consists of neutraliza-
tion for control of pH and equalization basins to minimize shock
loads on the biological systems.
The selection of plants was not based on a cross section of the
entire industry, but rather was biased in favor of those segments
of the industry that had the more efficient wastewater treatment
facilities. Table 14-26 indicates the types of treatment tech-
nology and performance characteristics which were observed during
the survey. In most of the plants analyzed, some type of bio-
logical treatment was utilized to remove dissolved organic mate-
rial. Table 14-27 summarizes the expected effluents from waste-
water treatment processes throughout the Petroleum Refining
Industry. Typical efficiencies for these processes are shown in
Table 14-28.
During the survey program, wastewater treatment plant performance
history was obtained when possible. These historical data were
analyzed statistically and the individual plant's performance
evaluated in comparison to the original design basis. After this
evaluation, a group of plants was selected as being exemplary,
and data from these plants are presented in Table 14-27. The
treatment data in Table 14-28 represent the annual daily average
performance (50% probability of occurrence).
Date; 8/31/82 R Change 1 11.14-57
-------
Date: 9/25/81
H
H
1 — '
1
cn
CO
TABLE \l4-26. OBSERVED REFINERY TREATMENT SYSTEM AND EFFLUENT LOADINGS [2-4U]
Observed average net effluent loadings
kq/I.OOO cu.m of feedstock (Ib/I.OOO bbl of feedstock)
Subcateqory
Topp i ng
Cracking
Cracking
Cracking
Cracking
Cracking
Pe troche* leal
Petrochemical
Petrochemical
Lube
Lube
Integrated
Treatment type
Oxidation pond
Aerated lagoon, polishing
pond
Aerated lagoon, filtration
Equalization, dissolved air
flotation, activated sludge
Oxidation pond
Dissolved air flotation,
aerated lagoon, polishing
pond
Dissolved air flotation,
activated sludge
Dissolved air flotation,
activated sludge
Dissolved air flotation,
aerated lagood, polishing
pond
Equalization, trickling
filter, activated sludge
Equalization, activated sludge
Dissolved air flotation.
BODt 5 )
8
8.0
5.9
10
3.7
13
2.7
2.6
7.1
11
18
(2.8)
(2.8)
(2.1)
(3.6)
(1.3)
(1.6)
(0.95)
(0.91)
(2.6)
(5.0)
(6.2)
COD
39
68
96
71
39
67
51
57
110
320
(11)
(21)
(31)
(25)
(11)
(21)
( 19)
(20)
(18)
(110)
TSS
25
31
8.5
1.2
11
8.5
7
12
38
36
(8.7)
(12)
(3.0)
(1.5)
(3.0)
(2.5)
(1.3)
(H)
(13)
Oi 1 and
a rea se
2.0 (0.7)
2.3 (0.8)
9 (3.2)
1.0 ( 1.1)
2.8 ( 1.0)
6.5 (2.3)
1 (1.1)
7.2 (2.6)
22 (7.7)
Phenol ic
NHI31-N compounds
0.11 (0.05)
0.003 (0.001 )
0.1 (0.11)
0.37 (0.13)
1.8 ( 1.7) 0.05 (0.018)
0.11 (0.05) 0.006 (0.002)
1.5 ( 1.6) 0.06 (0.023)
2 (0.7)
1.2 (0.11) 0. 17 (0.06)
2.3 (0.8) 0.017 (0.006)
Sulf ide
0.03 (0.009)
0.2 (0.07)
0 (0)
0.03 (0.010)
0.011 (0.005)
0.05 (0.018)
0.20 (0.07)
activated sludge, polishing
pond
-------
D
0)
rt
fD
TABLE IU-27. EXPECTED EFFLUENTS FROM PETROLEUM TREATMENT PROCESSES [2-U4]
00
\
U)
oo
to
o
V
fu
3
^
ro
H
Ul
VD
Process
1.
2.
3.
14.
5.
6.
7.
8.
9.
10.
II.
12.
API separator
Clarirler
Dissolved air
Dotation
Granular media filter
Oxidation pond
Aerated lagoon
Activated sludge
Trickling filter
Cool Ing tower
Activated carbon
Granular media filter
Activated carbon
Process
Inf luentfa )
Raw waste
1
1
1
1
2.3,1
2.3,1
1
2,3,1
2.3,1
5-9
5-9 and 1 1
BOOI51
250 - 350
15 - 200
15 - 200
10 - 170
10 - 60
10 - 50
5-50
25 - 50
25 - 50
5 - 100
3-10
COI
260 -
130 -
130 -
100 -
50 -
50 -
30 -
80 -
17 -
30 -
30 -
0 TOC
700
150
150
100
300
200
200 20 - 80
350
350 70 - 150
200
25 - 61
100 1 - 17
Effluent concentration. ma/L
SS
50 - 200
25 - 60
25 - 60
5-25
20 - 100
10 - 80
5-50
20 - 70
1.5 - 100
10-20
3-20
1 - 15
Oil
20 -
5 -
5 -
6 -
1.6 -
5 -
1 -
10 -
20 -
2 -
3 -
0.8 -
1
100
35
20
20
50
20
15
80
75
20
17
2.5
Pheno 1
6 - 100
10 - 10
10 - 10
3-35
0.01 - 12
0. 1 - 25
0.01 - 2.0
0.5 - 10
0. 1 - 2.0
-------
-------
TABLE 16-30. MINIMUM DETECTION LIMITS FOR
TOXIC POLLUTANTS [2-50]
Pollutant Detection Limit
(yg/L)
Methylene chloride 1
Trichlorofluoromethane 3
1,1-Dichloroethane 1
Chloroform 1
1,2-Dichloroethane 1
1,1,1-Trichloroethane 1
1,1,2,2-Tetrachloroethane 1
Carbon tetrachloride 1
Dichlorobromomethane 1
Trichloroethylene 1
Dibromochloromethane 1
Benzene 1
Bromoform 1
Tetrachloroethylene 1
Toluene 1
Chlorobenzene 1
Ethylbenzene 1
Diethyl phthalate 5
Di-n-butyl phthalate 1
Butyl benzyl phthalate 5
Bis(2-ethylhexyl)phthalate 1
Di-n-octyl phthalate 1
Phenol 5
2-Chlorophenol 5
2,4-Dichlorophenol 5
2,3,6-Trichlorophenol 5
Pentachlorophenol 5
p-Chloro-m-cresol 5
2,4-Dinitrophenol 500
Isophorone 100
Napthalene 10
Acenaphthene 10
Acenaphtylene 10
Anthracene 10
Fluoranthene 10
Pyrene 10
Chrysene 10
Date: 8/31/82 R Change 1 11.16-43
-------
o
(U
rt
fD
oo
CO
O
sr
(D
TABLE 16-31. RAW WASTE LOADS FOR SELECTED MILLS [2-48]
Subcateqory
Dissolving Kraft
Market Bleached Kraft
BCT Bleached Kraft
Fine Bleached Kraft
Unbleached Kraft
- Linerboard
- Bag and Other Products
Semi-Chemica 1
Unbleached Kraft and
'Semi-Chemica 1
Dissolving Sulfite Pulp
Papergrade Sulfite
Blow Pit Wash
Drum Wash
Groundwood-Thermo-Mechanica 1
Groundwood - CMN Papers
Groundwood - Fine Papers
De- ink
- Fine Papers
- Tissue Papers
- Newsprint(b)
Paperboard from Wastepaper
Tissue from Wastepaper
Wastepaper-Mo Ided Products
Builders' Paper and Roofing Felt
Non integrated
- Fine Papers
- Tissue Papers
- Lightweight Papers
- Lightweight
- Lightweight Electrical
- Filter and Nonwoven Papers
- Paperboard
- Mi see 1 laneous
Mill number
032002
030031
030026
030049
010038
010005
020013
015002
046003
010002
040013
070001
054004
052003
140005
140010
1 1000 1
085004
150002
120004
080003
090001
090015
105071
105029
085008
080006
Production
Mq/d
(a)
309
1,046
1,068
716
1, 1 16
543
(a)
562
496
262
141
58
485
344
(a)
871
43
18
62.6
22.7
18
58.2
23.8
3.7
45.3
(a)
Flow cu.m/Mq
218
332
121
72.4
105
66.2
39.5
47
291
312
136
81 .3
94
87.8
99.9
1 18
28.3
142
20.4
4.2
149
104
224
254
144
62.5
43.3
Raw Waste Load
BOD5 cu.m/Mq
39
44
46
22
16
20
39
14
1 10
84
41
19
27
12
17
56
12
22
4.6
5.5
6
4.5
58
1 1
18
10
4. 1
TSS cu.m/Mq
130
130
33
55
16.
20
38
14
1 1
21
32
41
100
61
200
130
19
1 10
20
1.5
7
5
150
19
15
25
35
Blanks indicate data not available.
(a)Product ion data held confidentia
(b)AII data held confidential.
-------
II.16.4 POLLUTANT REMOVABILITY [2-48]
The Pulp, Paper and Paperboard industry employs many types of
wastewater treatment systems to reduce the levels of pollutants
contained in mill effluents. Biological treatment systems are
currently employed extensively by pulp, paper, and paperboard
mills to reduce BOD5 and TSS loads. A summary of treatment
systems currently employed in the pulp, paper and paperboard
industry is shown in Table 16-32. As noted, aerated stabili-
zation is the most common treatment process employed at mills
discharging directly to a receiving water. Primary treatment
only is employed at a relatively large number of plants in the
nonintegrated and secondary fiber subcategories. Primary treat-
ment can often achieve substantial BOD5 reductions, if BOD5 is
predominantly contained in suspended solids.
Primary Treatment
Often primary treatment is necessary to remove suspended organic
and inorganic materials that may damage or clog downstream treat-
ment equipment. This can be accomplished by sedimentation,
flotation, or filtration. Sedimentation can involve mechanical
clarifiers or sedimentation lagoons. Mechanical clarification is
the most common technology for removing suspended solids.
Dissolved Air Flotation
Dissolved air flotation (DAF) units also have been applied to
effluents from paper mills and have, in some cases, effectively
removed suspended solids. At high pollutant concentrations or
under shock loadings, the effectiveness of DAF units in removing
pollutants is significantly reduced.
Primary Clarification
Because of the biodegradable nature of a portion of the settle-
able solids present in pulp, paper and paperboard wastewaters,
clarification results in some BOD5 reduction. Typical BOD5
removals through primary clarification in integrated pulp and
paper mills varies between 10% and 30%. The exact BOD5 removal
depends on the relative amount of soluble BOD5 present in the raw
wastewater. Primary clarification can result in significantly
higher BOD5 reductions at nonintegrated mills than at integrated
mills. Responses to the data request program indicate that
roughly 50% of the raw wastewater BOD5 is commonly removed at
nonintegrated mills through primary clarification.
Biological Treatment
Currently, the most common types of biological treatment used in
the Pulp, Paper and Paperboard industry include oxidation basins,
aerated stabilization basins, and the activated sludge process or
Date: 8/31/82 P. Change 1 11.16-45
-------
o
ft)
ft
(D
oo
\
u>
oo
NJ
TABLE 16-32. SUMMARY OF METHOD OF DISCHARGE AND INPLACE TECHNOLOGY [2-U8]
n
&
Oi
y
iQ
(D
Subcateoorv
Dissolving Kraft
Harket Kraft
BCT Bleached Kraft
Alkal toe-fine
Unbleached Kraft
1 i ne rboa rd
Kraft
Sea>i-cne*ical
Unblaached Kraft and
Dissolving Sulfit* Pulp
Papergrade Suiflte (b)
Thenao-Hechanical Pulp
Groundvood-CMN Paperi
Croundwood-Flne Paper*
Oe-fnh-r loe
De-ink Tissue
De-lnk-Mevtpriflt
Wa itepaper- T i ssue
Wa stepa pe r- Pa pe rboa rd
Bui idert Paper and
Roofing leit
Non integrated- Fine
Mon integrated-! issue
Nonintegrated-Lightveight
Nonwoven
Don i n tog ra ted - Pa pe rboa ra
Subtotal
Mfacel laneous •! 1 Is
Total
No.
of
• i lit
3
12
9
20
20
8
20
10
6
5
9
5
6
23
66
45
28
18
14
16
554
_152
706
Treatment schoaM - Direct dlscharoe
Method uf discharge No Aerated ASH w/ ASB w/
Direct Indirect onawry fc direct contained Unknown treatment only basin IASB) oond Domf sludne oond Other
1
1
4
1
1
1
1
3 1
2 1
1
1 2
7
3
1
1
I 6 24
20 19 3 35
5 19 1 4
4421 7
3 1 9
1 4
3 1
3 1
3 6
4 1
2 2
8
5 2
3 1
12 1
2 1
2
2 1 1
1 4 2
1
1
4 4
5
1
2
6
1
1
2
9
'
1 I
I 3
I
1 7
2
27 7 1 77 38 7 48 7 13 46 42 52 17 47 9 51
101 25 _fl__5_fi_Z .1 2515 2fl _J 21 _IU
378 202 46 12 !>4 14 14 71 57 72 20 70 10 64
(b)lncludet papergrade i
-------
1. Clarification followed by downflow granular carbon activated
columns;
2. Lime treatment and clarification followed by granular acti-
vated carbon columns;
3. Biological oxidation and clarification followed by granular
activated carbon columns; and
4. Lime treatment and clarification followed by fine activated
carbon effluent treatment.
Table 16-37 presents the results of the pilot-plant investiga-
tion.
Date: 8/31/82 R Change 1 11.16-51
-------
TABLF. 16-37. RESULTS OF ACTIVATED CARBON PILOT PLANTS TREATING UNBLEACHED KRAFT MILL
EFFLUENT [2-U8]
AC columns preceded by
biological oxidation and
clarification
AC columns preceded by
primary clarification
AC columns preceded by biological
oxidation and clarifloat ion
Description of
carbon process
influent
Effluent
Remova I ,
percent
Influent
Effluent
Remova I ,
percent
Influent
Effluent
Remova I ,
percent
Hydraulic load,
Lps/sq.m
Carbon
Contact time, min.
1.4
Granular
11)0
0.95
Granular
0.18
Granular
150
710
57
210
62
72
220
920
83
ISO
62
80
310
1,200
120
200
61
83
Fresh carbon dosage
kg/cu.m.
2.5
3.5
(Ib carbon/),000
gal )
(8)
(20)
(28)
AC columns preceded by
Iime treatment and
clari fication
FACET svsteafal
Description of
carbon process
1 nf luent Effluent
Remova 1 ,
percent
Influent
Effluent
Remova 1 ,
percent
Hydraulic load,
gpm/sq. ft. 0.95
Carbon Granular
contact time, min. 108
Inteniedlate(c)
180
250
100
76
26
14
70
160
160
100
73(b)
38
51
Fresh carbon dosage
kg/cu.m.
0.5
(Ib ca rbon/1,000
gal)
(2.5)
(3.9)
Blanks indicate no data available.
(a)Fine activated carbon effluent treatment (FACET).
(b)FiItered.
(c)Intermediate size between powdered and granular.
Date: 8/31/82 R Change 1 11.16-52
-------
Subcategory 8 - Wet Digestion Reclaimed Rubber
This subcategory represents a process that is used to recover
rubber from fiber-bearing scrap. Scrap rubber, water, reclaiming
and defibering agents, and plasticizers are placed in a steam-
jacketed, agitator-equipped autoclave. Reclaiming agents used to
speed up depolymerization include petroleum and coal tar-base
oils and resins as well as various chemical softeners such as
phenol alkyl sulfides and disulfides, thiols, and amino acids.
Defibering agents chemically do the work of tht hammer mill by
hydrolyzing the fiber; they include caustic soda, zinc chloride,
and calcium chloride.
A scrap rubber batch is cooked for up to 24 hours and then dis-
charged into a blowdown tank where water is added to facilitate
subsequent washing operations. Digester liquor is removed by a
series of screen washings. The washed rubber is dewatered by a
press and then dried in an oven. Two major sources of wastewater
are the digester liquor and the washwater from the screen wash-
ings.
Two rubber reclaiming plants use the wet digestion method for
reclamation of rubber.
Subcategory 9 - Pan, Dry Digestion, and Mechanical
Reclaimed Rubber
This subcategory combines processes that involve scrap size
reduction before continuing the reclaiming process. The pan
digestion process involves scrap rubber size reduction on steel
rolls, followed by the addition of reclaiming oils in an open
mixer. The mixture is discharged into open pans which are stack-
ed on cars and rolled into a single-cell pressure vessel where
live steam is used to heat the mixture. Depolymerization occurs
in 2 to 18 hours. The pans are then discharged and the cakes of
rubber are sent on for further processing. The steam condensate
is highly contaminated and is not recycled.
The mechanical rubber reclaiming process, unlike pan digestion,
is continuous and involves fiber-free scrap being fed into a
horizontal cylinder containing a screw that works the scrap
against the heated chamber wall. Reclaiming agents and catalysts
are used for depolymerization. As the depolymerized rubber is
extruded through an adjustable orifice, it is quenched. The
quench vaporizes and is captured by air pollution control equip-
ment. The captured liquid cannot be reused and is discharged for
treatment.
Nine plants use these techniques to reclaim rubber.
Date: 9/25/81 II.17-9
-------
Subcategory 10 - Latex-Dipped, Latex-Extruded, and
Latex-Molded Goods
These three processes involve the use of latex in its liquid form
to manufacture products. Latex dipping consists of immersing an
impervious male mold or article into the latex compound, with-
drawing it, cleaning it, and allowing the adhering film to air
dry. The straight dip process is replaced by a coagulant dip
process when heavier films are desired. Fabric or other items
may be dipped in latex to produce gloves and other articles.
When it has the required coating, the mold is leached in pure
water to improve physical and electrical properties. After air
drying, the items are talc-dusted or treated with chlorine to
reduce tackiness. Water is often used in several processes, for
makeup, cooling, and stripping. Products from dipping include
gloves, footwear, transparent goods, and unsupported mechanical
goods.
Latex molding employs casts made of unglazed porcelain or plaster
of paris. The molds are dusted with talc to prevent sticking.
The latex compound is then poured into the mold and allowed to
develop the required thickness. The mold is emptied of excess
rubber and then oven dried. The mold is removed and the product
is again dried in an oven. Casting is used to manufacture dolls,
prosthetics, printing matrices, and relief maps.
Subcategory 11 - Latex Foam
No latex foam facilities are known to be in operation at this
time.
II.17.2 WASTEWATER CHARACTERIZATION [2-50]
The raw wastewater emanating from rubber manufacturing plants
contains toxic pollutants that are present due to impurities in
the monomers, solvents, or the actual raw materials, or are asso-
ciated with wastewater treatment steps. Both inorganic and
organic pollutants are found in the raw wastewater, and classical
pollutants may be present in significant concentrations.
Date: 8/31/82 R Change 1 11.17-10
-------
Toxic pollutants found in the wastewater streams are normally
related to solvents and solvent impurities, product additives,
and cooling water treatment chemicals. Table 17-7 presents a
listing of the potential wastewater sources and the associated
contaminants for this industry.
TABLE 17-7. SUMMARY OF WASTEWATER SOURCES FROM SOLUTION CRUMB
RUBBER PRODUCTION [2-50]
Processing unit Source Nature of wa_stewa_ter contaminants
Caustic soda sc rubber Spent caustic solution High pH, alkalinity, and color. Extremely
low average flow rate.
Monomer and so I vent Water removed from mono- U i sso t ved and sepa rable organ ics.
d ry i ng co I ttmns mers and so I vent Very I ow f I ow.
So I vent purification Fractionator bottoms Dissolved and separable organ i cs.
Monomer recovery Decant water layer Dissolved and separable organics.
Crumb dewatering Crumb rinse water over- Dissolved organics, and suspended
flow and dissolved solids. Source of
highest volume wastewater flow.
Allplantareas Area washdowns D i ssolvod and scpa rabIe organ ics, and
suspended and dissolved solids.
II.17.2.4 Latex Rubber Production
Process contact water is not currently used by the latex rubber
industry. Raw material recycling is not practiced because of
poor control of monomer feeds and the buildup of impurities in
the water. Wastewater may be generated during the removal of in-
hibitors or during the stripping of excess monomer from the latex
product. Wastewater also may be generated during process equip-
ment cleaning. Table 17-8 presents potential wastewater sources
and general contaminants for this industry.
Organic toxic pollutants and chromium are present in the raw
wastewater and normally consist of raw materials, impurities, and
metals used as cooling water corrosion inhibitors.
TABLE 17-8. SUMMARY OF WASTEWATER SOURCES FROM LATEX RUBBER
PRODUCTION [2-50]
Processing unit Source Nature of wastewater contaminants
Caustic soda scrubber Spent caustic solution High pH, alkalinity, and color.
Extremely low average flow rate.
Excess monomer stripping Decant water layer Dissolved and separable organics.
La tex evaporators Water removed duri ng D i ssoIved organ i cs, suspended and
latex concentration dissolved solids. Relatively high
wastewater flow rates.
Tanks, reactors, and Cleanout rinse water Dissolved organics, suspended and
strippers di ssoIved so I ids. High quanti ties
of uncoagutated latex.
Tank cars and tank trucks Cleanout rinse water Dissolved organics, suspended and
dissolved solids. High quantities of
uncoagulated latex.
Allplantareas Area washdowns D i ssoIved and sepa rabIe organ i cs, and
suspended and d i ssoIved so I ids.
Date: 8/31/82 R Change 1 11.17-21
-------
II.17.2.5 General Molding, Extruding, and Fabricating Rubber
Plants
Toxic pollutants resulting from production processes within this
industry are generally the result of leaks, spills, and poor
housekeeping procedures. Pollutants include organics associated
with the raw materials and lead from the rubber curing process.
II.17.2.6 Rubber Reclamation
Wastewater effluents from this subcategory contain high levels of
toxic organic and inorganic pollutants. These pollutants gener-
ally result from impurities in the tires and tubes used in the
reclamation process. The wastewater from the pan process is of
low volume (0.46 m3/Mg [56 gal/1,000 lb]), but is highly contami-
nated, requiring treatment before discharge. The mechanical
reclaiming process uses water only to quench the reclaimed
rubber, but it uses a much higher quantity (1.1 m3/Mg). Steam
generated from the quenching process is captured in a scrubber
and sent to the treatment system. Wet digestion uses 5.1 m3 of
water per Mg (610 gal/1,000 lb) of product in processing, of
which 3.4 m3/Mg (407 gal/1,000 lb) of product is used in air
pollution control.
II.17.2.7 Latex-Dipped, Latex-Extruded, and Latex-Molded
Goods
Wastewater sources in this subcategory are the leaching process,
makeup water, cooling water, and stripping water. Toxic pollutants
are present at insignificant levels in the wastewater discharges.
II.17.2.8 Latex Foam
No information is available on the wastewater characteristics of
this subcategory.
II.17.3 PLANT SPECIFIC DESCRIPTION [2-50]
Only two subcategories of the rubber industry have not been
recommended as Paragraph 8 exclusions of the NRDC Consent Decree:
Wet Digestion Reclaimed Rubber, and Pan, Mechanical, and Dry
Digestion Reclaimed Rubber. Of these two, plant specific data
are available only for the latter. Of the nine remaining sub-
categories, plant specific information is available only for
Emulsion Crumb Rubber and Solution Crumb Rubber, and is pre-
sented below. Two plants in each subcategory are described.
They were chosen as representative of their subcategories based
on available data.
Date: 9/25/81 11.17-22
-------
II.17.3.1 Emulsion Crumb Rubber Production
Plant 000012 produces 3.9 x 104 Mg/yr (8.7 x 107 Ib/yr) of emul-
sion crumb rubber, primarily neoprene. The contact wastewater
flow rate is approximately 8.45 m3/d (2.25 x 103 gpd) and in-
cludes all air pollution control equipment, sanitary waste,
maintenance and equipment cleanup, and direct contact wastewater.
The treatment process consists of activated sludge, secondary
clarification, sludge thickening, and aerobic sludge digestion.
Noncontact wastewater, with a flow rate of approximately 1.31 x
105 m3/d (3.46 x 107 gpd), is used on a once-through basis and is
returned directly to the river source. Contact wastewater is
also returned to the surface stream after treatment.
Plant 000033 produces three types of emulsion crumb rubber in
varying quantities. Styrene butadiene rubber (SBR) is the bulk
of production, at nearly 3.7 x 105 Mg/yr (8.2 x 108 Ib/yr), with
nitrile butadiene rubber (NBR) and polybutadiene rubber (PBR)
making up the remainder of production (4.5 x 104 Mg/ yr [1.0 x
108 Ib/yr] and 4.5 x 103 Mg/yr [1 x 107 Ib/yr], respectively).
Wastewater consists of direct contact process water, non-
contact blowdown, and noncontact ancillary water. The total flow
of contact water is approximately 1.27 x 104 m3/d (3.355 x 106
gpd), and the total flow of noncontact water is 340.4 m3/d (9 x
104 gpd). Treatment of the wastewater consists of coagulation,
sedimentation, and biological treatment with extended aeration.
Treated wastewater is discharged to a surface stream.
Tables 17-9 and 17-10 present plant specific toxic pollutant data
for the selected plants.
II.17.3.2 Solution Crumb Rubber Production
Plant 000005 produces approximately 3.2 x 104 Mg/yr (7.0 x 107
Ib/yr) of isobutene-isopropene rubber. Wastewater generally
consists of direct processes and MEG water. Contact wastewater
flow rate is approximately 1,040 m3/d (2.75 x 105 gpd), and
noncontact water flows at about 327 m3/d (8.64 x 104 gpd).
Treatment consists of coagulation, flocculation, and dissolved
air flotation, and the treated effluent becomes part of the
noncontact cooling stream of the on-site refinery.
Plant 000027 produces polyisoprene crumb rubber (4.5 x 104 Mg/yr
[1 x 10s Ib/yr]), polybutadiene crumb rubber (4.5 x 104 Mg/yr
[1.0 x 108 Ib/yr]), and ethylene-propylene-diene-terpolymer
rubber (EPDM; 4.5 x 104 Mg/yr [1.0 x 108 Ib/yr]). Wastewater
consists of contact process water, MEG, cooling tower blowdown,
boiler blowdown, and air pollution control. Wastewater is pro-
duced at about 12,100 m3/day (3.2 x 106 gpd). Treatment consists
Date: 8/31/82 R Change 1 11.17-23
-------
D
OJ
ft
CD
CO
U)
h-1
\
00
O
U
0)
3
iQ
(D
TABLE 17-9. PLANT SPECIFIC VERIFICATION DATA FOR EMULSION CRUMB RUBBER
PRODUCTION PLANT 000012 [2-50]
Flow rate, cu.m/d: contact = 8.45; noncontact = 131,000.
Location in process line
Po 1 1 utant
Toxic pollutant. uq/L
Cadm i um
Mercury
Nickel
Bis (2-ethylhexyl Jphtha late
Dimethyl phthalate
N-n i trosod ipheny lamine
Pheno 1
N i trobenzene
To 1 uene
Carbon tetrachlor ide
Ch loroform
1, 1 -Dich loroethy lene
Methylene chloride
Tetrach loroethy lene
1,1, 1 -Tr i ch 1 oroethane
Stripper
decant
4
67
<0. 1
<0. 1
2.5
<0. 1
<0. 1
NBR
finishing
-------
of API separators, sedimentation, stabilization, and lagooning,
followed by discharge to a surface stream.
Tables 17-12 and 17-13 show plant specific toxic pollutant data
for the above plants.
II.17.3.3 Dry Digestion Reclaimed Rubber
Data summary for plant 000134 is given in Table 17-15. Pro-
duction, wastewater flow, and treatment data are currently not
available for a plant within this subcategory.
II.17.4 POLLUTANT REMOVABILITY [2-50]
In this industry, numerous organic compounds, BOD, and COD are
typically found in the plant wastewater effluent. Industry-wide
flow and production data show that these pollutants can be
reduced by biological treatment. In emulsion crumb and latex
plants, uncoagulated latex contributes to high suspended solids.
Suspended solids are produced by rubber crumb fines and include
both organic and inorganic materials. Removal of such solids is
possible using a combination of coagulation/flocculation and
dissolved air flotation.
Solvents, extender oils, and insoluble monomers are used through-
out the rubber industry. In addition, miscellaneous oils are
used to lubricate machinery. Laboratory analysis indicates the
presence of oil and grease in the raw wastewater of these plants.
Oil and grease entering the wastewater streams are removed by
chemical coagulation, dissolved air flotation, and, to some
extent, biological oxidation.
Wastewater sampling indicates that toxic pollutants found in the
raw wastewater can be removed. Biological oxidation (activated
sludge) adequately treats all of the organic toxic pollutants
identified in rubber industry wastewater streams. Significant
removal of metals was also observed across biological treatment.
The metals are probably absorbed by the sludge mass and removed
with the settled sludge. Treatment technologies currently in use
are described in the following subcategory descriptions.
II.17.4.1 Emulsion Crumb Rubber Plants
There are a total of 17 plants in the United States producing
emulsion-polymerized crumb rubber. Five of these plants dis-
charge to POTW's; 10 discharge to surface streams; 1 plant dis-
charges to an evaporation pond; and 1 plant employs land applica-
tion with hauling of settled solids. Of the five plants dis-
charging to POTW's, 4 pretreat using coagulation and primary
treatment and 1 employs equalization with pH adjustment. All 10
of the plants discharging to surface streams employ biological
:Date: 8/31/82 R Change 1 11.17-25
-------
TABLE 17-11 DELETED
TABLE 17-12. PLANT SPECIFIC VERIFICATION DATA FOR SOLUTION CRUMB RUBBER
PRODUCTION PLANT 000005 [2-50]
Flow rate, cu.m/d. contact = 1,040; noncontact = 327
Pol lutant, uq/L
Cadmi urn
Chromium
Copper
Zinc
Bis(2-ethylhexyl )phtha late
Phenol
Benzene
Ethyl benzene
Toluene
Carbon tet rach lor i de
Ch 1 oroform
Methyl chloride
Methylene chloride
1 , 1 ,2-Tri ccilo roe thane
Trichloroethylene
Location
Screen-
tank 1 and 2 comp.
-------
D
&>
rt
CD
oo
oo
N)
TABLE 17-13. PLANT SPECIFIC VERIFICATION DATA FOR SOLUTION CRUMB
RUBBER PRODUCTION PLANT 000027 [2-50]
Total flow rate: 12,100 cu.m/d.
O
tr
PJ
3
^
CD
H
Pol lutant. uq/L
Cadm i um
Ch rom i um
Copper
Mercury
Bi s(2-ethylhexyl )phtha late
Phenol
Benzene
Ethylbenzene
To 1 uene
Ch loroform
1 , 1 , 2, 2-Tet rach 1 oroe thene
SN/CB
process
450
1*
1 .8
77
13
<0 . 1
<0 . 1
<0 . i
1
<0. 1
EPDM
process
820
<2
2. 3
120
670
39,000
<0 . I
-------
ct
(D
TABLE 17-15. PLANT SPECIFIC VERIFICATION DATA FOR PAN, DRY
RUBBER DIGESTION, AND MECHANICAL RECLAIMING
PLANT 000 I 34 [2-50]
CO
U)
M
\
CO
O
tr
0)
^Q
(D
I
N)
CO
Pol lutant. ua/L
Cadmfum
Chromium
Copper
Lead
Me rcu ry
Zinc
Bis(2-ethylhexyl )phthalate
Di-n-butyl ph thai ate
2, 4-Di methyl phenol
Pheno 1
Benzene
Chlorobenzene
Ethyl benzene
To 1 uene
Acenaphthy lene
Anthracene
Phenanthrene
F 1 uo rene
Naphthalene
Pyrene
Chloroform
Me thy lene chloride
Cadmium
Ch rom i urn
Copper
Lead
Me rcu ry
Zinc
Bls(2-ethylhexyl Jphthalate
Di-n-butyl phthalate
2, (4-D i methyl phenol
Pheno 1
Benzene
Ch 1 o robenzene
Ethyl benzene
Toluene
Acenaphthy lene
Anthracene
Phenanthrene
Fluorene
Naphthalene
Pyrene
Chloroform
Methylene chloride-
Treatment Influent,
automatic sampler
<(
6
31
70
too
16,000
58,000
26,000
<60
6,600
2,700
<33
1,400(0)
2,000(c)
I00,000(c)
6,700(c)
1.9
Cooling tower blowdown,
arab composite
-------
TABLE 17-20.
TOXIC POLLUTANT REMOVAL EFFICIENCY AT DRY
DIGESTION RECLAIMING PLANT 000134,
VERIFICATION DATA [2-50]
Treatment techno logy: Cartridge filtration, activated ca rbon (oil removaI),
activated sludge, sedimentation
Discharge point: Noncontact cooling water system, blowdown of this system
to surface stream
Concent r
Pol lutant. uq/L
Cadmium
Chromi urn
Copper
Lead(b)
Mercury
Zinc
Bis(2-ethylhexyl )phtha late(c)
2,U-Dimethyl phenol
Phenol (d)
Benzene
Ethylbenzene
Toluene
Acenaphthylene
F Itiorene
Naphtha lene(e)
Phenanthrene
Pyrene
Ch lorof orm
i nf luent
16
58
26
8
2
2
100
1
6
1
6
28
70
100
,000
,000
,000
60
,600
,700
<33
,000
,000
.300
,800
1.9
fttlonJjgZL_
err 1 uentl a )
3
21
12
670
2.3
2,500
H , 200
25,000
1,900
<0. 1
<0. 1
<0 . 1
<8
< 1 2
'|2
300
1 1
l.ll
remova 1
NH
NH
57
NH
NH
71
57
81
>99
>99
>99
NH
>99
>99
77
>99
26
Cool ing
towe r
blowdown, (a )
liq/L
2
2
29
0.5
100
100
120
27
<0 . 1
<0 . 1
<0 . 1
<8
< 1 2
13
-------
-------
rt
(D
oo
LO
I-1
\
oo
TABLE 18-10. POLLUTANTS FOUND IN THE DIRECT DISCHARGES FOR SIX ESTABLISHMENTS HAVING NPDES PERMITS [2-53]
Wastewater flow, cu.m/day: Establishment I = 3,290; Establishment II = 2,650;
Establishment III = 5,220; Establishment IV = 87.1; EstabI ishment V = 2,600;
Establishment VI = 2,610; Total = 16,500
O
(D
H
OO
I
Establishment number
Pol lutant
Classical pollutants
BODS
TSS
0 i 1 and grease
Tox ic po 1 1 utants
Chromi um
Copper
Cyanide
Lead
Nickel
Zinc
Di-n-butyl phthalate
Pentachlorophenol
Pheno 1
Benzene
Phenanthrene/t ri ch lo roe thy lene
1 , 1 -D ich lo roe thy lene
1
6. 1
6. 1
2.6
0. 15
0.06
0.02
0.06
0.02
0.001
0.05
0.0002
0.0006
0.03
1 1
6. 1
6. 1
2.6
0. 16
0.06
0.001
0.02
0.06
0.35
0.002
0.020
0.05
0.0003
0.0009
0.03
1 1 1
Di scha rqe
12
12
5.3
0.31
0. 1 1
0.05
0. 12
O.OM
0.001
0. 1 1
O.OOOM 0
0.001
0.05
IV
. kq/dav
O.OU
0.09
O.OM
0.002
0.0006
0.0002
0.0006
0.0002
0.00001
0.0005
.000005
0.00001
0.0003
V
2.6
0.09
O.OM
0.05
0.02
0.007
0.02
0.007
0.0002
0.02
0.0001
0.0002
0.008
VI
6. 1
6. 1
2.6
0. 16
0.06
0.02
0.06
0.02
0.0007
0.05
0.0002
0.0006
0.03
Total
di scharge,
kq/dav
33
31
13
0.83
0.31
0.001
0. 12
0.33
O.M5
0.006
0.02
0.29
0.001
O.OO'I
0. 15
Average
concentration,
uq/L
2,000
1,900
800
50
19
0. 1
7. it
20
28
0.3
1 .2
18
0. 1
0.2
8.9
Analytic methods: V.7.3.30, Data sets 1,2.
Blanks indicate no data avaliable.
-------
Table 18-11 presents treatment methods for the removal or elim-
ination of pollutants found in wastewaters from soap and deter-
gent manufacture. Important features and details of the various
treatment methods and abatement systems can be readily found in
the literature. As seen in this table, organics (especially
those of a toxic nature) can be treated primarily by bioconver-
sion processes and activated carbon adsorption systems. The
remainder of the major pollutants can be treated by filtration,
sedimentation or clarifying processes, and other treatment tech-
niques. As an example, coagulation and sedimentation of the
wastewaters can help remove insoluble precipitate residuals
characteristic of soap manufacturing processes. The relative
efficiency of removal of pollutants for these various processes
is given in Table 18-12, which shows that for most pollutant
treatment processes, removability efficiency can be as high as
90-95%. The efficiency achieved is governed by operating para-
meters of the various processes and by the types and amounts of
pollutants in the wastewater.
Date: 8/31/82 R Change 1 11.18-22
-------
11.19 STEAM ELECTRIC POWER GENERATING
II.19.1 INDUSTRY DESCRIPTION [2-55,56,73]
II.19.1.1 General Description
The Steam Electric Power Generation Industry is defined as those
establishments primarily engaged in the steam generation of
electrical energy for distribution and sale. Those establish-
ments produce electricity primarily from a process utilizing
fossil-type fuel (coal, oil, or gas) or nuclear fuel in conjunc-
tion with a thermal cycle employing the steam-water system as the
thermodynamic medium. The industry does not include steam elec-
tric power plants in industrial, commercial, or other facilities.
The industry falls under two Standard Industrial Classification
(SIC) Codes, SIC 4911 and SIC 4931.
At the end of 1978 there were 842 steam electric power generating
plants in operation in the United States. Of these plants,
approximately 35% generate in excess of 500 megawatts (MW) and
approximately 12% generate 25 MW or less. These steam electric
power generating plants represent about 79% of the entire elec-
tric utility generating capacity, and in 1978 they generated 85%
of electricity produced by the entire electric utility industry.
Within the steam electric power generation industry, plants built
after 1970 represent 44% of the total capacity, and plants built
before 1960 represent 26% of capacity.
In the operation of a power plant, combustion of fossil fuels--
coal, oil, or gas--supplies heat to produce steam that is used to
generate mechanical energy in a turbine. This energy is subse-
quently converted by a generator to electricity. Nuclear fuels,
currently uranium, are used in a similar cycle except that the
heat is supplied by nuclear fission. A number of different
operations by steam electric powerplants discharge chemical
wastes. Many wastes are discharged more or less continuously as
long as the plant is operating. These include wastewaters from
the following sources: cooling water systems, ash handling
systems, wet-scrubber air pollution control systems, and boiler
blowdown. Some wastes are produced at regular intervals, as in
water treatment operations, which include a cleaning or re-
generative step as part of their cycle (ion exchange, filtration,
clarification, evaporation). Other wastes are also produced
intermittently but are generally associated with either the
shutdown or startup of a boiler or generating unit, such as
Date: 1/24/83 R Change 2 II.19-1
-------
during boiler cleaning (water side), boiler cleaning (fire side),
air preheater cleaning, cooling tower basin cleaning, and clean-
ing of miscellaneous small equipment.
The discharge frequency for these varies from plant to plant.
Some or all of the various types of wastewater streams occur at
almost all of the plant sites in the industry. However, most
plants do not have distinct and separate discharge points for
each source of wastewater; rather, they combine certain streams
prior to final discharge.
Additional wastes exist which are essentially unrelated to pro-
duction. These depend on meteorological or other factors.
Rainfall runoff, for example, causes drainage from coal piles,
ash piles, floor and yard drains, and from construction activity.
Table 19-1 presents industry summary data for the Steam Electric
Power Generating (utility) point source category in terms of the
number of subcategories and number of dischargers.
TABLE 19-1. INDUSTRY SUMMARY [2-55,56]
Industry: Steam Electric Power Generating
Total Number of Subcategories: 9
Number of Subcategories Studied: 9
Number of Dischargers in Industry:
• Direct: 1,050
• Indirect: 100
• Zero (a): 10
(a) Zero discharge is practical only in arid
areas where system discharges can be dis-
posed of by means of solar evaporation.
Current BPT regulations for the Steam Electric Power Industry for
generating, small and old units are presented in Table 19-2.
"Small units" are defined by the EPA as generating units of less
than 25-MW capacity. "Old units" are defined as generating units
of 500-MW or greater rated net generating capacity which were
first placed into service on or before January 1, 1970, as well
as any generating unit of less than 500-MW capacity first placed
in service on or before January 1, 1974.
The term "10-year, 24-hour rainfall event" refers to a rainfall
event with a probable recurrence interval of once in 10 years
as defined by the National Weather Service.
Date: 1/24/83 R Change 2 II.19-2
-------
rt
(D
TABLE 19-2. CURRENT BPT REGULATIONS FOR THE STEAM ELECTRIC POWER INDUSTRY [2-55]
CO
U)
O
fl>
NJ
H
H
\->
VO
OJ
Subca teqo ry/Ef f 1 uent cha racte r i st i c
Once Through Cooling Water
Free available chlorine
PCB
Coo 1 i nq Towe r B 1 owdown
Free available chlorine
PCB
pH
Ash Transport Water (fly ash and bottom ash)
PH
TSS
Oil and grease
PCB compounds
Low Volume Waste
PH
TSS
Oil and grease
PCB compounds
Bo i ler Slowdown
PH
TSS
Oil and grease
Copper, total
1 ron, tota 1
PCB
Metal Cleaning Wastes
PH
TSS
Oil and grease
Copper, tota 1
1 ron, tota 1
PCB
Coa 1 Pile Runoff (a )
TSS
PH
(a)Any untreated overflow from facilities designed
volume of material storage runoff and construct
Daily maximum. mq/L
0.5
No Discharge
0.5
No Discharge
Within the range
Within the range
100
20
No Discharge
Within the range
100
20
No Discharge
Within the range
100
20
1 .0
1 .0
No Discharge
Within the range
100
20
1.0
1 .0
No Discharge
Not to exceed
Within the range
, constructed, and operated to
ion runoff which is associated
30-day averaqe. mq/L
0.2
No Discharge
0.2
No Discharge
6.0 to 9.0
6.0 to 9.0
30
15
No Discharge
6.0 to 9.0
30
15
No Discharge
6.0 to 9.0
30
15
1 .0
1 .0
No Discharge
6.0 to 9.0
30
15
1 .0
1 .0
No D i scha rge
50 mg/L
6.0 to 9.0
treat the
with the
10-year, 24-hour rainfall event is not subject to these limitations
-------
II.19.1.2 Subcategory Descriptions [2-55]
Subcategories for the steam electric utility point source cate-
gory, as shown in Table 19-3, were developed according to chemical
waste stream origin within a plant. This approach is a departure
from the usual method of subcategorizing an industry according to
different types of plants, products, or production processes.
Categorization by waste source provides the best mechanism for
evaluating and controlling waste loads since the steam electric
powerplant waste stream source has the strongest influence on the
presence and quantity of various pollutants as well as on flow.
The breakdown in Table 19-3 into subcategories and subdivisions
is based on similarities in wastewater characteristics throughout
the industry. Descriptions of the nine broad subcategories are
given in this section.
TABLE 19-3. STEAM ELECTRIC POWER GENERATING SUBCATEGORIES
AND SUBDIVISIONS [2-55]
Once-through Cooling Water
Recirculating Cooling System Slowdown
Fly Ash Transport Water
Bottom Ash Transport Water
Low Volume Wastes
Clarifier blowdown
Makeup water filter backwash
Ion exchange softener regeneration
Evaporator blowdown
Lime softener blowdown
Reverse osmosis brine
Demineralizer regenerant
Powdered resin demineralizer back flush
Floor drains
Laboratory drains
Diesel engine cooling system discharge
Metal cleaning wastes (water cleaning only)
Metal Cleaning Wastes (chemical cleaning only)
Boiler tube cleaning
Cleaning rinses
Fireside wash
Air preheater wash
Ash Pile, Chemical Handling, and Construction Area Runoff
Coal Pile Runoff
Wet Flue Gas Cleaning Blowdown
Date: 1/24/83 R Change 2 II.19-4
-------
Once Through Cooling Water
In a steam electric power plant, cooling water is utilized to
absorb heat that is liberated from the steam when it is condensed
to water in the condensers. The cooling water is withdrawn from
a water source, passed through the system, and returned. Shock
(intermittent) chlorination is employed in many cases to minimize
the biofouling of heat transfer surfaces. Continuous chlorina-
tion is used only in special situations. Based on 308 data,
approximately 65% of the existing steam electric powerplants have
once through cooling water systems.
Recirculating Cooling Water
In a recirculating cooling water system, the cooling water is
withdrawn from the water source and passed through condensers
several times before being discharged to the receiving water.
After each pass through the condenser, heat is removed from the
water through evaporation. Evaporation is carried out in cooling
ponds or canals, in mechanical draft evaporative cooling towers,
and in natural draft evaporative cooling towers. In order to
maintain a sufficient quantity of water for cooling, additional
makeup water must be withdrawn from the water source to replace
the water which evaporates.
When water evaporates from the recirculating cooling water sys-
tem, the dissolved solids content of the water remains in the
system, and the dissolved solids concentration tends to increase
over time. If left unattended, the formation of scale deposits
will result. Scaling due to dissolved solids buildup is usually
controlled through the use of a bleed system called cooling tower
blowdown. A portion of the cooling water in the system is dis-
charged via blowdown, and since the discharged water has a higher
dissolved solids content than the intake water used to replace
it, the dissolved solids content of the water in the system is
reduced. Makeup water also is required to replace system blow-
down.
Chemicals such as sulfuric acid are used to control scaling in
the system. Anti-biofoulants such as chlorine and hypochlorite
are widely used by the industry. These additives are discharged
in the cooling tower blowdown.
Ash Transport
Steam electric power plants using oil or coal as a fuel produce
ash as a waste product of combustion. The total ash product is a
combination of bottom ash and fly ash. The presence of ash is an
extremely important consideration in the design of a coal-fired
boiler since the ash content of coal is much greater than for
oil. Accumulated ash deposits are removed and transported to a
disposal system.
Date: 1/24/83 R Change 2 n.19-5
-------
The method of transport may be either wet (sluicing) or dry
(pneumatic). Dry handling systems are more common for fly ash
than bottom ash. The dry ash is usually disposed of in a land-
fill, but the ash is also sold as an ingredient for other pro-
ducts. Wet ash handling systems produce wastewaters which are
either discharged as blowdown from recycle systems or are dis-
charged to ash ponds and then to receiving streams in recycle and
once through systems.
Ash from oil-fired plants. Fly ash is a light material
which is carried out of the combustion chamber in the flue gas
stream. The ash from fuel oil combustion usually is in the form
of fly ash. The many elements which may appear in oil ash de-
posits include vanadium, sodium, and sulfur.
Ash from coal-fired plants. More than 90% of the coal used
by electric utilities is burned in pulverized coal boilers. In
these boilers, 65 to 80% of the ash produced is in the form of
fly ash. This fly ash is carried out of the combustion chamber
in the flue gases and is separated from these gases by electro-
static precipitators and/or mechanical collectors. The remainder
of the ash drops to the bottom of the furnace as bottom ash.
While most of the fly ash is collected, a small quantity may pass
through the collectors and be discharged to the atmosphere. A
small portion of the coal ash is vaporized during fuel combus-
tion. Some of these vapors are discharged into the atmosphere;
others are condensed onto the surface of fly ash particles and
may be collected in one of the fly ash collectors.
Low Volume Wastes
Low volume wastes include wastewaters from all sources except
those for which specific limitations are otherwise established in
40 CFR 423. Waste sources include, but are not limited to,
wastewaters from wet scrubber air pollution control systems, ion
exchange water treatment systems, water treatment evaporator
blowdown, laboratory and sampling streams, floor drainage, cool-
ing tower basin cleaning wastes, and blowdown from recirculating
house service water systems. Sanitary wastes and air condi-
tioning wastes are specifically excluded from the low volume
waste subcategory.
Boiler Blowdown
Powerplant boilers are either of the once-through or drum-type
design. Once-through boilers operate under supercritical condi-
tions and have no blowdown streams directly associated with
their operation. Drum-type boilers operate under subcritical
conditions where steam generated in the drum-type units is in
equilibrium with boiler water. Boiler water impurities are con-
centrated in the liquid phase. Boiler blowdown serves to main-
tain concentrations of dissolved and suspended solids at accept-
Date: 1/24/83 R Change 2 II.19-6
-------
able levels for boiler operation. The sources of impurities in
the blowdown are the intake water, internal corrosion of the
boiler, and chemicals added to the boiler. Phosphate is added to
the boiler to control solids deposition.
In modern high-pressure systems, blowdown water is normally of
better quality than the water supply. This is "because plant
intake water is treated using clarification, filtration, lime/
lime soda softening, ion exchange, evaporation, and in a few
cases reverse osmosis to produce makeup for the boiler feedwater.
The high quality blowdown water is often reused within the plant
for cooling water makeup or it is recycled through the water
treatment and used as boiler feedwater.
Metal Cleaning Wastes
Metal cleaning wastes result from cleaning compounds, rinse
waters, or any other waterborne residues derived from cleaning
any metal process equipment, including but not limited to, boiler
tube cleaning, boiler fireside cleaning, and air preheater clean-
ing. This may be accomplished with chemical cleaning solutions
such as acids, degreasers, and metal complexers only. Wastes which
result from metal cleaning with water are considered under the low
volume wastes subcategory.
Boiler tube cleaning. Chemical cleaning is designed to
remove scale and corrosion products that accumulate in the steam-
side of the boiler. Hydrochloric acid, which forms soluble
chlorides with the scale and corrosion products in the boiler
tubes, is the most frequently used boiler tube cleaning chemical.
In boilers containing copper, a copper complexer is used with
hydrochloric acid to prevent the replating of dissolved copper
onto steel surfaces during chemical cleaning operations. If a
complexer is not used, copper chlorides, formed during the
cleaning reaction, react with boiler tube iron to form soluble
iron chlorides while the copper is replated onto the tube sur-
face .
Alkaline cleaning (flush/boil-out) is commonly employed prior to
boiler cleaning to remove oil-based compounds from tube surfaces.
These solutions are composed of trisodium phosphate and a surfac-
tant and act to clear away the materials which may interfere with
reactions between the boiler cleaning chemicals and deposits.
Citric acid cleaning solutions are used by a number of utilities
in boiler cleaning operations. The acid is usually diluted and
ammoniated to a pH of 3.5 and then used for cleaning in a two-
stage process. The first stage involves the dissolution of iron
oxides. In the second stage, anhydrous ammonia is added to raise
the pH of the cleaning solution to between 9 and 10 and air is
bubbled through the solution to dissolve copper deposits.
Date: 1/24/83 R Change 2 II.19-7
-------
Ammoniated EDTA has been used in a wide variety of boiler clean-
ing operations. The cleaning involves a one solution, two-stage
process. During the first stage, the solution solubilizes iron
deposits and chelates the iron. In the second stage, the solu-
tion is oxidized with air to induce iron chelates from ferric to
ferrous and to oxidize copper deposits into solution where the
copper is chelated.
When large amounts of copper deposits in boiler tubes cannot be
removed with hydrochloric acid due to the relative insolubility
of copper, ammonia-based oxidizing compounds have been effective.
Used in a single separate stage, the ammoniacal sodium bromate
step includes the introduction into the boiler system of solu-
tions containing ammonium bromate to rapidly oxidize and dissolve
the copper.
The use of hydroxyacetic/formic acid in the chemical cleaning of
utility boilers is common. It is used in boilers containing
austenitic steels because its low chloride content prevents
possible chloride stress corrosion cracking of the austenitic-
type alloys. It has also found extensive use in the cleaning
operations for once-through supercritical boilers. Hydroxy-
acetic/ formic acid has chelation properties and a high iron
pick-up capability; thus it is used on high iron content systems.
It is not effective on hardness scales.
Sulfuric acid has found limited use in boiler cleaning opera-
tions. It is not feasible for removal of hardness scales due to
the formation of highly insoluble calcium sulfate. It has found
some use in cases where a high-strength, low-chloride solvent is
necessary. Use of sulfuric acid requires high water usage in
order to rinse the boiler sufficiently.
Boiler fireside washing. Boiler firesides are commonly
washed by spraying high-pressure water against boiler tubes while
they are still hot.
Air preheater washing. Air preheaters employed in power
generating plants are either the tubular or regenerative types.
Both are periodically washed to remove deposits which accumulate.
The frequency of washing is typically five washings per year.
Many preheaters are sectionalized so that heat transfer areas
may be isolated and washed without shutdown of the unit.
Ash Pile, Chemical Handling and Construction Area Runoff
Fly ash and bottom ash stored in open piles, chemicals spilled in
handling, and soil distributed by construction activities will
be carried in the runoff caused by precipitation events.
Date: 1/24/83 R Change 2 II.19-8
-------
Coal Pile Runoff
In order to insure a consistent supply of coal for steam genera-
tion, plants typically maintain an outdoor 90-day reserve supply.
The piles are usually not enclosed, so the coal comes in contact
with moisture and air which can oxidize metal sulfides to sul-
furic acid. Precipitation then results in coal pile runoff with
minerals, metals, and low pH (occasionally) in the stream.
Wet Flue Gas Cleaning Blowdown
Depending on the fossil fuel sulfur content, an SO2 scrubber may
be required to remove sulfur emissions in the flue gases. These
scrubbing systems result in a variety of liquid waste streams
depending on the type of process used. In all of the existing
FGD (flue gas desulfurization) systems, the main task of absorb-
ing S02 from the stack gases is accomplished by scrubbing the
existing gases with an alkaline slurry. This may be preceded by
partial removal of fly ash from the stack gases. Existing FGD
processes may be divided into two categories: regenerable and
nonregenerable (throwaway). Regenerable processes include the
Wellman-Lord Sulfite Scrubbing process and the Magnesia Slurry
Absorption Process. Additional discussion of regenerable FGD
processes is not provided since under normal circumstances no
wastewater is discharged from these systems. Nonregenerable FGD
processes include lime, limestone, and lime/limestone combination
and double alkali systems.
In the lime or limestone FGD process, S02 is removed from the
flue gas by wet scrubbing with a slurry of calcium oxide or
calcium carbonate. The waste solid product is disposed by pond-
ing or landfill. The clear liquid product can be recycled. Many
of the lime or limestone systems discharge scrubber waters to
control dissolved solids levels.
A number of processes can be considered double alkali processes,
but most developmental work has emphasized sodium based systems
which use lime for regeneration. -This system pretreats the flue
gas in a prescrubber to cool and humidify the gas and to reduce
fly ash and chlorides. The gas passes through an absorption
tower where SO2 is removed into a scrubbing solution which is
subsequently regenerated with lime or limestone in a reaction
tank.
The disadvantage of all non-regenerable systems is the production
of large amounts of throwaway sludges.• Onsite disposal is
usually performed by sending the waste solids to a settling pond.
The supernatant from the ponds may be recycled; however, accord-
ing to 308 data, 82% of the plants with FGD systems discharged
the supernatant into surface waters.
Date: 1/24/83 R Change 2 II.19-9
-------
II.19.2 WASTEWATER CHARACTERIZATION [2-55]
Wastewater produced by a steam electric power plant can result
from a number of operations at the site. Many wastewaters are
discharged more or less continuously as long as the plant is
operating. These include wastewaters from the following sources:
cooling water systems, ash handling systems, wet-scrubber air
pollution control systems, and boiler blowdown. Some wastes are
produced at regular intervals, as in water treatment operations
which include a cleaning or regenerative step as part of their
cycle (ion exchange, filtration, clarification, evaporation).
Other wastes are also produced intermittently but are gen-
erally associated with either the shutdown or startup of a
boiler or generating unit such as during boiler cleaning (water
side), boiler cleaning (fire side), air preheater cleaning,
cooling tower basin cleaning, and cleaning of miscellaneous small
equipment. Additional wastes exist which are essentially un-
related to production. These depend on meteorological or other
factors. Rainfall runoff, for example, causes drainage from coal
piles, ash piles, floor and yard drains, and from construction
activity. A diagram indicating potential sources of wastewaters
containing chemical pollutants in a coal-fueled steam electric
powerplant is shown in Figure 19-1.
Data on wastestream characteristics presented in this section are
based on the results of screening sampling done at 8 plants,
verification sampling carried out at 18 plants, and periodic
surveillance and analysis sampling carried out as part of compli-
ance monitoring at 8 plants. These data were stored on a compu-
terized data file and analyzed for presentation in Reference
2-55. All waste streams discussed in Section 19.1.1 were
analyzed during the screening program, while the verification
program focused on the following wastestreams: once-through
cooling water; cooling tower blowdown; and ash handling waters.
Table 19-4 is a summary of all priority pollutants detected in
any waste stream based on the data stored in the computerized
data file. The wastewater characteristics of the various waste
streams are discussed in the following sections. Where they are
available, only verification data are presented. Where verifica-
tion data are limited or not available, screening and/or sur-
veillance and analysis data are presented. The data source is
clearly indicated on each table and in the text.
Date: 1/24/83 R Change 2 11.19-10
-------
rt
(D
00
U)
o
3
H
vo
I
CHEMKALS
BOILER TIBE
CLEWING, FIRESIDE
AW AIR PREHEA1ER
WASHINGS
BOILER FEEMA1ER
FIB. _
COHB'N AIR - —
BOTTOM
ASH
MATER FOR
PERIODIC
CLEANING
COMPENSATE
WATER
TOA1
WJSPHERE
QfMICALS
QENICALS
ONCE THROUGH
*—•- COOLING WATER
•\X\CHEH1CALS
WATER
RECIRCULATING COOLING WATER
SANITARY WASTES
LABORATORY t SAMPLING WASTES
INTAKE SCREEN BACKWASH, CLOSED
COOLING WATER SYSTEMS, CON-
STRUCTION ACTIVITY
IMISC, WASTE-
HATER STREAMS
LEGEND:
LIQUID FLOW
GAS & STEAM FLOW
CHEMICALS
OPTIONAL FLOW
WASTEWATER
Figure 19-1.
Potential sources of wastewater in a steam
electric powerplant.
-------
TABLE 19-4.
SUMMARY TABLE OF ALL PRIORITY POLLUTANTS DETECTED
IN ANY OF THE WASTE STREAMS FROM STEAM ELECTRIC
POWERPLANTS [2-55]
Benzene
Chlorobenzene
1,2-Dichloroethane
1,1,1-Trichloroethane
1,1,2-Trichloroethane
2-Chloronaphthalene
Chloroform
2-Chlorophenol
1,2-Dichlorobenzene
1,4-Dichlorobenzene
1,1-Dichloroethylene
1,2-trans-Dichloroethylene
2,4-Dichlorophenol
Ethylbenzene
Methylene chloride
Bromoform
Dichlorobromomethane
Trichlorofluoromethane
Chiorodibromomethane
Nitrobenzene
Pentachlorophenol
Phenol
Bis(2-ethylhexyl) phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Di-n-octyl phthalate
Diethyl phthalate
Dimethyl phthalate
Tetrachloroethylene
Toluene
Trichloroethylene
4,4-DDD
Antimony (total)
Arsenic (total)
Asbestos (total-fibers/L)
Beryllium (total)
Cadmium (total)
Chromium (total)
Copper (total)
Cyanide (total)
Lead (total)
Mercury (total)
Nickel (total)
Selenium (total)
Silver (total)
Thallium (total)
Zinc (total)
II.19.2.1 Cooling Water
In general, wastewater characteristics of once-through cooling
water and recirculating cooling water systems are similar.
Pollutants discharged from both systems are caused by the ero-
sion or corrosion of construction materials plus the chemical
additives used to control corrosion, scaling, and biological
growth (biofouling). The wastewater generated from a recircu-
lating cooling water system also depends on the design limits
for dissolved solids in the system.
Erosion
The fill material in natural draft cooling towers is frequently
asbestos cement. Erosion of this fill material may result in the
discharge of asbestos in cooling water blowdown. In a testing
program for detection of asbestos fibers in the waters of 18
cooling systems, seven of the 18 sites contained detectable
concentrations of chrysotile asbestos in the cooling tower waters
at the time of sampling.
Date: 1/24/83 R Change 2 11.19-12
-------
Corrosion
Corrosion is an electrochemical process that occurs when metal is
immersed in water and a difference in electrical potential be-
tween different parts of the metal causes a current to pass
through the metal, between the region of lower potential (anode)
and the region of higher potential (cathode). The migration of
electrons from anode to cathode results in the oxidation of the
metal at the anode and the dissolution of metal ions into the
water.
Copper alloys are used extensively in powerplant condensers, and
as a result, copper can usually go into a corrosion product film
or directly into solution as an ion or as a precipitate in the
initial stages of condenser tube corrosion. As corrosion pro-
ducts form and increase in thickness, the corrosion rate de-
creases until a steady state is achieved. Studies indicate that
copper release is a function of flow rate more so than of the
salt content of the makeup water.
Data on copper concentrations in both once-through cooling and
recirculatory cooling systems indicate that corrosion products
are more of a problem in cooling tower blowdown than in once-
through systems discharge. The concentration of pollutants (via
evaporation) in recirculating systems probably accounts for most
of the difference in the level of metals observed between once-
through discharge and cooling tower blowdown.
Chemical Treatment
Chemical additives are needed at some plants with recirculating
cooling water systems in order to prevent corrosion and scaling.
Chemical additives are not frequently used at plants with
once-through cooling water systems for corrosion controls.
Scaling occurs when the concentration of dissolved materials,
usually calcium and magnesium containing species, exceeds their
solubility levels. The addition of scaling control chemicals
allows a higher dissolved solids concentration to be achieved
before scaling occurs.
Therefore, the amount of blowdown required to control scaling can
be reduced. Chemicals added to recirculating cooling water to
control corrosion and scaling are usually present in the dis-
charges. The solvent and carrier components which may be used
in conjunction with scaling and corrosion control agents are
listed in Table 19-5.
Date: 1/24/83 R Change 2 11.19-13
-------
TABLE 19-5. SOLVENT OR CARRIER COMPONENTS THAT MAY BE USED
IN CONJUNCTION WITH SCALING AND CORROSION CON-
TROL AGENTS [2-55]
Dimethyl formamide
Methanol
Ethylene glycol monomethyl _ether
Ethylene glycol monobutyl ether
Methyl ethyl ketone
Glycols to hexylene glycol
*Heavy aromatic naphthalene
Cocoa diamine
Sodium chloride
Sodium sulfate
Polyoxyethylene glycol
Talc
Sodium aluminate
Monochlorotoluene
Alkylene oxide - alchohol glycol ethers
* Indicates that the compound is known to contain a priority
pollutant. Some of the other compounds may contain or may
degrade into priority pollutants but no data were available
to make a definite determination.
Chlorine and hypochlorite are used to control biofouling in both
once-through and recirculating cooling water systems. The addi-
.tion of chlorine to the water causes the formation of toxic
compounds and chlorinated organics which may be priority pollu-
tants.
Eleven plants with once-through cooling water systems were sam-
pled as part of the verification program and the surveillance and
analysis sampling efforts. Four of these plants have estuarine
or salt water intakes, and the remaining seven plants have fresh
water intakes. Sampling was carried out only during the period
of chlorination. Samples were analyzed for all organic priority
pollutants except the pesticides, and for total organic carbon
and total residual chlorine (9 plants). Table 19-6 is a summary
of the data collected in the verification and surveillance and
analysis sampling efforts. Only the priority pollutants which
were detected are shown. Table 19-7 is a summary of once-through
cooling system flow rates based on responses to 308 question-
naires.
Date: 1/24/83 R Change 2 11.19-14
-------
rt-
(D
TABLE 19-6. SUMMARY OF PRIORITY POLLUTANTS IN THE STEAM ELECTRIC INDUSTRY ONCE THROUGH
COOLING WATER, SURVEILLANCE AND ANALYSIS AND VERIFICATION DATA [2-55]
CO
U)
n
to
H
H
•
I-1
I
Ul
Pollutant
classical pollutants, mg/L
Total residual chlorine
coo
TOS
TSS
TOC
Free residual chlorine
Phenol ics
Barium
Calcrua
Manganese
Magnesium
Sodium
Iron
Aluminum
Boron
Tin
Titanium
Molybdenum
Cobalt
Vanadium
Toxic pollutants, M9/L
Toxic Beta Is and Inoroanlcs
Antimony
Arsenic
Cadmium
ChromfiNi
Copper
Cyanide
Lead
Nercury
Nickel
Selenium
Silver
Zinc
Toxic oroanlcs
Bromoform
Ch lo rod ibromome thane
Bis(2-ethylhexyl) phthalate
Gamma-BHC
2 , 4-O I ch 1 o ropheno 1
1,2-Dlchlorobenzene
1,4 Dichlorobenzene
Benzene
2-Ch 1 oronaptha 1 era
chloroform
1, l-Oichloroethylene
Ethyl benzene
Hetnylene chloride
Phenol
Butyl benzyl phthalate
Ol-n-butyl phthalate
To 1 uene
Trichloroethylene
1. 1,1-Trichloroethane
Pentach 1 o ropheno 1
Dlethyl phthalate
Tetrachloroethylene
Benzidine
Methyl chloride
Number of
samoles
II
II
II
II
II
10
II
1 1
II
II
1 1
II
1 1
II
1 1
II
II
1 1
II
II
II
II
II
1 1
II
1 1
II
II
II
II
II
II
9
10
II
10
II
II
II
10
II
10
10
10
10
II
II
II
10
10
II
II
II
1 1
1 1
II
Number of Range of Median of Mean of Number of Number of Range of Median of Mean of
detections detections detections detections samoles detections detections detections detections
6
1
1 1
8
II
I
6
5
5
5
5
5
4
3
2
3
1
2
0
3
3
2
6
6
|
2
3
3
2
1
II
0
0
n
0
0
0
3
0
1
1
1
3
1
It
1
1
0
0
1
1
0
1
Intake
-------
D
P)
rt
TABLE 19-6. SUMMARY OF PRIORITY POLLUTANTS IN THE STEAM ELECTRIC INDUSTRY ONCE THROUGH
COOLING WATER, SURVEILLANCE AND ANALYSIS AND VERIFICATION DATA (continued)
oo
u>
O
tr
fa
H
H
Number of
Classical pollutants, mg/L
Total residual chlorine
COD
TDS
TSS
TOC
Free residual chlorine
Pheno lies
Barium
Calcium
Manganese
Magnesium
Sodium
1 ron
Aluminum
Boron
Tin
Titanium
Molybdenum
Coba 1 t
Vanadium
Toxic pollutants, ug/L
Toxic metals and inoraanics
Antimony
Arsenic
Ch rom i urn
Copper
Cyanide
Lead
Mercury
Nickel
Selenium
Si Iver
Thallium
Zinc
Toxic oraanics
Bromoform
Chlorod ibromome thane
Bis(2-ethylhexyl ) phthalate
2,4-Dicn lorbphenol
Gamma BNC
1 , 2-D i ch 1 o robenzene
1 , 4-D i ch 1 o robenzene
Benzene
2-Chloronapthalene
Chloroform
1 , l-Dich to roe thy lene
Ethylbenzene
Methyl ene chloride
Pheno 1
Butyl benzyl phthalate
Di-n-butyl phthalate
To 1 uene
T r i ch 1 o roe thy 1 ene
1,1, l-Trichloroe thane
Pen tach 1 o ropneno 1
Oiethyl phthalate
Te t rach 1 o roe thy 1 ene
Benzidene
Methyl chloride
4
4
4
4
3
4
4
3
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
4
3
4
4
4
4
4
4
4
4
4
4
4
4
4
4
1)
4
Number of
2
1
4
1
0
1
1
3
4
4
4
4
3
3
3
1
2
2
1
2
2
4
4
0
1
3
0
2
1
0
1
0
0
2
1
0
1
0
3
1
4
1
0
3
2
1
3
0
3
0
1
1
1
0
1
Range of Median of
Ch lorinated
0.04 - 0.21
33
220 - 520 270
10
0.063
0.015
0.013 - 0.031 0.018
0.073 - 45 39
0.061 - 0.086 0.067
12-30 13
15 - 35 IB
0.54 - 2.3 0.72
0.24 - 2.2 0.44
0.051 - 0. 14 0.056
0.03
0.019 - 0.058
0.01 - 0.016
<0.005
3-10
3-5
10 - 25 13
9-23 12
34
0. 1 - 0.6 0.7
3 - 8.3
3
68
-------
TABLE 19-7. ONCE THROUGH COOLING WATER FLOWRATES (308
QUESTIONNAIRE) [2-55]
Va r i a b 1 e
Fuel :
Flow:
Flow:
Fuel :
F low:
Flow:
Fuel :
Flow:
Flow:
Coa 1 (a )
cu.m/day/p lant
cu.m/day/MW
Gasta )
cu.m/day/plant
cu.m/day/MW
Oi l(a)
cu.m/day/p lant
cu.m/day/MW
Number of
D lants
239
239
105
IOU
138
137
Mean
1, 130,000
(b)
783,000
2,410,000
1,490,000
5,260
Ranqe
0. 189 -
0.001 -
0.29 -
0.006 -
0.007 -
O.OOOOU -
6,280,000
209,000
7,230,000
13,800,000
26,700,000
219,000
(a) Fuel designations are determined by the fuel which contributes the
most Btu for power generation for the year 1975.
(b) Data not presented due to suspected error.
The data indicate that there were net increases in all of the
following compounds: total dissolved solids, total suspended
solids, total organic carbon, total residual chlorine, free
available chlorine, 2-4 dichlorophenol, 1,2-dichlorobenzene,
phenolics, chromium, lead, copper, mercury, silver, iron, arsenic,
zinc, barium, calcium, manganese, sodium, methyl chloride, alu-
minum, boron, and titanium. However, the net increase was
greater than 10 vg/L only for 1,2-dichlorobenzene, total
phenolics, lead, zinc, and methylene chloride.
Eight power plants with cooling towers were sampled at intake and
discharge points during the verification sampling program. The
results of the verification sampling program for cooling tower
blowdown (recirculating cooling water) are presented in
Table 19-8. Only the priority pollutants which were detected are
shown. Table 19-9 is a summary of cooling tower blowdown flow
rates based on responses to 308 questionnaires.
The data indicate that there was a net increase from the influent
concentration to the effluent concentration for the following
compounds: trichlorof luoromethane, bromoform, chl.orodibromo-
methane, bis(2-ethylhexyl) phthalate, antimony," arsenic, cadmium,
chromium, mercury, nickel, selenium, silver, thallium, benzene,
tetrachloroethylene, toluene, copper, cyanide, lead, zinc, chloro-
form, phenol, asbestos, total dissolved solids, total suspended
solids, total organic carbon, total residual chlorine,
1,2-dichlorobenzene, 2,4-dichlorophenol, boron, calcium, mag-
nesium, molybdenum, total phenolics, sodium, tin, vanadium,
cobalt, iron, chloride, 2,4,6-trichlorophenol, and pentachloro-
phenol. It must be recognized, however, that recirculating
cooling systems tend to concentrate the dissolved solids present
in the make-up water and, thus, a blowdown stream with many
different compounds showing concentration increases is to be
expected. Of the priority pollutants detected as net discharges,
the concentration increase was greater than 10 vg/L only for
Date: 1/24/83 R Change 2 11.19-17
-------
ti-
ro
TABLE 19-8. SUMMARY OF PRIORITY POLLUTANTS IN THE STEAM ELECTRIC SUBCATEGORY VERIFICATION
DATA RECIRCULATING COOLING WATER [2-55]
00
CO
O
(D
H
H
V£>
00
Pol lutant
Number of
samples
Number of Range of
detections detections
Median of
detections
Mean of
detections
Intake
Classical pollutant, mg/L
TDS
TSS
TOC
Phenol ics
Total residual chlorine
Sod i um
Tin
Titanium
1 ron
Vanadiun
Barium
Boron
Ca 1 c i um
Chloride
Coba 1 1
Manganese
Magnesium
Molybdenum
A 1 lire i nun
Toxic pollutants, ug/L
Toxic metals and inorganics
Antimony
Arsenic
Cadmium
Ch rom i um
Copper
Cyanide
Lead
Nickel
S i 1 ve r
Se I en i um
Zinc
Tha 1 I i um
Me rcu ry
Toxic oraanics
Benzene
Carbon tetrachloride
Chloroform
1 ,2-Dichlorobenzene
0 i en 1 o rob romome t ha ne
Ch 1 o rod i b romome tha ne
To 1 uene
T r i ch 1 o roethy 1 ene
I,l»-Dichloro benzene! a)
2, 4 , 6- T r i ch 1 o ropheno 1
2 , 4-0 i ch 1 o ropheno 1
Pentach 1 o ropheno 1
Bromoform
8
7
8
7
8
8
8
8
8
8
8
8
8
7
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
8
7
8
6
6
8
8
8
8
8
7
7
6
7
8
5
3
5
3
4
5
4
4
5
6
1
4
6
5
4
2
2
1
5
6
8
2
6
6
4
2
5
1
1
2
I
I
2
0
0
2
1
1
0
14
2
0
190
0.005
-------
D
fa
rt
(D
TABLE 19-8. SUMMARY OF PRIORITY POLLUTANTS IN THE STEAM ELECTRIC SUBCATEGORY VERIFICATION
DATA RECIRCULATING COOLING WATER (continued)
NJ
00
U)
o
tr
(D
NJ
I
\->
vo
Number of
Pol lutant samples
Number of Range of
detections detections
Med ian of
detect i ons
Mean of
detections
Discharqe
Classical pollutant, mg/L
IDS
TSS
TOC
Phenol ics
Total residual chlorine
Sod i urn
Tin
Titanium
1 ron
Vanadium
Ba r i urn
Boron
Ca 1 c i urn
Coba 1 t
Manganese
Magnesium
Molybdenum
Aluminum
Toxic pollutant, ng/L
Toxic metals and inorganics
Ant imony
Arsenic
Cadmi um
Chromium
Copper
Cyanide
Lead
Nickel
Si 1 ve r
Se 1 en i um
Zinc
Tha 1 1 i um
Mercury
Toxic orqanics
Benzene
Carbon tetrachlor ide
Chloroform
1 ,2-Dichlorobenzene
D i ch 1 o rob romome tha ne
Ch 1 o rod i b romome tha ne
Toluene
Trichloroethy lene
1 ,4-Dichlorobenzene
2,4,6-Trichlorophenol
2,4-Oichlorophenol
Pentach 1 oropheno 1
Bromoform
8
8
8
7
8
8
8
8
8
8
7
8
8
8
8
8
8
8
8
8
8
8
8
8
7
8
8
8
8
8
8
8
7
8
7
8
8
7
8
7
8
8
8
8
6
8
8
it
6
5
4
3
5
6
3
5
6
14
5
5
4
2
2
2
6
8
8
2
1*
8
5
0
5
2
2
2
0
2
2
2
2
1
1
0
1
2
3
1
430
2
9
<0.005
<0.02
33
0.03
0.02
0.3
0.01
0.02
0.06
6.9
0.008
0.05
14.9
0.02
0.4
5
2
0.9
2
36
3
1.5
14
0.35
20
8
0.2
-------
bis(2-ethylhexyl) phthalate, cadmium, chromium, nickel, selenium,
silver, toluene, copper, cyanide, lead, zinc, phenol,
1,2-dichlorobenzene, total phenolics, and 2,4,6,-trichlorophenol.
TABLE 19-9. COOLING TOWER SLOWDOWN FLOWRATES (308
QUESTIONNAIRE) [2-55]
Variable Number of plants Mean Range
Fuel : Coa 1 (a )
Flow: cu.m/day/p lant
Flow: cu. m/day/p lant
Fue 1 : Gas(a )
Flow: cu. m/day/p 1 ant
Flow: cu. m/day/p lant
Fuel: Oil (a)
Flow: cu.m/day/p lant
Flow: cu.m/day/p lant
82
82
120
1 19
47
47
8,440
1 1.2
1, 190
1 1.6
1,040
7.04
0
0
0
0
0
0
- 152,000
- 239
- 10,900
- 99
- 12, 100
- 63.2
(a)Fuel designations are determined by the.fuel which contri-
butes the most Btu for power generation for the year 1975.
II.19.2.2 Ash Transport
The chemical compositions of both types of bottom ash, dry or
slag, are quite similar. The major species present in bottom ash
are silica (20-60 weight percent as Si02), alumina (10-35 weight
percent as A1203), ferric oxides (5-35 weight percent as Fe203),
calcium oxide (1-20 weight percent as CaO), magnesium oxide
(0.3-0.4 weight percent as MgO), and minor amounts of sodium and
potassium oxides (1-4 weight percent). In most instances, the
combustion of coal produces more fly ash than bottom ash. Fly
ash generally consists of very fine spherical particles, ranging
in diameter from 0.5 to 500 microns. The major species present
in fly ash are silica (30-50 weight percent as Si02), alumina
(20-30 weight percent as A12O), and titanium dioxide (0.4-1.3
weight percent as Ti02). Other species which may be present
include sulfur trioxide, carbon, boron, phosphorus, uranium, and
thorium.
In addition to these major components, a number of trace elements
are also found in bottom ash and fly ash. The trace elemental
concentrations can vary considerably within a particular ash or
between ashes. Generally, higher trace element concentrations
are found in the fly ash than bottom ash; however, there are
several cases where bottom ash exceeds fly ash concentration.
Fly ash demonstrates an increased concentration trend with de-
creasing particle sizes.
During the verification sampling effort, the ash pond overflows
of nine facilities were sampled to further quantify those effluent
pollutants identified in the screening program. The data are
presented in Table 19-10.
Date: 1/24/83 R Change 2 11.19-20
-------
TABLE 19-10. SUMMARY OF PRIORITY POLLUTANTS IN THE STEAM ELECTRIC INDUSTRY
ASH POND OVERFLOW, VERIFICATION DATA [2-55]
Number Number Range Median
of of of of
Pollutant samples detections detections detections
Mean
of
detections
Intake
Classical pollutants, mg/L
Oi 1 and grease 10 1
TDS 1 1 8
TSS 9 8
TOC 10 8
Phenol ics 10 5
Chloride 10 1
Aluminum 5
Barium 7
Boron 6
Calcium 8
Coba 1 t 3
Manganese 8
Magnesium 8
Molybdenum 2
Sod i urn 8
Tin 3
Titanium 4
1 ron 9
Vanadium 10 3
Yttrium 1 0
Toxic pollutants, Mg/L
Toxic metals and inorganics
Antimony
Arsenic
Be ry 1 1 i urn
Cadmium
Chromium
Copper
Cyanide
Lead
Mercury
Nickel
Selenium
Si 1 ve r
Tha 1 1 ium
Zinc
Toxic orqanics
Benzene
Carbon tetrachloride
Chloroform
1 , 2-D ichlo robenzene
Ethylbenzene
Toluene
Trichloroethylene
1, l-Dichloroethylene
1 ,4-Dichlorobenzene
Methylene chloride
Pheno 1
Bis (2-ethylhexyl )
phtha late
Butyl benzyl phthalate
Di-n-butyl phthalate
Diethyl phthalate
Dimethyl phthalate
Tetrachloroethylene
1 , 1 ,2,2-Tetrachloroethane
1,1, l-Tr ichlo roe thane
Pen tach 1 o ropheno 1
3
2
0
5
9
1 1
2
9
2
10
2
2
1
7
3
1
3
1
9 0
2
2
0
0
2
Pest ic i des
4,4TM)UD 1 1
25
130
0.005
5
0.006
1
0.2
0.017
0.06
6.9
0.007
0.04
4.5
0.009
-------
TABLE 19-10. SUMMARY OF PRIORITY POLLUTANTS IN THE STEAM ELECTRIC
ASH POND OVERFLOW (CONTINUED)
INDUSTRY
Pol lutant
Classical pollutants, mg/L
Oil and grease
TDS
TSS
TOC
Phenol ics
Chloride
Al umi num
Barium
Boron
Ca 1 c i urn
Coba 1 1
Manganese
Magnesium
Molybdenum
Sod i urn
Tin
Ti tanium
1 ron
Vanad ium
Yttrium
Toxic pollutants, ug/L
Toxie metals and inorganics
Antimony
Arsenic
Be ry 1 1 i urn
Cadmium
Chromium
Copper
Cyanide
Lead
Mercury
Nickel
Selenium
Si Ivor
Thai 1 ium
Zinc
Toxic oraanics
Benzene
Carbon tetrachlor ide
Chloroform
1 , 2-D i ch 1 orobenzene
Ethyl benzene
Toluene
Trichloroethylene
1 , 1 -Dicti lo roe thy lene
1 , i4-Dichlorobenzene
Mo thy lene chloride
Phenol
Bis (2-ethylhexyl )
phtha 1 ate
Butyl benzyl phtha late
Ui-n-butyl phthalate
Diethyl ph that ate
Dimethyl phthalate
Tetrachlo roe thy lene
1 , 1 ,2,2-Tetrachloroethane
1, 1 , l-Trichlo roe tha ne
Pentach 1 o ropheno 1
Pesticides
57^-000
Number
of
samples
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
12
1 1
12
12
12
12
12
12
1 1
12
12
12
12
12
12
1 1
1 1
1 1
12
12
10
12
12
12
12
12
12
12
12
12
1 1
1 1
II
12
1 1
Number
of
detections
2
9
1 I
9
7
2
6
9
9
9
14
8
9
9
9
6
2
9
5
1
l|
2
3
8
12
1 1
2
8
3
12
3
6
0
8
3
0
2
0
3
2
0
1
1
2
1
1
0
1
1
1
0
0
0
1
0
Range
of
detections
Discharge
1 - 24
14 - 2, UOO
5 - 160
3-150
0.006 -0.014
37 - 37
0.06 - 5
0.01 - 0.092
0.02 - 3
21 - mo
0.007 - 0.05
0.01 - 1
5.6 - 20
0.008 - 0.3
-------
11.19.2.3 Low Volume Wastes
Low volume waste sources include water treatment processes which
prevent scale formation such as clarification, filtration, lime/
lime soda softening, ion exchange, reverse osmosis, and evapora-
tion. Also included are drains and spills from floor and yard
drains and laboratory streams.
Clarification
Clarification is the process of agglomerating the solids in a
stream and separating them by settling. Chemicals which are
commonly added to the clarification process do not contain any of
the listed priority pollutants.
Ion Exchange
Ion exchange processes can be designed to remove all mineral
salts in a one-unit operation and, as such, are the most common
means of treating supply water. The process uses an organic
resin that must be regenerated periodically by backwashing and
releasing the solids. A regenerant solution is passed over the
bed and is subsequently washed.
The resulting exchange wastes are generally acidic or alkaline
with'the exception-of sodium chloride solutions which are neutral.
While these wastes do not have significant amounts of suspended
solids, certain chemicals such as calcium sulfate and calcium
carbonate have extremely low solubilities and are often precipi-
tated because of common ion effects.
Spent regenerant solutions, constituting a significant part of
the total flow of wastewater from ion exchange regeneration,
contain ions which are eluted from the ion exchange material
plus the excess regenerant that is not consumed during regenera-
tion. The eluted ions represent the chemical species which were
removed from water during the service cycle of the process.
Table 19-11 presents a summary of ion exchange demineralizer
regenerant wastes characterized in the surveillance and analysis
study.
Lime Softener Wastewater
Softening removes hardness using chemical precipitation. The two
major chemicals used are calcium hydroxide and sodium carbonate,
thus no priority pollutants will be introduced into the system.
Reverse Osmosis Wastewater
Reverse osmosis is a process used by some plants to remove dis-
solved salts. The waste stream from this process consists of
reverse osmosis brine. In water treatment schemes reported by
Date: 1/24/83 R Change 2 11.19-23
-------
0
0)
ft
(D
TABLE 19-11. SUMMARY OF PRIORITY POLLUTANTS IN THE STEAM ELECTRIC INDUSTRY DEMINERALIZER
REGENERANT, SURVEILLANCE AND ANALYSIS DATA [2-55]
00
U)
O
tr
0)
3
iQ
(D
to
vo
I
K)
Pol lutant
Classical pollutants, mg/L
IDS
TSS
TOC
Acetone
A 1 un i nun
Ba r i urn
Boron
Ca 1 c i urn
Manganese
Magnesiun
Molybdenum
Sod i urn
T i tan i UN)
1 ron
Toxic pollutants, ug/L
Antimony
Arsenic
Cadmium
Copper
Ch ron i un
Cya n i de
Lead
Mercury
Nickel
Se I en i u«
Si iver
Zinc
Tha 1 1 i un
Toxic oraanics
Benzene
Chloroform
1 , l-Dichloroethylene
Methylene chloride
Bromoforn
0 i ch to rob romome thane
Ch lo rod i bromone thane
Dichlorofluo rone thane
Pheno 1
Bis (2-ethylhexyl)
phtha late
Butyl benzyl phthalate
Di-n-butyl phthalate
Di-n-octyl phthalate
Oiethyl phtha tate
Tet rach 1 o roe thy 1 ene
Trichloroethyl ene
Chlorobenzene
,1,1 -Trichlo roe thane
, 1 , 2-Trichloroetnane
, 2-0 i oh 1 o robenzene
, 3-0 i ch 1 o robenzene
, U-Dich lo robenzene
Ni t robenzene
Number
of
sanolos
3
2
3
2
3
3
3
3
3
3
3
2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Nunber
of
detections
2
1
2
0
n
0
0
1
2
0
2
1
3
1
0
0
3
1
1
0
3
0
1
2
0
1
2
1
1
1
2
1
1
1
0
1
1
2
0
0
1
0
0
0
0
Range Median
of of
detections detections
Intake
210 - 290
2.8
2.3 - 9
0.50
0.017
19
0.065
15
0.018
0.01 - 0.81
2-3
-------
D
D>
rt-
TABLE 19-M. SUMMARY OF PRIORITY POLLUTANTS IN THE STEAM ELECTRIC INDUSTRY
DEMINERALIZER REGENERANT (continued)
CO
o
tr
NJ
I
K)
Ul
Pol lutant
Classical pollutant, mg/L
TDS
TSS
TOC
Acetone
A 1 urn i nuM
Barium
Boron
Calcium
Manganese
Magnes i urn
Molybdenum
Sod i u«
Titanium
1 ron
Toxic pollutant, ug/L
Toxic metals and inoraanics
Antimony
Arsenic
Cadmium
Copper
Chromium
Cyanide
Lead
Mercury
Nickel
Se 1 en i urn
Si Iver
Zinc
Thai 1 ium
Toxic oraanics
Benzene
Chloroform
1 , l-Dichloroethylene
Methylene chloride
Bromoform
Dichlorobromomethane
Ch 1 o rod i b romome thane
Oichlorofluoro me thane
Pheno 1
Bis(2-ethylhexyl)
phtha late
Butyl benzyl phtha late
Oi-n-butyl phtha late
Di-n-octyl phtha late
Diethyl phtha late
Tetrachloroethylene
T r i ch 1 o roe thy 1 ene
Chlorobenzene
1,1,1 -T rich lo roe thane
1 , 1 , 2-Trichlo roe thane
1 ,2-0 t Chlorobenzene
1 , 3-0 ich lorobenzene
1 , 1-D ich lorobenzene
1 , 3-D ich lorobenzene
1 , 4-D i ch 1 o robenene
Ni trobenzene
Number
of
samoles
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
3
2
3
3
3
2
3
2
3
2
3
3
3
3
3
2
3
3
2
3
3
2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Number
of
detect ions
2
2
2
0
2
1
0
2
2
2
2
1
2
2
1
1
1
1
0
3
1
2
1
1
1
0
2
1
0
1
1
1
1
1
1
1
1
1
1
1
1
1
1
Range Median
of of
Discharae
3,000 - 1,600
9.2 - 17
4.8 - 8
0.0087
0.28
0.063
170
0.009
17
0.015
160
0.79 - 5
20
5-35
27 - 65
11-26
0.01 - 17
21
1.6-6
200 - 230
1
58
51
ISO
1.8 - IUO 38
220
I10
2.9
Analytic methods: v.7.3.31. Data set 2.
-------
the industry, reverse osmosis was always used in conjunction with
demineralizers, and sometimes with clarification, filtration, and
ion exchange softening.
Floor and Yard Drain Wastewater
As a result of the numerous potential sources of wastewater from
equipment drainage and leakage throughout a steam electric fa-
cility, the pollutants encountered in such wastewaters may be
diverse. There have been little data reported for these waste
streams; however, the pollutant parameters that may be of concern
are oil and grease, pH, and suspended solids.
Laboratory Drain Wastewater
The wastes from the laboratories vary in quantity and constit-
uents, depending on the use of the facilities and the type of
powerplant. The chemicals are usually present in extremely small
quantities. It has been common practice to combine laboratory
drains with other plant plumbing.
II.19.2.4 Boiler Slowdown
Boiler blowdown is generally of fairly high quality because the
boiler feedwater must be maintained at high quality. Boiler
blowdown having a high pH may contain a high dissolved solids
concentration depending on boiler pressure. The sources of
impurities in the blowdown are the intake water, internal corro-
sion of the boiler, and chemicals added to the boiler system.
Impurities contributed by the intake water are usually soluble
inorganic species (Na+, K+, Cl", So4"2, etc.) and precipitates
containing calcium/magnesium cations. Products of boiler corro-
sion are soluble and insoluble species of iron, copper, and other
metals. A number of chemicals are added to the boiler feedwater
to control scale formation, corrosion, pH, and solids deposition.
Table 19-12 presents a summary of toxic and classical pollutants
detected in verification analyses of boiler blowdown.
II.19.2.5 Metal Cleaning Wastes
Chemical metal cleaning wastewater means any wastewater resulting
from the cleaning of any metal process equipment with added chem-
ical cleaning agents, including, but not limited, to, boiler tube
cleaning. Non-chemical metal cleaning wastewater means any
wastewater produced by the cleaning of metal process equipment
without the addition of chemical cleaning agents, including,
but not limited to, boiler fireside cleaning and air preheater
cleaning.
Date: 1/24/83 R Change 2 11.19-26
-------
a
0)
rt
(D
to
TABLE 19-12. SUMMARY OF PRIORITY POLLUTANTS IN THE STEAM ELECTRIC
SLOWDOWN, VERIFICATION DATA [2-55]
INDUSTRY BOILER
O.
U)
O
CD
to
H
I
[O
-J
Number
of
Pollutant samoles
Classical pollutants, mg/L
TDS
TSS
TOC
Oi 1 and grease
phenol ics
Aluminum
ca 1 c i um
Manganese
Magnesium
Molybdenum
Sod i um
1 ron
T i tan i um
Toxic pollutants, Mg/L
Toxic metals
Antimony
Arsenic
Cadmium
Ch rom t un
Copper
Lead
Mercury
N i eke 1
Se 1 en i um
Zinc
Toxic oraanlcs
Benzene
1,1, l-Trichloroethane
1 , 1 ,2,2-Tetrachloroethane
Chloroform
1 , 1 -0 i ch 1 o roethy 1 ene
Ethylbenzene
Methyl ene chloride
Bis(2-ethylhexyl )
phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Diethyl phthalate
Tetrachlo roe thy lone
Toluene
T r i ch 1 o roethy 1 ene
0 i ch 1 o rob romome thane
Ch 1 o rod i b romome thane
1 , 1 ,2-Trichlo roe thane
Bromoform
1 , 3-Dichloropropene
Pheno 1
3
2
3
2
3
3
3
3
3
3
2
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Number Range Median Mean .
of of of of
detections detections detections detections
Intake
*
2 210 - 290 250
1 2.8
2 2.3-9 5.6
0
1 <0.02
0
1 49
1 0.065
1 15
0
0
2 0.01 - 0.84 0.42
1 0.018
0
2 2-3 2.5
1 4
1 10
3 9-22 22 18
0
3 0.2 - 1.5 1 0.9
1 8
0
3 10 - 100 88 66
1
-------
Chemical Cleaning of Boiler Tubes
The characteristics of waste streams emanating from the chemical
cleaning of utility boilers are similar in many respects. The
major constituents consist of boiler metals; i.e., alloy metals
ued for boiler tubes, hot wells, pumps, etc. Although waste
streams from certain cleaning operations which are used to remove
certain deposits; i.e., alkaline degreaser to remove oils and
organics; do not contain heavy concentrations of metals, the
primary purpose of the total boiler cleaning operation (all
stages combined) is removal of heat transfer-retarding deposits,
which consist mainly of iron oxides resulting from corrosion.
This removal of iron is evident in all total boiler cleaning
operations through its presence in boiler cleaning wastes.
Cleaning mixtures used include alkaline chelating rinses, proprie-
tary chelating rinses, organic solvents, acid cleaning mixtures,
and alkaline mixtures with oxidizing agents for copper removal.
Wastes from these cleaning operations may contain iron, copper,
zinc, nickel, chromium, hardness, and phosphates. In addition to
these constituents, wastes from alkaline cleaning mixtures may
contain ammonium ions, oxidizing agents, and high alkalinity;
wastes from acid cleaning mixtures may contain fluorides, high
acidity, and organic compounds; wastes from alkaline chelating
rinses may contain high alkalinity and organic compounds; and
wastes from most proprietary processes may be alkaline and may
contain organic and ammonium compounds. Other waste constituents
present in spent chemical cleaning solutions include wide ranges
of pH, high dissolved solids concentrations, and significant
oxygen demands (BOD and/or COD). The pH of spent solutions
ranges from 2.5 to 11.0 depending on whether acidic or alkaline
cleaning agents are employed.
Table 19-13 presents a summary of toxig and classical pollutants
detected in three common cleansing solutions: ammoniacal sodium
bromate, hydrochloric acid without copper complexer, and hydro-
chloric acid with copper complexer.
Boiler Fireside Wastewater
When boiler firesides are washed, the waste effluents produced
contain an assortment of dissolved and suspended solids. Acid
wastes are common for boilers fired with high-sulfur fuels.
Sulfur oxides absorb onto fireside deposits, causing low pH and a
high sulfate content in the waste effluent.
Air Preheater Wastewater
Fossil fuels with significant sulfur content will produce sulfur
oxides which absorb on air preheater deposits. Water washing of
these deposits produces an acidic effluent. Alkaline reagents
are often added to wash water to neutralize acidity, prevent
Date: 1/24/83 R Change 2 11.19-28
-------
D
OJ
rt
CD
to
£*
\
CD
O
tr-
ey
(B
to
TABLE 19-13. SUMMARY OF PRIORITY POLLUTANTS IN THE STEAM ELECTRIC INDUSTRY METAL CLEANING WASTES,
VERIFICATION DATA [2-55]
I
to
Pol lutant
Classical pollutants, mg/L
IDS
TSS
COD
Oi 1 and grease
pH, pH Units'
Phosphorus
B rom i de
Chloride
F 1 uo r t de
A 1 urn i nun
Ca 1 c i un
Ba r i u«
Sod i UNI
Potass IUM
Tin
1 ron
Manganese
Magnesium
Toxic pollutants, ug/L
Toxic me tali
Arsenic
Beryl 1 iun
Cadmiun
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Si Iver
Zinc
Number
of
sa moles
2
1
1
7
1
1
2
1
7
2
2
3
7
3
3
Number Range Median
of of of
detections detections detections
A
2
1
1
7
1
1
2
1
7
2
2
3
7
3
3
nunoniated ED
60,000 -
21
HI
8.8 -
260
31
21 -
370
2,200 -
50 -
1 1 -
10,000 -
170 -
12,000 -
79,000 -
TA Solutions
71,000
10 9.2
15
8,300 6,900
73
21
26,000 12,000
12,000,000 120,000
110,000 68,000
110,000 120,000
Mean
of
detections
67,000
9.3
33
6,300
61
16
16,000
1,900,000
73,000
1 10,000
Number
of
samples
3
3
2
2
2
2
2
1
2
2
3
2
3
2
'2
5
3
3
3
2
2
1
6
3
3
5
3
2
5
Number
of
detect!
A.
3
3
2
2
2
2
2
1
2
2
2
2
3
2
2
1
3
2
3
2
2
3
6
3
3
1
3
2
5
Range •
of
ons detections
ffiion i a 1 Sod i u
310 -
8 -
21 -
<5 -
10 -
10 -
<5 -
60
1.5 -
<0.2 -
0.1 -
<0. 1 -
3.7 -
70 -
-------
o
t»
rt
(D
ro
TABLE 19-13. SUMMARY OF PRIORITY POLLUTANTS
VERIFICATION DATA (continued)
IN THE STEAM ELECTRIC INDUSTRY METAL CLEANING WASTES,
oo
CO
O
tr
(D
to
H
H
vo
I
u>
o
Pollutant
Nuaber
or
sanoles
Niwber Range Median
or or or
detections detections detections
Mean Nuaoer
or or
detections saaules
Hydrochloric Acid without
Coooer Cow lex
Classlca'l pollutants, mg/L
JOS
JSS
COO
TOC
Oi 1 and grease
Phenols
Phosphorus
Su irate
AluMinuat
Iron
Magnes i urn
Manganese
Potassiuaj
Sodliua
Tin
Calciu*
Bariuia
pH, pH units
Toxic pollutants, ug/L
Toxic actals
Arsenic
Beryllium
Ct dm turn
Chromium
Copper
Lead
Mercury
Nickel
Seleniuai
Silver
Zinc
6
6
6
6
6
6
6
4
6
6
4
6
6
7
5
7
II
4
7
6
6
6
6
6
6
4
j|
7
4
6
4
4
4
6
4
6
6
4
6
6
7
5
. 4
7
4
4
7
8
I.20O
90
<5
0.02
1.2
-------
corrosion of metallic surfaces, and maintain an alkaline pH.
Alkaline reagents might include soda ash (Na2C03), caustic soda
(NaOH), phosphates and/or detergent. Preheater wash water con-
tains suspended and dissolved solids which include sulfates,
hardness, and heavy metals including copper, iron, nickel, and
chromium.
11.19.3 PLANT SPECIFIC DATA [2-55]
II.19.3.1 Plant 1226
Plant 1226 is a bituminous coal, oil and gas fired electricity
plant. The recirculating cooling water system influent was sam-
pled from a stream taken from the river and the effluent from the
cooling tower blowdown stream. The effluent stream is used again
in the ash sluice stream. Table 19-14 presents the data. The
following additives are combined with the cooling tower influent:
• chlorine (biocide)
• calgon Cl-5 (corrosion inhibitor)
• sulfuric acid (scale prevention)
The addition is necessary for the control of pipe corrosion.
TABLE 19-14. PLANT SPECIFIC DATA FOR PLANT 1226
RECIRCULATING COOLING WATER [2-55]
Pollutant Influent Effluent (al
Classical pollutants, mg/L
TOS 190 1,000
TSS 111 8
TOC 10 II
Phenolics 0.01 0.008
TRC(b) NO
-------
II.19.3.2 Plant 1245
Plant 1245 is an oil and gas fired electric generating facility.
The samples chosen are the influent and effluent from a once
through cooling tower stream. The influent sample was taken from
the makeup stream comprised of river water, with the effluent
stream being a direct discharge from the condensers to the river.
The cooling water does not undergo any treatment to remove pol-
lutants. The data reflect the changes that may occur to such a
stream due to evaporation and pipe corrosion. Table 19-15 pre-
sents plant specific data for plant 1245.
TABLE 19-15.
PLANT SPECIFIC DATA FOR PLANT 1245, ONCE-THROUGH
COOLING WATER [2-55]
Pol lutant
Influent
Effluent(a)
Classical pollutants, mg/L
IDS
TSS
TOC
Phenol ics
TRC(b)
Flow, L/s
35,000
6
14
<0.005
al. The fly ash from
this fuel is sent to a settling pond in the form of ash sluice.
The effluent from the pond is sent to a discharge canal. Removal
data are presented in Table 19-16. The generating capacity of
this plant is 96 MW.
II.19.3.4 Plant 5409
Plant 5409 is a 2,900 MW bituminous coal and oil fired electric
generating facility. The recirculating cooling water was sampled
at the influent stream, made up of raw water from the river, and
an effluent stream located just after the tower. Table 19-17
reflects the change in concentration for various priority pollu-
tants. The cooling water blowdown is not treated prior to dis-
charge. The pollutant increase can be mainly attributed to
corrosion of the pipe work.
II.19.3.5 Plant 3920
Plant 3920 is a bituminous coal and oil fired plant with a gen-
erating capacity of 557 MW. This plant uses 1,220,000 Mg/yr
Date: 1/24/83 R Change 2 11.19-32
-------
TABLE 19-16. PLANT SPECIFIC DATA FOR PLANT 3924, ASH
POND OVERFLOW [2-55]
Pollutant
Classical pollutant, mg/L
TDS
TSS
TOC
Phenolics
Barium
Boron
Calcium
Manganese
Magnesium
Molybdenum
Sodium
Iron
Aluminum
Tin
Toxic pollutants, yg/L
Toxic metals
Chromium
Copper
Lead
Nickel
Zinc
Flow, L/s
Influent
480
15
21
0.04
0.04
0.1
57
0.1
13
ND
43
0.5
ND
ND
3.5
14
5
9
10
13.1
Effluent
670
16
16
0.04
0.2
1
110
0.08
14
0.3
38
0.3
0.06
ND
48
16
12
32
10
13.1
Percent
removal
NM
NM
24
0
NM
NM
NM
20
NM
NM
12
40
NM
NM
NM
NM
NM
0
Analytic methods: V.7.3.13, Data set 2.
ND, not detected.
NM, not meaningful.
Date: 1/24/83 R Change 2 11.19-33
-------
TABLE 19-17,
PLANT SPECIFIC DATA FOR PLANT 5409, RECIRCULATING
COOLING WATER [2-55]
Pollutant
Classical pollutant, mg/L
TSS
TOC
Chloride
Vanadium
Flow, L/s
Toxic pollutants, yg/L
Toxic metals
Cadmium
Chromium
Copper
Cyanide
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
Toxic organics
Benzene
Carbon tetrachloride
Chloroform
1 , 2-Dichlorobenzene
Dichlorobromome thane
Chlorodibromome thane
Toluene
Trichloroethylene
1,3 and 1 ,4-Dichlorobenzene
Influent
0.005
20
NA
0.013
290
1.4
ND
27
15,000
8
ND
1.7
2
1.6
ND
15
2.4
<1
1.4
5.3
NA
NA
2
4
2.4
Effluent
460
21
110
0.017
11
1
37
3,800
5
130
1
4
ND
14
8
290
1.5
NA
2.4
NA
2.6
<1
NA
4
NA
Percent
removal
NM
NM
NM
29
NM
NM
>99
NM
NM
NM
>99
NM
NM
NM
38
NM
0
Analytic methods: V.7.3.31, Data set 2
ND, not detected.
NM, not meaningful.
NA, not available.
Date: 1/24/83 R Change 2 11.19-34
-------
of coal. An ash settling pond is used to remove wastes from coal
pile run off, regeneration wastes and fly ash. The influent data
were obtained from the pond inlet whereas the effluent data are
from the discharge stream to the river. The results of this
treatment are shown in Table 19-18.
TABLE 19-18. PLANT SPECIFIC DATA FOR PLANT 3920, FLY
ASH POND [2-55]
Percent
Po I lutant Influent Effluent remove I
Classical pollutant, mg/L
TDS 220 880 NM
TSS 12 73 NM
TOC 5 3 40
Phenolics 0.04 0.04 0
Aluminum NO 5 NM
Barium 0.03 0.06 NM
Boron 0.08 I NM
Ca I c i urn 28 120 NM
Cobalt ND 0.007 NM
Iron 0.5 2 NM
Manganese 0.05 0.3 NM
Magnesium 7.2 6.7 7
Molybdenum ND 0.01 NM
Sodium 18 35 NM
Tin ND ND NM
Flow, L/s 61.3 61.3
Toxic pollutants, u.g/L
Toxic meta Is
Be ry 1 1 i urn
Cadmium
Chromium
Copper
Lead
Nickel
S i 1 ve r
Zinc
ND
ND
1 1
4
10
12
ND
ND
2
ND
30
15
4
18
ND
140
NM
NM
NM
NM
60
NM
NM
NM
Analytic methods: V.7.3.31, Data set 2.
ND, not detected.
NM, not meaningful.
II.19.3.6 Plant 1742
Plant 1742 is a bituminous coal and oil fired plant producing 22
MW of electricity. Table 19-19 represents data that are from
both the ash pond and the once through cooling tower.
11.19. 3.. 7 Plant 3001
Plant 3001 is a lignite coal and gas fired facility with a gene-
rating capacity of 50 MW. The plant uses approximately 277,000
Mg/yr of coal. The fly ash and bottom ash from the boiler are
combined and put through a series of three settling ponds. The
effluent from the ponds is discharged to the river. Table 19-20
shows the effectiveness of this treatment technology.
Date: 1/24/83 R Change 2 11.19-35
-------
I
TABLE 19-19. PLANT SPECIFIC DATA FOR PLANT 1712 [2-55]
H
U)
Pol lutant
Classical pollutant, mg/L
TDS
TSS
TOG
Phenol ics
TRC
Aluminum
Barium
Boron
Ca 1 c i urn
Coba 1 1
Manganese
Magnesium
Molybdenum
Sod i urn
Tin
T i ta n i urn
1 ron
Vanad ium
Flow, L/s
Toxic pollutants, ng/L
Toxic metals
Cadmium
Chromium
Copper
Lead
Nickel
S i 1 ve r
Zinc
Mercury
Influent
Ash
340
100
10
0.006
NO
2
0.06
0.09
51
0.01
0.2
23
0.009
21
0.03
0.04
4
ND
4.38
40
22
20
4.5
8.5
ND
35
ND
Effluent
Pond
370
15
150
0.012
ND
ND
0.05
0.2
51
0.05
0.3
20
0.05
26
0.03
ND
8
10
U.38
10
1,000
78
4.5
470
ND
ND
1.5
Percent
remova I
NM
85
NM
NM
NM
>99
17
NM
NM
NM
NM
13
NM
NM
0
>99
NM
NM
75
NM
NM
0
NM
0
>99
NM
Inf 1 uent
Once-Through
340
100
10
0.006
NA
2
0.06
0.09
51
0.01
0.2
23
0.009
21
0.03
0.04
4
ND
1,440
40
22
20
4.5
8.5
ND
35
ND
Effluent
Cool ing Water
1,200
90
9
0.26
0.72
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
1,440
NA
NA
NA
NA
NA
NA
NA
ND
Percent
remova 1
NM
10
10
NM
Analytic methods: V.7>3.3I, Data set 2.
ND, not detected.
NM, not meaningful.
NA, not analyzed.
-------
TABLE 19-20.
PLANT SPECIFIC DATA FOR PLANT 3001, MULTIPLE
ASH PONDS [2-55]
Pollutant
Influent
Effluent
Percent
removaI
Classical pollutant, mg/L
TDS 530 490 8
TSS 170 30 82
Oil and grease 25 24 k
Phenolics NA 0.0 It
Aluminum 0.5 2 NM
Barium O.OU 0.2 NM
Boron 0.06 2 NM
Calcium 38 64 NM
Iron 0.2 ND >99
Manganese 0.04 ND >99
Magnesium 23 II 52
Molybdenum ND 0.03 NM
Sodium 57 70 Ntf
Tin ND 0.007 NM
Vanadium ND 0.01 NM
Flow, L/s 23.3 unknown
Toxic pollutants, (ig/L
Toxic metaIs
Cadmium ND 8 NM
Chromium 5 95 NM
Copper 5 ND >99
Lead ND 1.5 NM
Nickel 3 18 NM
Toxic organics
I,I,2,2-Tetrachloroethane 24 NA
Analytic methods: V.7.3.31,Data set 2.
ND, not detected.
NM, not meaningful.
NA, not analyzed.
II.19.4 POLLUTANT REMOVABILITY [2-55]
Table 19-21 presents a summary of end-of-pipe treatment tech-
nologies commonly employed on the Steam Electric Industry, their
objectives, equipment and processes required, and efficiency.
Table 19-22 presents the same information for solid/liquid
separation systems commonly employed in the Steam Electric
Industry.
Date: 1/24/83 R Change 2 II.19-37
-------
D
fu
rt
TABLE 19-21. END-OF-PIPE TREATMENT TECHNOLOGIES [2-55,73]
00
O
fl>
to
U>
CO
Method
Neutra 1 izat ion
Chemical reduction
Precipitation
Disinfection
Disti 1 lation
Objectives
pH adjustment,
usual ly to within the
range of 6 to 9
Reduction of hexa-
valent chromium to
trivalent chromium
Removal of ions by
forming insoluble
salts
Destruction of
microorganisms
Separation of dis-
solved matter by
Chemicals or
equipment used
Acid or base as
requi red, usua 1 ly
sulfuric acid or lime
Sulfur dioxide.
sodium bisulfite.
sodium metabi sulf i te.
ferrous salts
Lime, hydrogen sul-
fide, organic pre-
cipitants, soda ash
Chlorine, hypo-
chlorite salts.
phenol, phenol
derivatives, ozone.
salts of heavy
metals, chlorine
dioxide
Multistage flash
disti 1 lation.
Process
reaui rements
pH range of
2 to 3
Optimium pH
depends on the
ions to be
removed
May requ i re pH
adjustment
May requ i re pH
adjustment
Efficiency
of remova 1
99.7%
Copper - 96.6%
Nickel - 91.7%
Chromium - 98.8%
Zinc - 99.7%
Phosphate - 93.6%
100%
Demonstration status
Practiced extensively by
industry
Not practiced extensively
by industry
Practiced extensively by
industry
Disinfection by chlorine is
practiced extensively by
industry
Practiced only to a
moderate extent by
evaporation of the
water
multiple-effect
long-tube verti-
cal evaporation,
submerged tube
evaporation,
vapor compression
submerged tube type unit
-------
D
&>
rt
(D
to
CO
OJ
O
y
0)
3
iX3
fl>
K)
VD
I
U)
TABLE 19-22. SOLID/LIQUID SEPARATION SYSTEMS [2-55,73]
Unit ooeration
Skimming
C 1 a r i f i ca t i on
Flotation
Fi It rat ion
Screening
Thickening
Pressure
f i Itration
Sand bed drying
Vacuum
fi Itration
Emulsion
breaking
Process objectives
Removal of floating
solids or liquid wastes
from the water
Removal of suspended
sol ids by settl ing
Separation of suspended
solids and oil and grease
by flotation followed by
skimming
Remova 1 of suspended
sol ids by fi Itration
through a bed of sand
and gravel
Removal of large solid
matter by passing through
screens
Concentration of sludge
by removing water
Separation of solid from
liquid by passing through
a semi permeable membrane
under pressure
Removal of moisture from
sludge by evaporation and
drainage through sand
Solid liquid separation
by vacuum
Separation between
emulsified oi 1 and water
Methods or
units used
Settl ing ponds,
c 1 a r i f i e rs
Froth flotation,
dispersed air
flotation,
dissolved ai r
flotation,
gravity flotation,
vacuum flotation
Multimedia bed,
m i xed med i a bed
Coarse screens,
bar screens
Gravity thickening,
ai r flotation
thickening
Covered beds,
uncovered beds
Retention
time
1-15 min.
Days
to
weeks
20-30 min.
NA
NA
NA
1-3 hr.
Fi Itration
1-2 days
1-5 min.
2-8 hr
Chemicals used
None
Coagulants,
coagulant aids,
pH adjustment
Aluminum and
ferric salts,
activated si 1 ica
organic polymers
None
None
None
None
None
None
Aluminum salts,
iron salts, pH
adjustment (3-4)
Efficiency
of remova 1
70-90%
To 15 mg/L
90-995
50-90%
50-99%
Depends on
the nature
of sludge
To 50-75%
moisture
content
As f i Iter
15-20%
Produces 30%
sol id in.
f i Iter
cake
>99%
Demonstration
status
Practiced exten-
sively by in-
dustry
Practiced exten-
sively by i n-
dustry
Practiced exten-
sively by in-
dustry
Rarely used;
usual ly at
plants with no
space for ash
ponds.
Not practiced
extensively by
industry
Practiced ex-
tensively by
industry
Not practiced by
industry
Practiced exten-
sively by in-
dustry
Practiced exten-
sively by in-
dustry
Practiced exten-
sively by
industry
NA, not avai(able.
-------
-------
TABLE 20-2. CONCENTRATIONS OF TOXIC POLLUTANTS FOUND
SCREENING AND VERIFICATION DATA [2-57]
IN TEXTILE MILL WASTEWATER,
Number
of
Toxic pollutant. uo/L detections(a) Median Maximum
Metals and fnoroanics
Antimony
Arsenic
Be ry 1 1 i um
Cadmium
Ch rom 1 um
Copper
Cyanide
Lead
Mercury
Nickel
Se 1 en i um
SI Iver
Tha 1 1 i um
Zinc
Toxic oraanics
Bls(2-ethylhexyl ) phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Diethyl phthalate
Dimethyl phthalate
Acrylonitri le
1 ,2-Diphenylhydrazine
N-ni trosod iphenylamine
N-ni troso-di-n-propylamine
2-Ch lo ropheno 1
2, 4-D i ch 1 o ropheno 1
2, 4-0 1 methy 1 pheno 1
2-N It ropheno 1
4-N It ropheno 1
Pentach 1 o ropheno 1
Pheno 1
2,4,6-Trlchlorophenol
Parachlorometa cresol
Benzene
Chlorobenzene
1 , 2-0 i ch 1 o ro benzene
1 ,1-Oichloro benzene
2,6-Oini tro toluene
Ethyl benzene
Hexach 1 o robehzene
To 1 uene
1,2,1-Trichlo ro benzene
Acenaphthene
Anthracene
Benzo( b ) f I uoranthene
Benzo( k)fl uoranthene
Fluorene
Naphtha lene
Pyrene
2-Chloronaphtha lene
Chloroform
D i ch 1 o rob romomethane
, l-Dichloroethane
, 2-0 1 ch 1 o roethane
, l-Olchloroethylene
, 2-0 1 ch 1 o rop ropane
, 3-Dichloropropene
Methyl chloride
Methy lene chloride
Tet rach 1 o roe thy 1 ene
1,1, l-Trichioroeth»ne
T r i ch 1 o roethy 1 ene
Trichiorof luoromethane
Vinyl chloride
4,4'-OOT
Oieldrfn
6
4
4
5
5
6
4
6
4
6
6
6
4
12
6
0
1
3
0
0
0
0
0
0
0
0
0
0
0
5
0
0
2
0
0
0
0
0
0
1
0
0
3
0
0
2
0
0
0
6
2
0
0
0
0
1
0
2
0
1
0
0
0
0
0
<5
<5
<5
< 10
<5
10
I |
<5
0.2
<5
<5
<5
3
60
8.2
2. 1
10
<1( b }
0.8
0.2
0.2(b)
39
<5(b)
<5(b)
48
<5
<5
-------
rt
n>
OS
\
LO
00
to
o
TABLE 20-3. " RAW WASTEWATER POLLUTANT CONCENTRATIONS BY SUBCATEGORY, VERIFICATION AND HISTORICAL DATA [2-57J
to
O
I
Parameter
Flow, cu. m/day
BOD5, mg/L
COD, mg/L
TSS, mg/L
Sul fide, M9/L
Oil and grease, mg/L
Phenol, Mg/L
Chromium, M9/L
Color, APHA units
Flow, cu. m/day
BOD5, mg/L
COD, mg/L
TSS, mg/L
Sul fide, Mg/L
Oi 1 and grease, mg/L
Pheno 1 , Mg/L
Chromium, Mg/L
Color, APHA units
Flow, cu. m/day
BOD5, mg/L
COO, mg/L
TSS, mg/L
Sul fide, Mg/L
Oil and grease, mg/L
Phenol, M9/L
Chromium, |ig/L
Color, APHA units
Flow, cu. m/day
BOD5, mg/L
COD, mg/L
TSS, mg/L
Sul fide, M9/L
Oil and grease, mg/L
Phenol, M9/L
Chromium, |jg/L
Color, APHA units
Flow, cu. m/day
8005, mg/L
COD, mg/L
TSS, mg/L
Sulfide, mg/L
Oi 1 and grease, mg/L
Phenol, M9/L
Chromium, M9/L
Color, APHA uni ts
Numbe r
of
Subcateqorv 1
samples Ranqe
1 1
9
M
8
Kb)
7
(a)
2(b)
1
148
32
28
26
6
1 1
10
16
9
71
35
29
32
3
9
9
13
9
37
10
III
12
M
5
7
7
"
1 1
14
14
14
1 ( b )
(a)
(a)
(a)
Kb)
38 - 2,800
310 - 6,700
1 , 1 00 - 1 8 , 000
120 - 13,000
500
80 - 5,000
10-220
2,200
Subcateqory Ma
57 - 21,000
19 - 2,000
200 - 5,000
16 - 2, MOO
25 - 580
6 - I,MOO
10 - 600
1 - 530
20 - 10,000
Subcateqorv 5a
1 1 - 1 1,000
60 - 1,900
3MO - 19,000
21 - 2,200
20 - 7, 100
IM - M60
1 - 1,700
13-600
170 - 1,500
Subcateqory 6
76 - 6,900
190 - 560
280 - 2, 100
37 - 210
10 - M50
3-93
1 - 1 , 1 00
M - 300
65 - 1,900
Subcateqory 9
II - 1 , 500
55 - 380
230 - 2, 100
68 - 280
1,200
190
Subcateqory 2
Median
190
2,300
7,000
3,300
580
I20(c)
6>iO
270
900
62
72
69
M9
38
800
Number
of
samples
15
10
7
10
2(b)
(a)
2(b)
2(b)
2(b)
39
23
12
18
3
6
6
7
2(b)
Ranqe
190 -
66 -
280 -
17 -
1 , 1 00 -
90 -
190 -
1 , 000 -
Subca tei
'42 -
83 -
2MO -
MO -
too -
3M -
10 -
19 -
1 , 300 -
16,000
750
2,000
2MO
6 , 000
160
880
2,000
aory Mb
29,000
2,200
5, 100
870
120
160
600
1,200
1,500
Med i an
1 , 900
170
590
62
3,500(c)
I20(c)
5MO(c)
l,500< c)
1,500
350
1, 100
1 10
100
M6
5M
1 10
I,MOO(C)
Number
of
Subcateqorv 3
samples Ranqe
13
13
8
12
Kb)
Kb)
I
2
1
51
36
29
28
6(b)
5
5
1 1
6(b)
Subcateqorv 5b
1,500
210
870
53
55
83
1 10
78
MOO
35
19
1 1
19
14
6
5
8
7
1 10 -
120 -
5MO -
18 -
50 -
6 -
72 -
10 -
37 -
13,000
920
3,200
7MO
1,500
1 10
230
180
9MO
2,000
270
790
60
150
52
100
80
750
56
39
27
29
M
13
10
17
8
Subcateqory 7
1,600
MMO
1,200
67
180
18
130
30
M90
560
200
550
120
1 16
62
M6
59
9
18
12
25
1 I
M5 -
M3 -
IMO -
2 -
1 -
1 -
3 -
M -
57 -
9,600
1,600
M,800
M.200
M.MOO
180
620
1,600
3,000
960
180
680
38
200
21
170
100
570
1 1
M
3
M
Mb)
(a)
I ( b )
2(b)
2(b)
23-1, 100
37 - 2,600
120 - 3,000
10 - 530
1,000
80
80
15-97
10
Subcateqorv Me
3M - 21 ,000
120 - 2,600
370 - 2,800
1 - 1,300
20 - 5,600
5-100
1 M - 1 , 200
IM - 12,000
250 - MO, 000
Subcateqorv 5c
M - 1 , 500
38 - 790
M50 - 5,000
9-180
10 - 8,000
15 - 280
26 - 580
10 - 1,200
MO - 1 , 100
Subca teqorv b
53 - 1,900
6M - 630
200 - 3,900
59 - 180
1,000
M5
M - 10
35 - IMO
Median
230
290
690
180
56(c)
6MO
M20
1,200
150
1 , 700
68
150
100
1 ,900
180
320
I.MOO
82
560
99
62
80
M50
380
180
2, MOO
78
7(c)
88(c)
Analytic methods: V.7.3.32, Data sets 1,2.
(a) There are insufficient data to report value.
(b) Data are results of verification sampling.
(c) Average value.
-------
5. Coagulation, chemical or polymer (see Table 20-15)
Used by: Direct dischargers - 15 plants
Indirect dischargers - 10 plants
Zero dischargers - 3 plants
TABLE 20-14.
Pollutant
EFFECTIVENESS OF A POLISHING POND,
SUBCATEGORY 9 [2-57]
Influent
Effluent
Classical pollutants
COD, mg/L 550
TSS, mg/L 91
Phenols, \ig/L 52
Sulfide, (ig/L ND
Color, ADM I 280
Toxic pollutants, |ag/L
Naphthalene 56
Bis(2-ethylhexyl) phthalate 18
Chromium 35
Copper ND
Selenium 32
Zinc 45
260
22
28
ND
300
ND
ND
ND
18
18
100
ND, not detected.
II.20.4.2 Other Methods and Industry Applications
Other full-scale treatment methods that have been cited in the
literature, but for which no data were presented, include:
screening, neutralization, equalization, and biological beds.
Date: 8/31/82 R Change 1 11.20-23
-------
ft
(D
X.
NJ
U1
00
I — '
1 I
H
•
to
o
1
N)
M^
Subcateaorv
2
1b
1b(a)
1C
1C
1c(a)
5a
5a
5a
7
7
a
z
1a(a)
1c(a)
1a(b)
lafal
la
(a) Fabric pri
(b) Latex and
TABLE
Coagulants
Alum,
polymer
Alum
_
„
Polymer
Ferric
chloride.
lime
_
Polymer
Polymer
Alum,
polymer
Chlorinated
copperas.
lime
_
Lime
Lime,
alum
Ferric
chloride
Aluminum
chloride
Alum
Alum
nting Is a significant
PVC coating operations.
20-15. EFFECTIVENESS OF COAGULATION [2-57]
Treatment
steo
Seconda ry
clarlfler
Seconda ry
clarif ier
Flotation
unit
Seconda ry
clarif ier
Seconda ry
clarifler
Coag/f loc
raw waste
Coag/f loc
seconds ry
Seconda ry
claririer
Injection
pref 1 1 tra-
tlon
Seconda ry
clarifler
Seconda ry
clarifier
Flotation
postbio-
1 og i ca 1
Coag/f loc
raw waste
Flotation
Coag/clarify
print waste
Flotation
print waste
Coag/clarify
print waste
Flotation
BOD. ma/L
Influent Effluent
Direct dischargers
ISO 1 1
83 11
51
200 51
7
1
330 21
21
280 5
330 20
60 15
6
Indirect dischargers
-
250
120
310
320 130
Recycle olant
300 10
COD. ma/L
Influent Effluent
900
310 ISO
180
810 660
850 160
1 , 100 99
1,300 210
270
930 200
1 , 600 180
330 130
-
1 , 300 560
100
700
880
2,000 260
1,600
TSS.
Influent
190
13
-
82
-
170
-
-
11
26
31
-
-
-
-
-
160
-
ma/L
Effluent
61
35
190
110
51
30
10
65
7
23
II
11
560
30
120
210
72
5
portion of production.
-------
11.21 TIMBER PRODUCTS PROCESSING
II.21.1 INDUSTRY DESCRIPTION [2-60]
II.21.1.1 General Description
The Timber Products Processing Industry encompasses manufacturers
and processors who use forest materials to produce their goods
and merchandise. Fifteen distinct subcategories of manufacturers
and/or processors are engaged in the utilization of timber. This
section addresses three major subsections of the entire industry,
(encompassing five subcategories): Wood preserving; (steaming,
Boulton and nonpressure processes); insulation board manufac-
turing; and wet process hardboard manufacturing.
Table 21-1 presents industry summary data for the Timber Products
Processing point source category in terms of the number of sub-
categories and number of dischargers.
TABLE 21-1. INDUSTRY SUMMARY [2-60]
Industry: Timber Products Processing
Total Number of Subcategories: 15
Number of Subcategories Studied: 5
Number of Dischargers in Industry: 247
• Direct: 19
• Indirect: 52
• Zero: 176
II.21.1.2 Subcategory Description
This section presents general descriptions and process descrip-
tions for the five subcategories of the Timber Products Pro-
cessing point source category. The remaining ten subcategories
have been classified as Paragraph 8 exclusions and are not dis-
cussed in this report.
Wood Preserving
The three most prevalent types of preservatives used in wood
preserving are creosote, pentachlorophenol (PCP), and various
Date: 8/31/82 R Change 1 II.21-1
-------
formulations of water-soluble inorganic chemicals, the most com-
mon of which are the salts of copper, chromium, and arsenic. Fire
retardants are formulations of salts, the principal ones being J
borates, phosphates, and ammonium compounds. Eighty percent of
the plants in the United States use at least two of the three
types of preservatives. Many plants treat with one or two pre-
servatives plus a fire retardant.
The wood preserving process consists of two basic steps: (1)
preconditioning the wood to reduce its natural moisture content
and to increase the permeability; and (2) impregnating the wood
with the desired preservatives.
The preconditioning step may be performed by one of several
methods including (1) seasoning or drying wood in large, open
yards; (2) kiln drying; (3) steaming the wood at elevated pres-
sure in a retort folldwed by application of a vacuum; (4) heating
the stock in a preservative bath under reduced pressure in a
retort (Boulton process); or (5) vapor drying, heating of the
unseasoned wood in a solvent to prepare it for preservative
treatment. All of these preconditioning methods have, as their
objective, the reduction of the moisture content in the un-
seasoned stock to a point where the requisite amount of preserva-
tive can be retained in the wood.
Conventional steam conditioning (open steaming) is a process in
which unseasoned or partially seasoned stock is subjected to
direct steam impingement at an elevated pressure in a retort.
The maximum permissible temperature is set by industry standards
at 118°C and the duration of the steaming cycle is limited by
these standards to no more than 20 hours. Steam condensate that
forms in the retort exits through traps and is conducted to
oil-water separators for removal of free oils. Removal of
emulsified oils requires further treatment.
In closed steaming, a widely used variation of conventional steam
conditioning, the steam needed for conditioning is generated
in situ by covering the coils in the retort with water from a
reservoir and heating the water by passing process steam through
the coils. The water is returned to the reservoir after oil
separation and reused during the next steaming cycle. There is a
slight increase in volume of water in the storage tank after each
cycle due to water exuded from the wood. A small blowdown from
the storage tank is necessary to remove this excess water and to
control the level of wood sugars in the water.
Modified closed steaming is a steam conditioning process varia-
tion in which steam condensate is allowed to accumulate in the
retort during the steaming operation until it covers the heating
coils. At that point, direct steaming is discontinued and the
remaining steam required for the cycle is generated within the
retort by utilizing the heating coils. Upon completion of the
Date: 8/31/82 R Change 1 11.21-2
-------
steaming cycle, and after recovery of oils, the water in the
cylinder is discarded.
Preconditioning is accomplished in the Boulton process by heating
the stock in a preservative bath under reduced pressure in the
retort. The preservative serves as a heat transfer medium.
After the cylinder temperature has been raised to operating
temperature, a vacuum is drawn, and water, which is removed in
vapor form from the wood, passes through a condenser to an oil-
water separator. At this point low-boiling fractions of the
preservative are removed. The Boulton cycle may have a duration
of 48 hours or longer for large poles and piling. This fact
accounts for the lower production per retort day as compared to
plants that steam condition.
The vapor-drying process consists of exposing wood in a closed
vessel to vapors from any one of the many organic chemicals that
are immiscible with water and have a narrow boiling range.
Following the conditioning steps, the stock may be treated by
nonpressure wood preserving treatment processes, or pressure wood
preserving treatment processes employing waterborne inorganic
salts.
Table 21-2 presents a summary of information pertaining to the
wood preserving category.
Insulation Board Manufacturing
Insulation board is a form of fiberboard, which in turn is a
broad generic term applied to sheet materials constructed from
ligno-cellulosic fibers. Insulation board is a "noncompressed"
fiberboard, which is differentiated from "compressed" fiber-
boards, such as hardboard, on the basis of density. Densities of
insulation board range from about 0.15 to 0.50 g/cm3 (9.5 to 31
lb/ft3).
There are 15 insulation board plants in the United States with a
combined annual production capacity of over 330 million square
meters (3,600 million square feet) on a 13 mm (0.5 in.) basis.
All of the plants use wood as a raw material for some or all
Date: 8/31/82 R Change 1 II.21-3
-------
TABLE 21-2. WOOD PRESERVING SUBCATEGORY SUMMARY [2-60]
Number of Dischargers(a):
Boulton Steaming Inorganic salt Nonpressure
• Direct: 01 1 0
• Indirect: 10 29 5 0
• Zero: 25 66 56 23
Toxic pollutants found in treated effluents at two or more plants
above the minimum detection limit of 10 vg/L, organics and 2 yg/L,
metals:
Pentachlorophenol Arsenic
Phenol Nickel
Copper Zinc
Chromium Fluorene
3,4-Benzofluoranthene Fluoranthene
Benzo (k) fluoranthene Chrysene
Pyrene Bis(2-ethylhexyl)
Benzo (a) pyrene phthalate
Indeno (1,2,3-cd) pyrene Napthalene
Benzo (ghi) perylene Acenapthylene
(a)Those plants responding to questionnaires for industry study.
of their production. Four plants use mineral wood, a nonwood-
based product, as a raw material for part of their insulation
board production. Production of mineral wood board is classified
under SIC 3296 and is not within the scope of this section. Five
plants produce hardboard products as well as insulation board at
the same facility.
Insulation board can be formed from a variety of raw materials
including wood from softwood and hardwood species, mineral fiber,
waste paper, bagasse, and other fibrous materials. In this
section, only those processes employing wood as raw materials are
considered. Plants utilizing wood may receive it as roundwood,
fractionated wood, and/or whole tree chips. Fractionated wood
can be in the form of chips, sawdust, or planer shavings.
At the time of this compilation only limited data were available
on this subcategory. Available data are contained in .the tables
in Section II.21.2. Table 21-3 summarizes information pertaining
to the insulation board manufacturing subcategory.
Date: 8/31/82 R Change 1 II.21-4
-------
TABLE 21-3. INSULATION BOARD MANUFACTURING
SUBCATEGORY SUMMARY [2-60]
Number of Dischargers: 15(a)
• Direct: 5
• Indirect: 6
• Zero: 4(b)
Toxic Pollutants Found in Significant Quantities:
Copper Phenol
Nickel Benzene
Zinc Toluene
Beryllium
(a)Those plants responding to questionnaires for indus-
try study.
(b)One plant uses spray irrigation as a treatment method;
however, the irrigation tail water is eventually discharged
from the field to a nearby river.
Hardboard Manufacturing
Hardboard is a form of fiberboard, which is a broad generic term
applied to sheet materials constructed from ligno-cellulosic
fibers. Hardboard is a "compressed" fiberboard, with a density
greater than 0.50 g/cm3 (31 lb/ft3). The thickness of hardboard
products ranges between 2 and 13 mm (nominal 1/12 to 7/16 in).
Production of hardboard by the wet process method is usually
accomplished by thermomechanical fiberization of the wood
furnish. One plant produces wet-dry hardboard using primarily
mechanical refining.
Dilution of the wood fiber with fresh or process water then
allows forming of a wet mat of a desired thickness on a forming
machine. This wet mat is then pressed either wet or after dry-
ing. Chemical additives help the overall strength and uniformity
of the product. The uses of manufactured products are many and
varied, requiring different processes and control measures. The
quality and type of board are important in the end use of the
product.
Hardboard which is pressed wet immediately following forming of
the wet-lap is called wet-wet or smooth-one-side (SIS) hardboard;
that which is pressed after the wet-lap has been dried is called
wet-dry or smooth-two-side (S2S) hardboard.
There are 16 wet process hardboard plants in the United States,
representing an annual production in excess of 1.5 million metric
tons per year. Seven of the plants produce only SIS hardboard.
Nine plants produce S2S hardboard. Of these nine, five plants
also produce insulation board, while three plants also produce
SIS hardboard.
Date: 8/31/82 R Change 1 II.21-5
-------
Table 21-4 presents a summary of pertinent information pertaining
to the hardboard manufacturing subcategory.
TABLE 21-4. HARDBOARD MANUFACTURING SUBCATEGORY SUMMARY [2-60]
Number of Dischargers: 16(a)
• Direct: 12
• Indirect: 2
• Zero: 2
Toxic pollutants found in treated effluents at two or more
plants above the minimum detection limit of 10 yg/L, organics
and 2 yg/L, metals:
Copper Phenol
Beryllium Benzene
Nickel Toluene
Zinc
(a)Those plants responding to questionnaires for industry
study.
II.21.2 WASTEWATER CHARACTERIZATION [2-60]
The Timber Products Processing Industry was analysed in a screen-
ing program for the 129 priority pollutants. Those pollutants
detected in screening were further analysed in a verification sam-
pling analysis. The following tables present the verification
data. The minimum detection limit for toxic organics is 10 yg/L
and for toxic metals, 2 yg/L. Any concentration below its de-
tection limit is presented in the following tables as BDL, below
detection limit.
II.21.2.1 Wood Preserving
The quantity of wastewater generated by a wood preserving plant
is a function of the method of conditioning used, the moisture
content of the wood being treated, and the amount of rainwater
draining toward the treating cylinder. Most wood preserving
plants treat stock having a wide range of moisture contents.
Although most plants use predominantly one of the major condition-
ing methods, many plants use a combination of several condition-
ing methods, and the actual quantity of wastewater generated by a
specific plant may vary considerably. The average wastewater
volume from 14 Boulton plants is reported to be 21,200 L/d (5,600
gal/d) or 139 L/m3 (1.03 gal/ ft3) of production. The average
wastewater volume for eight closed loop steaming plants is 5,200
L/d (1,370 gal/d) or 60 L/m3 (0.45 gal/ft3). The average
wastewater volume for 10 plants which treat significant amounts
of dry stock is 13",300 L/d (3,510 gal/d) or 121 L/m3 (0.91
gal/ft3). Additionally the average wastewater volume for 14 open
steaming plants is 35,000 L/d (9,250 gal/d) or 236 L/m3 (1.87
gal/ft3).
Date: 8/31/82 R Change 1 II.21-6
-------
Table 21-5 presents concentrations of toxic pollutants found in
the raw wastewater (for both steaming and Boulton processes)
treated effluent (for steaming and Boulton processes combined).
Table 21-6 similarly presents toxic pollutant loadings in kg/m3
of product derived from the concentrations given in Table 21-5
for the wood preserving subcategory. Classical pollutant con-
centrations are shown in Table 21-7 and corresponding pollutant
loads in Table 21-8.
II.21.2.2 Insulation Board Manufacturing
Insulation board plants responding to the data collection portfo-
lio reported fresh water usage rates ranging from 95,000 to
5,700,000 L/d for process water (0.025 to 1.5 MGD). One insula-
tion board plant, Plant 108, which also produces hardboard in
approximately equal amounts, uses over 15 million L/d (4 MGD) of
fresh water for process water.
Water becomes contaminated during the production of insulation
board primarily through contact with the wood during fiber prep-
aration and forming operations, and the vast majority of pol-
lutants are fine wood fibers and soluble wood sugars and extrac-
tives.
More specifically potential sources of wastewater in an insula-
tion board plant include:
Chip wash water
Process Whitewater generated during fiber preparation
(refining and washing)
Process Whitewater generated during forming
Wastewater generated during miscellaneous operations
(dryer washing, finishing, housekeeping, etc.)
The average unit flow for Plant 36, which is 8.3 L/kg (2,000 gal/
ton), is considered to be representative of an insulation board,
mechanical refining plant which produces a full line of insula-
tion board products and which practices internal recycling to the
extent practicable.
Table 21-9 presents concentrations of toxic pollutants found in
insulation board manufacturing raw wastewater. Table 21-10
similarly presents toxic pollutant metals loading for this
subcategory.
II.21.2.3 Hardboard Manufacturing
Production of hardboard by wet process requires significant
amounts of water. Plants responding to the data collection
portfolio reported fresh water usage rates for process water
ranging from approximately 190,000 to 19 million L/d (0.05
to 5 MGD). One plant, 108, which produces both hardboard and
insulation board in approximately equal amounts, reported fresh
Date: 8/31/82 R Change 1 II.21-7
-------
o
p>
ft
TABLE 21-5. CONCENTRATIONS OF TOXIC POLLUTANTS FOUND IN STEAMING AND BOULTON
SUBCATEGORY WASTEWATER, VERIFICATION DATA [2-60]
00
\
U)
CO
K)
n
cr
H
H
I
00
Raw wastewater
Steam inq process
Toxic pollutant. ua/L
Metals and inorganics
Ant imony
Arsen i c
Be ry 1 1 i urn
Cadm i urn
Chromium
Copper
Lead
Mercury
Nickel
Se len i um
S i 1 ve r
Tha 1 1 i um
Zinc
Phtha 1 a tes
Bis(2-ethylhexyl ) phthalate
Pheno 1 s
2-Ch 1 oropheno 1
2,1- Dimethyl phenol
Pentach 1 oropheno 1
Phenol
2,4,6-Trichlorophenol
Monocvclic aroma tics
Benzene
Ethyl benzene
To 1 uene
Polycvclic aromatic hydrocarbons
Acenaphthene
Acenaphthy 1 ene
Anthracene/phenanthrene
Benzo(a (anthracene
Benzoja (pyrene
Benzoj b ) f 1 uo ranthene
Benzo(ghi Jperylene
Benzol ; k)f luo ranthene
Chrysene
Di benzol ah) anthracene
F 1 uoranthene
F 1 no rene
Indeno (1,2., 3-cd) pyrene
Naptha 1 ene
Pyrene
Haloqenated aliphatics
Methyl chloride
Ch loroform
Number or samples
Number of detections
above detection limit
9/5
9/9
9/2
9/3
9/8
9/9
9/8
9/0
9/9
9/1
9/3
9/2
9/9
9/U
5/2
5/3
9/9
5/5
5/2
5/K
5/5
5/5
9/9
9/7
9/9
9/8
9/K
9/<4
9/1
9/5
9/7
9/1
9/9
9/9
9/3
9/9
9/9
5/3
5/1
Range
BDL - 47
3 - 111, 000
BDL - 19
BDL - 10
BDL - 98
8 - 850
BDL - 91
BDL - BDL
3-150
BDL - 7
BDL - 6
BDL - 10
120 - 820
BDL - UUO
BDL - 1(2
BDL - 6,600
1,200 - 160,000
1,1(00 - 87,000
BDL - 530
BDL - 2,800
37 - 2, 100
27 - 3,200
1, 100 - 55,000
BDL - 1,200
2,000 - 39,000
BDL - 7,700
BDL - 2,700
BDL - 1,700
BDL - 320
BDL - 3,900
BDL - 4,700
BDL - U30
630 - 35,000
820 - 1(8,000
BDL - 5,500
380 - 1(5,000
360 - 22,000
BDL - 700
BDL - 20
Median
2
33
BDL
BDL
23
120
in
BDL
28
BDL
BDL
BDL
310
BDL
BDL
130
16,000
16,000
BDL
1,000
3PO
500
1,500
720
6,500
160
BDL
BDL
BDL
17
73
BDL
1,600
1,500
BDL
2,200
810
77
BDL
Boulton process
Number of samples
Number of detections
above detection limit
3/2
3/3
3/1
3/1
3/3
3/3
3/2
3/1
3/3
3/3
3/1
3/1
3/3
3/2
I/O
I/O
I/I
I/I
I/O
I/O
I/O
I/O
3/1
3/1
3/2
3/1
3/0
3/0
3/0
3/0
3/1
,3/0
3/1
3/1
3/0
3/1
3/0
I/I
I/O
Range Median
BDL - 13
3 - m
BDL - 2
BDL - 5
U - 3,900
80 - 1,600
BDL - |1(
BDL - 3.7
20 - 210
2-53
BDL - 2
BDL - 2
320 - 26,000
BDL - 1,500
BDL
BDL
27,000
71
BDL
BDL
BDL
BDL
BDL - 2,800
BDL - 2, 100
BDL - 1 ,500
BDL - 34
BDL
BDL
BDL
BDL
BDL - 18
BDL
BDL - 280
BDL - 820
BDL
BDL - 3, 100
BDL
2,600
BDL
3
7
BDL
BDL
9
1 10
5
BDL
94
3
BDL
BDL
840
1(30
BDL
BDL
920
BDL
BDL
BDL
BDL
BDL
-------
o
pj
ft
(D
TABLE 21-5. CONCENTRATIONS OF TOXIC POLLUTANTS FOUND IN STEAMING AND
BOULTON SUBCATEGORY WASTEWATER (CONTINUED)
00
u>
M
X.
00
n
ir
(U
3
id
(D
H
to
H
I
V£>
Toxic pol lutant. ua/L
Metals and inorqanics
Antimony
Arsenic
Be ry 1 1 1 um
Cadmium
Chrom I um
Copper
Lead
Mercury
Nickel
Se len i um
Si Iver
Tha 1 M um
Z i nc
Phthalates
Bis(2-ethylhexyl ) phthalate
Phenols
2-Ch loropheno 1
2, i|-Di methyl phenol
Pentachlorophenol
Pheno 1
2,'4,6-Trichlorophenol
Monocyclic aroma tics
Benzene
Ethyl benzene
To 1 uene
Polycyclic aromatic hydrocarbons
Acenaphthene
Acenapnthylene
Anthracene/phenanthrene
Benzol a (anthracene
Benzol a jpyrene
Benzo ( b ) f 1 uo ra n thene
Benzojghl (perylene
Benzol k ) f 1 uo ran thene
Chrysene
Di benzol ah (anthracene
Muoran thene
F luorene
Indeno (1,2,3-cd) pyrene
Naptha lene
Pyrene
Haloqenated allphatlcs
Methyl chloride
Chloroform
Treated
Number of samples
Number of detections
above detection limit
9/2
10/10
9/1
9/3
10/9
10/10
9/6
9/1
9/9
9/5
9/1
9/2
10/10
9/li
5/0
5/1
9/9
5/i|
5/0
5/3
5/1
5/3
9/7
9/K
9/8
9/3
9/3
9/3
9/2
9/3
9/3
9/0
9/7
9/7
9/3
9/6
9/7
5/5
5/1
effluent
Ranqe
BDL - IU
2 - 7,000
BDL - 13
BDL - 7
BOL - 14,000
18 - 270
BDL - 37
BDL - 2
2-150
BDL - 39
BDL - 'I
BDL - 7
'47 - III, 000
BDL - 300
BDL
BDL - IMO
32 - 8,300
BDL - 16,000
BDL
BDL - 33
BDL - 20
BDL - IUO
BDL - 18,000
BOL - 190
BDL - 37,000
BDL - 3,1400
BDL - 290
BDL - 2,500
BDL - 63
BDL - 210
BDL - 19,000
BDL
BDL - 17,000
BDL - 16,000
BDL - 1 10
BDL - 36,000
BDL - 9,1100
13-1, 900
BDL - 23
Median
BDL
35
BDL
BDL
8
57
U
BDL
18
2
BDL
BDL
200
BDL
BDL
2,700
15
10
BDL
23
90
BDL
59
BDL
BDL
BDL
BDL
BOL
BDL
1 10
36
BDL
33
77
mo
BDL
BDL, below detection limit.
-------
rf
(D
TABLE 21-6. TOXIC POLLUTANTS LOADINGS FOUND IN STEAMING AND BOULTON SUBCATEGORY WASTEWATERfa)
VERIFICATION DATA [2-60] v ''
CO
\
u>
M
\
00
n
fD
H
I
M
O
Toxic pollutant, kq/cu.m
Metals and inorqanics
Ant i mony
Arson ic
Ue ry 1 1 i urn
Cadm i urn
Chrom i urn
Copper
Lead
Mercury
Nickel
Se len i urn
Si Ivor
Tha 1 1 i um
Zinc
Phtha 1 a tes
Bi s( 2-ethylhexyl ) phthalate
Pheno 1 s
2-Ch 1 oropheno 1
2, 1-Di me thy 1 pheno 1
Pentach 1 o ropheno 1
Pheno t
2,1,6-Trichlorophenol
Monocyc 1 i c aroma tics
Benzene
EUiylbenzene
To iLiene
Po 1 vcvc I i c aromatic hydrocarbons
Acenoph thene
Acenaptha lene
Anthracone/phenanthrene
Benzol a (anthracene
Bcnzoja jpyrene
Benzo( b ) fluo ran thene
Bcnzo(gni) perylene
Benzo( k ) f 1 uo ran thene
Chrysene
Oi benzo( ah (anthracene
F 1 uoranthene
F 1 uorene
1 ndenol 1 , 2, 3-cd Jpyrene
Naphtha lene
Pyrene
Haloqenated aliohatlcs
Methyl chloride
Chloroform
Number
of
samp les
7
7
7
7
7
7
7
7
7
7
7
7
7
5
3
3
7
3
3
3
3
3
7
7
7
7
7
7
7
7
7
7
7
7
7
7
7
3
3
Steaminq process Boulton process
Number
of
Ranae Median samples Ranqe Med i
<0. 16
0.32
<0. 16
<0. 16
0. 16
1 .0
0. 16
<0. 16
0.3?
<0. 16
<0. 16
<0. 16
II
Treated effluent
Number
of
an samples Ranqe Median
-13 0.16 3 0.16-1.1 0.16 II <0 . 1 6 - 1 . 3
-------
a
0)
rt
n>
00
\
U)
00
to
TABLE 21-7. CONCENTRATIONS OF CLASSICAL POLLUTANTS FOUND IN STEAMING AND BOULTON
SUBCATEGORY WASTEWATER, SCREENING AND VERIFICATION DATA [2-60]
O
y
&
3
13
(D
Raw wastewater
Steaming process
Po 1 lutant . mq/L
Phenols
PCP
Oil and grease
COD
ISS
Number
of
samp les
20
20
20
20
Range
0.61 - 500
BDL - 310
II - 1 , 900
1,100 - 16,000
Median
56
21
630
6.700
Bou 1 ton process
Number
of
samples
5
5
5
5
1
Range
BOL - 1,300
BDL - 27
12 - 1,1(00
520 - 7,300
81
Median
180
0.01
39
3,700
Treated effluent
Steaming and Bou 1 ton process
Number
of
samples
17
I'l
17
17
Range
O.OM8 - 680
0.032 - 130
9.3 - 1,200
100 - 1 1,000
Median
19
5.8
52
2,300
Analytic methods: V.7.3.33, Data sets 1,2.
DDL, below detection limit.
TABLE 21-8. LOADINGS (kg/I,000 cu.m) OF CLASSICAL POLLUTANTS FOUND IN STEAMING AND BOULTON
SUBCATEGORY WASTEWATER, SCREENING AND VERIFICATION DATA [2-60]
Raw wastewater
Pol lutant
Phenols
PCP
Oi 1 and grease
COD
TSS
Steaming process
Number
of
samples Range Median
18 0. 18 - 180 17
18
-------
TABLE 21-9. CONCENTRATIONS OF TOXIC POLLUTANTS FOUND IN
INSULATION BOARD SUBCATEGORY RAW WASTEWATER,
VERIFICATION DATA [2-60]
Toxic pollutant. ug/L
Number
of
samples
Range
Med ian
Metals and inorganics
Ant imony
Arsen ic
Be ryI I i urn
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Se I eniurn
Si Iver
ThaI Iium
Zinc
Toxic organics
4
4
4
4
4
4
4
4
4
4
4
4
4
BDL
BDL
BDL
BDL
BDL
200
BDL
BDL
8.8
3.3
BDL
BDL
250
3
3.3
BDL
BDL
I I
450
21
7.5
240
5.0
BDL
BDL
720
BDL
2.5
BDL
BDL
4.9
310
3.3
5.8
58
4.5
BDL
BDL
530
Ch lo reform (a )
Pheno 1
Benzene
To 1 uene
3
3
3
3
BDL
BDL
BDL
BDL
- 20
- 40
- 70
- 60
BDL
BDL
50
40
Analytic methods: V.7.3.33, Data set 2.
BDL, below detection limits.
(a) One sample of raw wastewater contained 20 ng/L of
chloroform while plant intake water contained 10 u.g/L
of chloroform; therefore, chloroform is listed as
being BDL.
TABLE 21-10. LOADINGS OF TOXIC METALS FOUND IN INSULATION
BOARD SUBCATEGORY RAW WASTEWATER, VERIFICATION
DATA [2-60]
Toxic pollutant. mg/Mg
Number
of
samples
Range
Mean
Metals and inorganics
Ant imony
Arsen ic
Beryl 1 ium
Cadm i urn
Ch rom i urn
Copper
Lead
Mercury
Nickel
Se 1 en ium
Si 1 ve r
Tha 1 1 ium
Zinc
4
4
4
4
4
4
4
4
4
4
4
4
4
2. 1 -
13 -
4.2 -
2.8 -
5.5 -
1,900 -
6 -
21 -
90 -
14 -
2. 1 -
2.8 -
3,000 -
25
60
10
10
470
4, 100
170
80
850
70
10
17
6,000
15
29
6.7
6.5
160
1,900
63
42
500
38
5.6
7.6
4,600
Analytic methods: V.7.3.33, Data set 2.
Date: 8/31/82 R Change I 11.21-12
-------
water use of over 15 million L/d (4 MGD).
Water becomes contaminated during the production of hardboard
primarily through contact with the wood raw material during the
fiber preparation, forming, and, in the case of SIS hardboard,
pressing operations. The vast majority of pollutants consist
of fine wood fibers, soluble wood sugars, and extractives.
Additives not retained in the board also add to the pollutant
load.
The water used to process and transport the wood from the fiber
preparation stage through mat formation is referred to as process
Whitewater. Process Whitewater produced by the dewatering of
stock at any stage of the process is usually recycled to be used
as stock dilution water. However, in order to avoid undesirable
effects in the board when elevated concentrations of suspended
solids and dissolved organic materials occur, excess process
Whitewater is discarded.
Potential wastewater sources in the production of wet process
hardboard include:
Chip wash water
Process Whitewater generated during fiber preparation
(refining and washing)
Process Whitewater generated during forming
Hot press squeezeout water
Wastewater generated during miscellaneous operations
(dryer washing, finishing, housekeeping, etc.)
A unit flow of 12,000 L/kg (2,800 gal/ton) is considered to* be repre-
sentative of an SIS hardboard plant which produces a full line of
hardboard products and which practices internal recycling to the
extent practicable. A unit flow of 25,000 L/kg (5,900 gal/ton)
is considered to be representative of an S2S hardboard manufac-
turing plant which produces a full line of hardboard products and
practices internal recycling to the extent possible.
Available data analyses list primarily metals and inorganics as
toxic pollutants; no base/neutrals data are presented. Table
21-11 presents concentrations and pollutant loadings for toxic
and classical pollutants found in hardboard manufacturing raw
wastewater.
II.21.3 PLANT SPECIFIC DESCRIPTIONS [2-60]
Due to the nature of available plant specific data, only subcate-
gory wastewater characteristics could be derived, and plant
specific wastewater characterization information is not presented.
Date: 8/31/82 R Change 1 11.21-13
-------
ft
(D
00
\
co
oo
to
o
D)
(D
H
H
H
NJ
I
TABLE 21-11. CONCENTRATIONS AND LOADINGS OF TOXIC AND CLASSICAL POLLUTANTS FOUND IN HARDBOARD
MANUFACTURING SUBCATEGORY RAW WASTEWATER, VERIFICATION DATA [2-60]
Number
of
Pol lutant samples
Toxic pol lutant
Metals and inorqan icsta )
Antimony
Arsenic
Be ry 1 1 i urn
Cadm i urn
Chrom i urn
Coppe r
Lead
Mercury
Nickel
Selenium
S i 1 ve r
Tha 1 1 i urn
Zinc
Pheno 1 s
Phenol (b)
Phenol (c)
Monocvclic aromatics
Benzene( b )
Benzene ( c )
Ethylbenzene(b)
To 1 uene( b )
To 1 uene( c }
Haloqenated aliphatics
Chloroform(b)
Chloroform(c)
1 , 1 ,2-Trichloroethane(c)
Pesticides and metabo 1 i tesld )
Aldrin
PCB' s
Chlordane
Heptach 1 or
Classica 1 pol lutant
BOD5
Tota 1 pheno 1 s
Analytic methods: V.7.3.33, Data set
BDL, below detection limits.
(a) SIS and S2S combined for metals
(b) SIS type hardboard; no loading d
6
6
6
6
6
6
6
6
6
6
6
6
6
2
3
2
3
2
2
3
2
3
3
l(
1|
2.
- no
ata.
Concentration.
Range
BDL
BDL
BDL
BDL
BDL
33
2
BDL
3.3
BDL
BDL
BDL
190
BDL
BDL
BDL
BDL
BDL
15
BDL
BDL
BDL
BDL
BDL
observed
- 8
- BDL
- BDL
- b
- '120
- 530
- 55
- 18
- 270
- 3.8
- 7
- 1 .5
- 2,300
- 680
- 300
- 60
- 90
- 20
- 70
- 60
- 20
- 20
- 90
- 8,900
d i f ference.
Uq/L
Med ian
2.6
BDL
BDL
BDL
52
350
1(
BDL
7.5
2. 1
BDL
BDL
660
BDL
BDL
10
BDL
5
J LJ' (Jw ncituuuaiu, MU ivouinij viaia.
(c) S2S type hardboard; no loading data.
(d) SIS and S2S processes combined; number of plants was not specified.
-------
TABLE 21-12. CURRENT LEVEL OF IN-PLACE TECHNOLOGY,
BOULTON, NO DISCHARGERS(a) [2-60]
Primary oil separation
Oil separation by DAF
Evaporation ponds
Spray or soil irrigation
Cooling tower evaporation
Thermal evaporation
Effluent recycle to boilers
or condensers
Number
of
plants
19
1
15
1
4
1
4
Percent
83
4
63
4
17
4
17
(a) Plants may use more than one technology.
TABLE 21-13. CURRENT LEVEL OF IN-PLACE TECHNOLOGY,
BOULTON, INDIRECT DISCHARGERS(a) [2-60]
Number
of
plants Percent
Primary oil separation 10 100
Chemical flocculation and/
or oil absorbent media 4 40
Biological treatment 2 20
(a) Plants may use more than one technology.
Date: 8/31/82 R Change 1 11.21-15
-------
TABLE 21-14.
CURRENT LEVEL OF IN-PLACE TECHNOLOGY,
STEAMING, NO DISCHARGERS(a) [2-60]
Number
of
plants
Percent
Gravity oil-water separation 53 80
Chemical flocculation or oil
absorptive media 6 9.1
Sand filtration 9 41
Oxidation lagoon 5 7.6
Aerated lagoon 9 14
Spray irrigation 9 14
Holding basin 23 35
Thermal evaporation 3 4.5
Solar evaporation pond 26 39
Spray assisted solar
evaporation 17 26
Effluent recycle to boiler
or condenser 11 17
(a) Some plants use more than one technology.
TABLE 21-15.
CURRENT LEVEL OF IN-PLACE TECHNOLOGY,
STEAMING, DIRECT DISCHARGER(a) [2-60]
Number
of
plants
Gravity oil-water separation
Chemical flocculation or oil
absorptive media
Aerated lagoon
Holding basin
Spray assisted solar
evaporation
Effluent recycle to boiler
or condenser
1
1
1
1
1
1
Percent
100
100
100
100
100
100
(a) One plant.
Date: 8/31/82 R Change 1 11.21-16
-------
TABLE 21-16. CURRENT LEVEL OF IN-PLACE TECHNOLOGY,
STEAMING, INDIRECT DlSCHARGERS(a) [2-60]
Gravity oil-water separation
Chemical flocculation or oil
absorptive media
Sand f i 1 1 rat ion
Oxidation lagoon
Aerated lagoon
Holding basin
Spray assisted solar
evaporat ion
Effluent recycle to boiler
or condenser
Number
of
plants
28
8
4
1
1
17
2
2
Percent
97
28
14
3.4
3.4
59
6.9
6.9
(a)Some plants use more than one technology.
TABLE 21-17. WOOD PRESERVING CLASSICAL POLLUTANT DATA AVERAGES
FOR PLANTS WITH LESS THAN THE EQUIVALENT OF BPT
IN PLACE, SCREENING DATA [2-60]
Pol lutant
COD
Pheno 1 s
Oil and grease
Pen tachlo ropheno 1
Number
of
plants
3
3
3
3
Waste
load,
kq^ 1 ,000 cu.m
Raw
1,500
28
140
8
Treated
500
16
27
2.4
Percent
remova 1
67
43
81
70
Analytic methods: V.7.3.33, Data set I
TABLE 21-18. WOOD PRESERVING CLASSICAL POLLUTANT DATA AVERAGES
FOR PLANTS WITH CURRENT PRETREATMENT TECHNOLOGY IN-
PLACE, SCREENING AND VERIFICATION DATA [2-60]
Pol lutant
COD
Pheno 1 s
Oil and grease
Pentach 1 o ropheno 1
Number
of
plants
7
7
7
5
Number
of
samples
10
10
10
7
Waste load,
kq/ 1.000
Raw
1,300
50
120
<4.6
cu.m
Treated
670
32
15
1.2
Percent
remova 1
48
36
88
<74
Analytic methods: V.7.3.33, Data sets 1,2.
Date: 8/31/82 R Change 1 11.21-17
-------
II.21.4 POLLUTANT REMOVABILITY [2-60]
The following sections address the current level of in-place
treatment technology and the raw and treated effluent loads and
percent reduction for several pollutants and several plants.
Information is organized with respect to the aforementioned
subcategories [wood preserving including steaming and Boulton
processes, insulation board manufacturing, and hardboard manu-
facturing (SIS and S2S)].
II.21.4.1 Wood Preserving
Tables 21-12 through 21-16 present the current level of in-place
treatment technology for Boulton-no dischargers, Boulton-indirect
dischargers, steaming-no dischargers, steaming-direct dischargers,
and steaming-indirect dischargers, respectively.
Tables 21-17 through 21-19 present average raw and treated waste
loads and percent removal for COD, phenols, oil and grease, and
pentachlorophenol for plants with less than BPT in place, current
pretreatment technology in place, and current BPT in place.
TABLE 21-19.
WOOD PRESERVING CLASSICAL POLLUTANT DATA AVERAGES
FOR PLANTS WITH CURRENT BPT IN-PLACE, SCREENING
AND VERIFICATION DATA [2-60]
Pollutant
COD
Phenols
Oil and grease
Number
of
Plants
4
4
4
Pentachlorophenol 3
Number
of
Samples
6
6
6
5
Waste load,
kg/1,
Raw
500
38
69
<4.3
OOOcu.m
Treated
96
0.16
<13
0.16
Percent
removal
81
>99
>81
<96
Analytic methods: V.7.3.33, Data sets 1,2.
Table 21-20 presents average raw and treated waste loads and
percent removals of methylene chloride, trichloromethylene,
benzene, ethylbenzene, and toluene for plants with current BPT
in place. Tables 21-21 and 21-22 present similar
data for base/neutral toxic pollutants for current pretreatment
technology and current BPT in place.
Tables 21-23 and 21-24 present similar data for wood preserving
phenols data for plants with current pretreatment technology in
place and current BPT in place.
In addition, Tables 21-25 through 21-29 present data for average
raw and treated waste loads and percent removals of metals for
plants with current pretreatment technology and current BPT
inplace.
Date: 8/31/82 R Change 1 11.21-18
-------
TABLE 21-20.
WOOD PRESERVING VOLATILE ORGANIC ANALYSIS DATA
AVERAGES FOR PLANTS WITH CURRENT BPT IN-PLACE,
VERIFICATION DATA [2-60]
Pollutant
Methylene chloride
Trichloromethylene
Benzene
Ethylbenzene
Toluene
Number
of
plants
3
3
3
3
3
Waste
kg/ 10
Raw
78
<0.16
320
1,600
380
load,
cu.m
Treated
69
<3.2
<4.8
<1.6
<14
Percent
removal
12
NM
>98
>99
>96
Analytic methods: V.7.3.33, Data set 2.
NM, not meaningful.
TABLE 21-21.
WOOD PRESERVING BASE NEUTRALS DATA AVERAGES
FOR PLANTS WITH CURRENT PRETREATMENT TECHNOLOGY
IN-PLACE, VERIFICATION DATA [2-60]
Pollutant
Fluoranthene
Benzo (b ) f luoranthene
Benzo (k)f luoranthene
Pyrene
Benzo(a)pyrene
Indeno(l ,2 ,3-CD)pyrene
Benzo (ghi)perylene
Phenanthrene/
anthracene
Benzo ( a ) anthracene
Dibenzo(a,h)
anthracene
Naphthalene
Acenaphthene
Acenaphthylene
Fluprene
Chrysene
Bis(Z-ethylhexyl)
phthalate
Number
of
plants
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Waste load,
kg/10 cu.m
Raw
<91
<0.16
<0.16
<61
<0.16
<0.16
<0.16
<510
<9.6
<0.16
<220
<260
<190
<190
<4.8
<99
Treated
<4.8
<0.6
<0.16
<0.16
<0.16
<0.16
<0.16
<12
<0.16
<0.16
<120
<13
<16
<4.8
<0.16
<16
Percent
removal
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
NM
Analytic methods: V.7.3.33, Data set 2.
NM, not meaningful.
Date: 8/31/82 R Change 1 11.21-19
-------
TABLE 21-22. WOOD PRESERVING BASE NEUTRALS DATA AVERAGES FOR PLANTS WITH CURRENT
BPT IN-PLACE, VERIFICATION DATA [2-60]
Pol lutant
Fluo ranthene
Benzo ( b ) f 1 uo ranthene
Benzo( k ) f 1 uo ra nthene
Pyrene
Benzo(a Jpyrene
lndeno( 1 ,2, 3-CD)pyrene
Benzo (ghi Jperylene
Phenanthrene/anthracene
Benzo (a Janthracene
Dibenzo(a, h)anthracene
Naphtha lene
Acenaphthene
Acenaphthylene
Fl uorene
Chrysene
Bis(2-ethylhexyl ) phthalate
Number
of
plants
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
Number
of
samp les
4
1 4
4
4
4
i\
4
it
4
H
4
4
k
4
H
4
Waste load,
kq/IOE6 cu.m
Raw
850
3,000
700
78
540
89
92
NM
NM
NM
>94
NM
NM
>99
95
>96
>96
NM
NM
Analytic methods: V.7.3.33, Data set 2.
NM, not meaningful.
TABLE 21-23. WOOD PRESERVING PHENOLS DATA AVERAGES FOR PLANTS
WITH CURRENT PRETREATMENT TECHNOLOGY IN-PLACE,
SCREENING AND VERIFICATION DATA [2-60]
Pol lutant
Pheno 1 s
2-ChJorophenol
2,4-Dimethylphenol
2,4,6-Trichlorophenol
Pentach 1 o ropheno 1
Number
of
plants
2
2
2
2
7
Waste load,
ka/l .000 cu.m
Raw
100
-------
TABLE 21-24. WOOD PRESERVING PHENOLS DATA AVERAGES FOR PLANTS
WITH CURRENT BPT IN-PLACE, VERIFICATION DATA [2-60]
Pol lutant
Pheno 1 s
2-Ch to ropheno 1
2, 4-Di methyl phenol
2,4,6-Trichlorophenol
Pentach 1 o ropheno 1
Number
of
plants
3
3
3
3
5
Waste load,
kq/l .000 cu.m
Raw
5,600
<6.4
700
<80
1,200
Treated
<3.2
99
NM
>98
NM
82
Analytic methods: V.7.3.33, Data set 2.
NM, not meaningful.
TABLE 21-25. WOOD PRESERVING METALS DATA, ORGANIC PRESERVATIVES
ONLY, AVERAGES FOR PLANTS WITH CURRENT PRETREATMENT
TECHNOLOGY IN-PLACE, VERIFICATION DATA [2-60]
Pol lutant
Antimony
Arsenic
Beryl 1 ium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Se 1 en ium
Si Iver
Tha 1 1 ium
Zinc
Number
of
D lants
2
2
2
2
2
2
2
2
2
2
2
2
2
Waste load,
kq/IOE6 cu.m
Raw
<0. 16
0.148
<0. 16
<0. 16
0. 16
22
1.3
<0. 16
0.8
0. 16
<0. 16
0. 16
54
Treated
0.32
0.8
<0. 16
<0. 16
1.4
15
0.32
<0. 16
0. 16
0.8
<0. 16
0.32
160
Percent
remova 1
NM
NM
NM
NM
NM
32
75
NM
80
NM
NM
NM
NM
Analytic methods: V.7.3.33, Data set 2.
NM, not meaningful.
TABLE 21-26. WOOD PRESERVING METALS DATA, ORGANIC PRESERVATIVES
ONLY, AVERAGES FOR PLANTS WITH CURRENT BPT IN-PLACE,
VERIFICATION DATA [2-60]
Pol lutant
Ant imony
Arson ic
Beryl 1 ium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Si 1 ve r
Tha 1 1 ium
Zinc
Number
of
plants
4
4
4
4
4
4
4
4
4
4
4
4
4
Waste
kq/IOE6
Raw
3.5
990
<0. 16
<0. 16
1.9
7.7
6.9
<0. 16
1.6
0.32
<0. 16
<0. 16
26
load,
cu.m
Treated
63
45
NM
NM
16
27
>5I
NM
0
0
NM
NM
42
Analytic methods: V.7.3.33, Data set 2.
NM, net meaningful.
Date: 8/31/82 R Change 1 11.21-21
-------
TABLE 21-27,
WOOD PRESERVING METALS DATA, ORGANIC AND
INORGANIC PRESERVATIVES, ONE PLANT WITH LESS
THAN CURRENT BPT TECHNOLOGY IN-PLACE, SCREEN-
ING DATA [2-60]
Pollutant
Arsenic
Chromium
Copper
Waste load,
kg/106m3
Raw Treated
6.9 7.0
8.5 8.9
27 27
Percent
removal
NM
NM
0
Analytic methods: V.7.3.33, Data set 1.
TABLE 21-28,
WOOD PRESERVING METALS DATA, ORGANIC
AND INORGANIC PRESERVATIVES, AVERAGES
FOR PLANTS WITH CURRENT PRETREATMENT
TECHNOLOGY IN-PLACE, SCREENING AND VERI-
FICATION DATA [2-60]
Pollutant
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
Number
of
plants
2
6
2
2
5
6
2
2
2
2
2
2
4
Waste
kg/ 10
Raw
<0.8
<4.8
<0.16
<0.32
120
62
0.48
<0.16
9.9
3.0
0.32
<0.16
960
load
6m3
Treated
<0.48
<9.6
<0.16
<0.48
100
42
0.8
<0.16
11
2.2
<0.16
<0.16
900
Percent
removal
NM
NM
NM
NM
17
32
NM
NM
NM
27
>50
NM
6
Analytic methods: V.7.3.33, Data sets 1,
NM, not meaningful.
2.
Date: 8/31/82 R Change 1 11.21-22
-------
II.21.4.2 Insulation Board Manufacturing
Table 21-30 summarizes the current level of in-place treatment
technology for six plants. Tables 21-31 through 21-36 present
treated effluent characteristics and various average raw and
treated waste characteristics and removals for the insulation
board manufacturing subcategory.
II.21.4.3 Hardboard Manufacturing
Table 21-37 summarizes the current level of in-place treatment
technology for 13 hardboard manufacturing plants. Tables
21-38 through 21-44 present treated effluent characteristics
and various raw and treated waste characteristics and percent
removals for the hardboard manufacturing subcategory.
Date: 8/31/82 R Change 1 11.21-23
-------
TABLE 21-29. WOOD PRESERVING METALS DATA,
ORGANIC AND INORGANIC PRESER-
VATIVES, ONE PLANT WITH CURRENT
BPT IN-PLACE, VERIFICATION DATA
[2-60J
Po 1 lutant
Antimony
Arsenic
Be ry 1 1 i urn
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Si 1 ver
Tha 1 1 ium
Zinc
Waste
kq/IOE6
Raw
<0. 16
to
<0. 16
0.32
7.2
21
5.0
O.U8
30
<0. 16
<0. 16
<0. 16
37
load,
cu.m
Treated
<0. 16
to
<0. 16
1.6
15
29
U.8
0. 16
5.14
<0. 16
<0. 16
<0. 16
50
Percent
remova 1
NM
0
NM
NM
NM
NM
U
67
82
NM
NM
NM
NM
Analytic methods: V.7.3.33, Data set 2.
NM, not meaningful.
TABLE 21-30. IN-PLACE TREATMENT TECHNOLOGY AT SIX
INSULATION BOARD MANUFACTURING PLANTS
[2-60]
Plant
number
Product/process
Treatment system
537 Structural/decorative
insulation board,
thermomechanicaI
108 Insulation board/
hardboard, tnermo-
mechan icaI
889 Mechanical process
insulation board
36 Structural/decorative
insulation board,
mechanical process
360 Structural/decorative
insulation board,
mechanical process
1035 Insulation board/S2S
hardboard, thermo-
mechan icaI
Clarifier, aerated lagoon
Oxygen-activated sludge system,
clarifier
Aerated lagoon, evaporation pond,
self-contained discharger
(i rrigation)
Clarifier, activated sludge
Floc-clarifier, aerated lagoon,
d i scha rge to POTW
Settling ponds aerated lagoon,
oxidation pond
Date: 8/31/82 R Change 1 11.21-24
-------
TABLE 21-31. INSULATION BOARD THERMOMECHANICAL REFINING TREATED
EFFLUENT CHARACTERISTICS (1977 ANNUAL AVERAGE) [2-60]
(D
00
00
K)
O
tr
OJ
3
iQ
(D
to
M
I
to
tn
Plant
number
537
I08(a)
1035
Production
Mq/d
145
605
359
tons/d
160
665(b)
395(b)
1.000 L/Mq
1.75
51.3
21.9
Flow
BOD
1 .000 qa I/ton kq/Mq
0.419
12.3
5.26
2.2
4. 1
2.2
Ib/ton
4.4
8. 1
4.3
TSS
kq/Mq
1 .3
12
0.94
Ib/ton
2.5
24
1.9
(a)Data are taken before paper wastewater is added.
(b) Includes both insulation board and hardboard production.
TABLE 21-32. INSULATION BOARD MECHANICAL REFINING ANNUAL AVERAGE( 1977)
RAW AND TREATED WASTE CHARACTERISTICS [2-60]
Plant
number
360
36
889
Raw waste
4.6
21
1.3
BOD. kq/Mq
Treated
eff 1 uent
1 .0
0.28
0.07
Percent
reduct ion
78
99
95
Raw waste
0.88
31
0.46
TSS^ kg/Mg__
Treated
ef f 1 uent
1 .2
1.5
0. 16
Percent
reduct ion
NM
95
65
NM, not meaningful.
TABLE 21-33. INSULATION BOARD THERMOMECHANICAL REFINING ANNUAL AVERAGE( 1977)
RAW AND TREATED WASTE CHARACTERISTICS [2-60]
Plant
number
537
I08(a)
1035
Raw waste
24(b)
30
43
BOD, kg/Mq
Treated
effluent
2.2
4. 1
2.2
Percent
reduction
91
86
95
Raw waste
39(b)
29
TSS. kq/Mq
Treated
effluent
1.3
12
0.94
Percent
reduct ion
97
59
(a)Data are taken before paper wastewater is added.
(b)Data obtained during 1977 and 1978 verification sampling programs.
-------
TABLE 21-34. RAW AND TREATED EFFLUENT LOADS AND PERCENT
REDUCTION FOR TOTAL PHENOLS, INSULATION
BOARD(a) [2-60]
Plant
number
36
183
360
537
Raw waste load
kq/Mq
0.00095
0.007
0.002U
0.009
O.OOOU
0.0022
0.0055
Treated waste load
kq/Mq
0.0001
0.00012
0.00008
0.0001 4
0.00065
Percent
reduct ion
89
98
80
94
88
(a)Total phenols concentration data obtained during 1977 (first
row of data) and 1978 (second row of data) verification
sampling programs. Average annual da ity waste flow and pro-
duction data supplied by plants in response to data collection
portfolio were used to calculate waste loads.
TABLE 21-35. RAW AND TREATED EFFLUENT LOADINGS AND PERCENT REDUCTIONS FOR
INSULATION BOARD METALS, VERIFICATION DATA f2-60]
Plant 360
Waste load,
mq/Mq
Pol lutant
Ant imony
Arsen ic
Be ry 1 1 i urn
Cadmium
Chromium
Copper
Lead
Mercury
Nicke 1
selenium
Si 1 ve r
[Mai I ium
L inc
Raw
2. 1
13
1.2
2.8
6
1.900
6
2. 1
800
11
2. 1
2.8
3.000
Waste
ma/Ma
Percent
Treated reduction Raw
18
6
2. 1
3.5
22
900
6
0.1
600
7
2. 1
8
1,100
NM
51
50
NM
NM
53
0
81
25
50
0
NM
53
25
27
7
8
60
2,300
170
11
850
35
1.9
1. I
1.200
Plant 183
load,
Treated
21
13
12
13
20
20
21
13
900
25
17
1. 1
I), 800
Plant 537
Waste load,
mq/Mq
Percent
reduction Raw
16
52
NM
NM
67
99
88
68
NM
29
NM
0
NM
11
60
10
10
170
11
27
21
250
70
10
17
5,000
Treated
2.8
6
1
1
6
180
3.8
1.9
13
1.1
1 .3
1.3
170
Plant 36
Waste load,
mq/Mq
Percent
reduction Raw
80
90
90
90
99
NM
86
91
95
91
87
92
97
22
17
5.5
5.5
120
3,600
55
80
90
35
5
6.5
6,000
Treated
18
20
5.5
5.5
90
1,200
8
0.7
37
32
7
8
800
Percent
reduction
NM
NM
0
0
25
67
85
99
59
9
NM
NM
87
Analytic methods: V.7.3.33, Data set 2.
NM, not meaningful.
Date: 8/31/82 R Change 1 11.21-26
-------
TABLE 21-36. INSULATION BOARD TOXIC POLLUTANT DATA, ORGAN ICS,
VERIFICATION DATA [2-60]
Pol lutant
Chloroform
Benzene
Toluene
Phenol
Plant 183
20
70
60
BDL
Average
Raw wastewater
Plant 36 .
BDL(b)
40(c)
40(c)
40
concentration. uq/L
Plant 537
BDL
BDL
BDL
BDL
Treated
Plant 36
BDL
BDL
BDL
BDL
ef f 1 uent
Plant 537(a)
BDL
BDL
BDL
BDL
Analytic methods: V.7.3.33, Data set 2.
BDL, below detection limits.
(a)One of three treated effluent samples contained 40 u.g/L of tricnloro-
fluoromethane.
(b)One sample of raw wastewater contained 20 |ig/L of chloroform while
plant intake water contained 10 u,g/L of chloroform; therefore,
chloroform is listed as being BDL.
(c)Plant intake water contained 50 ug/L and 30 ug/L of benzene and
toluene, respectively.
TABLE 21-37. IN-PLACE TREATMENT TECHNOLOGY AT
13 HARDBOARD MANUFACTURING PLANTS [2-60]
Plant
number
678
933
673
929
980
348, 3,
207
108
1
919
931
1035
Product
SIS, S2S
SIS
SIS, S2S
SIS
S2S
SIS
S2S
SIS, S2S
SIS
SIS
S2S
Treatment system
Activated sludge, aerated lagoon
Lime neutralization, discharge to POTW
Activated sludge, humus ponds, aerated
lagoons, settling pond
Sett 1 ing ponds
Kinecs Air Pond(a), Infilco Aero Accelerators,
aerated lagoons, facultative lagoon
Settling pond, aerated lagoon
Not specified
Settling pond, aerated lagoon
Settling ponds, activated sludge, aerated
lagoon
Aerated lagoons, settling ponds
Clarifier, aerated lagoon, oxidation ponds
(a)Primary aerated equalization pond.
Date: 8/31/82 R Change 1 11.21-27
-------
D
(u
rt
(D
oo
00
NJ
n
i^
PI
3
ua
(D
H
H
•
to
M
I
tO
00
TABLE 21-38. SIS HARDBOARD TREATED EFFLUENT CHARACTERISTICS
(1977 ANNUAL AVERAGE) [2-60]
Plant
number
348
3
931
9l9(b)
673
678
929
207
Production
Mq/d
89
190
120
92
340
1,100
1 10
80
F 1 ow BOD
1 . 000 L/Mq kq/Mq
47(a) 9.0(a)
9.4 9.4
8.1 0.74
4.2 0.13
9.4 0.97
0.62 5.1
14 4.3
TSS
kq/Mq
I7(a)
8.5
2.5
0. 12
1. 1
0.59
9.8
Analytic methods: V.7.3.33, Data set 2.
(a) Hardboard and paper waste streams are com ing led.
(b) All of the treated effluent is recycled.
Plant
number
980
1035
108
1
TABLE 21-39.
Production Flow
Mq/d 1.000 L/Mq
220 20
360(a) 22
570(a) 23(b)
310 26
S2S HARDBOARD ANNUAL 1977 AVERAGE RAW AND
CHARACTERISTICS [2-60]
Raw waste
62
43
30
120
BOD. kq/Mq
Treated Percent
effluent reduction
2.9 95
2.2 95
2.l(b) 93
21 82
TREATED WASTE
TSS. kq/Mq
Treated
Raw waste effluent
12 4.7
0.94
29 2.2(b)
20 44
Percent
reduct ion
61
92
NM
Analytic methods: V.7.3.33, Data set 2.
NM, not meaningful.
(a)Includes both insulation board and hardboard production.
(b)Data represent period of 9/21/79 through 4/30/80 when oxygen activated sludge
system was in operation.
-------
TABLE 21-40. SIS HARDBOARD 1977 ANNUAL AVERAGE RAW AND TREATED WASTE
CHARACTERISTICS [2-60]
Plant
number
348(a)
3
931
207
673
678
Raw waste
33
25
34
34
l.9(b)
22(c)
BOD. kq/Mq
Treated
effluent
9.0
9.3
0.7U
4.3
0. 1
1.0
Percent
reduct ion
* 73
63
98
87
95
95
Raw waste
6.9
13
13
5
0.56(b)
5.8(c)
TSS. kq/Mq
Treated
effluent
17
8.5
2.5
9.8
0. 12
1. 1
Percent
reduct ion
NM
35
81
NM
79
81
Analytic methods: V.7.3.33, Data set 2.
NM, not meaningful.
(a) Hardboard and paper waste streams are comingled.
(b) Raw waste loads shown are for combined weak and strong wastewater streams.
(c) Raw waste load taken after primary clarification, pH adjustment, and nutrient addition.
TABLE 21-41. RAW AND TREATED EFFLUENT LOADS AND PERCENT
REDUCTION FOR TOTAL PHENOLS, HARDBOARD
[2-60]
Plant
number
207
673
678
931
933
979
1
Raw waste load
ka/Mq
0.001
0.01
0.003
0.03
NR
0.0015
0. 10
Treated waste load
kq/Mq
0.0062
0.0002
NR
0.06
0.003
0.003
0.001
Percent
reduction
80
98
NM
NM
NM
NM
99
NM, not meaningful.
NR, not reported.
Date: 8/31/82 R Change 1 11.21-29
-------
TABLE 21-42. RAW AND TREATED EFFLUENT LOADINGS AND PERCENT REDUCTIONS FOR
HARDBOARD METALS, VERIFICATION DATA [2-60]
Pol lutant
Ant imony
Arsenic
Be ry 1 1 i urn
Cadmi urn
Ch rom i urn
Copper
Lead
Mercury
Nickel
Selenium
Si Ivor
Tha 1 1 i urn
Zinc
Antimony
Arson ic
Be ry II i urn
Cadmium
Ch rom i urn
Copper
Lead
Mercury
Nickel
Selenium
SI Iver
Thai 1 lum
Zinc
Raw
200
12
6
290
290
3,900
60
18
2,1400
18
6
13
9,000
214
|l»
5
5
90
1, 100
20
1 1
60
21
5
5
211,000
Plant 931
Waste load,
ma/Mq
Percent
Treated reduction Raw
8.5 96 80
20 NM 26
U.5 25 13
U.5 98 60
6 98 190
1,1)00 6U 1 U.OOO
20 67 120
18 0 1.3
200 92 1,800
6 67 20
0.5 92 180
7 16 13
2,500 72 i|,800
Plant 933
9
17
9
9
17
9,000
35
310
60
60
9
9
IM.OOO
Plant 980
Waste load,
mq/Mq
Treated
9
2i|
9
37
113
9,000
37
37
330
19
85
13
800
Plant 207
9
17
9
9
35
11,000
26
70
35
117
9
9
6,600
Plant
673
Waste load,
mq/Mq
Percent
reduct ion
89
8
31
38
77
36
69
NM
82
5
53
0
83
0
0
0
0
NM
56
26
77
142
22
0
0
53
Raw
80
16
8
7
100
MHO
800
2.7
800
50
7
13
3,000
100
15
7
7
6,000
3,300
142
22
120
23
9
9
7,000
Trea ted
10
7
2.8
8
214
17
33
1 . 1
214
20
3.3
2.3
260
Plant
1 1
0.14
14.8
14.8
820
1.8
36
0.14
60
19
60
8
1,900
Percent
reduct ion
87
56
65
NM
76
96
96
59
97
60
53
82
91
678
89
97
31
31
86
>99
|I4
98
50
17
NM
1 1
73
Analytic methods: V.7.3.33, Data set 2.
NM, not meaningful.
Date: 8/31/82 R Change 1 11.21-30
-------
TABLE 21-43. SIS HARDBOARD SUBCATEGORY TOXIC POLLUTANT DATA,
ORGANICS, VERIFICATION DATA [2-60]
Average concentration, yg/L
Raw wastewater Treated effluent
Pollutant Plant 207(a) Plant 931 Plant 207 Plant 931
Chloroform
Benzene
Ethylbenzene
Toluene
Phenol
BDL
BDL
20
15
BDL
20
80
BDL
70
680
BDL
10
BDL
BDL
BDL
BDL
80
BDL
70
20
Analytic methods: V.7.3.33, Data set 2.
BDL, Below detection limits.
(a) Plant 207 intake water contained 10 yg/L toluene and
97 yg/L phenol.
TABLE 21-44. S2S HARDBOARD SUBCATEGORY TOXIC POLLUTANT
DATA, ORGANICS, VERIFICATION DATA [2-60]
Averaae concentration. uo/L
Raw wastewater
Pol lutant
chloroform
1, 1,2-Trichloroethane
Benzene
Toluene
Pheno 1
Plant 980
BDL
BDL
BDL
BDL
BDL
Plant 1
20
BDL
90(a)
60(a)
300
Plant 9i»3
BDL
90
BDL
10
BDL
Treated effluent
Plant 980
BDL
BDL
DDL
I00(b)
BOL
Plant 1
BDL
BDL
10
30
BDL
Plant 9K3
BOL
BDL
BDL
BDL
BDL
Analytic methods: V.7.3.33, Data set 2.
BDL, below detection limits.
(a)Plant Intake water was measured at 120 ug/L benzene and 80 ug/L toluene.
(b)Plant reported a minor solvent spill In final settling pond prior to sampling.
Date: 8/31/82 R Change 1 11.21-31
-------
-------
TABLE 22-1 CONCENTRATIONS OF CLASSICAL AND TOXIC POLLUTANTS FOUND IN THE
RAW WASTEWATER ENTERING POTW A [2-61]
Pol lutant
Toxic pollutant, ug/L
Metals and inorganics
Ant i mony
Arsen i c
Be ry 1 1 i urn
Cadm i um
Chrom i um
Copper
Cyan t de
Lead
Mercury
Nickel
Se 1 en i um
Si 1 ve r
Tha 1 1 ium
Zinc
Ethers
Bi s(2-chloroethoxy)methane
Phtha 1 a tes
Bi s( 2-ethylhexyl ) phthslate
Butyl benzyl phthalate
Di-n-butyl phthalate
Diethyl phthalate
Di-n-octyl phthalate
Dimethyl phthalate
Pheno 1 s
Pentach to ropheno 1
Pheno I
2,it,6-Trichlorophenol
p-Ch t oro-m-c re so 1
Aroma t i cs
Benzene
Ch 1 orobenzene
1 ,2-Dich 1 orobenzene
1 , 3-D t ch 1 orobenzene
1 . ii-D i ch 1 orobenzene
F thy 1 benzene
Hcxachl orobenzene
lo 1 uene
1 , 2, i4-Trichloro benzene
Polycyclic aromatic hydrocarbons
Acenaphthene
Acenaphthy 1 ene
Anthracene
Chrysene
F 1 uoranthene
F lourene
Indenol 1 , 2, 3-cd jpyrene
Naphtha 1 ene
Phenanthrene
Pyrene
Haloqenated aliphatics
Bromofo rm
Carbon tet rach 1 or i de
Ch I o rod i b romome thane
Ch 1 orof orm
D i ch 1 o rob romome thane
1 , 1 -D i ch 1 o roe thane
1 ,2-Dichloroethane
1 , 1 -D i ch 1 oroethy 1 ene
l,2-7rans-dichl oroethy 1 ene
Hexachlorobutad iene
Methylene chloride
Tet rach 1 oroethy 1 ene
1,1, l-Trichloroethane
1 , 1 ,2-Trichlo roe thane
Trichloroethylene
Tr i ch 1 orof 1 uorome thane
Classical pollutants, mg/L
BOD
COD
TOC
TSS
Phenols, total
Oil and grease
Number of
samp 1 es
23
23
23
23
23
23
8M
23
23
23
23
23
23
23
28
28
28
28
28
28
28
28
28
28
28
82
8?
28
28
28
82
28
82
28
28
28
28
28
28
28
28
28
28
28
82
82
82
82
82
82
82
82
82
28
82
82
87
82
82
82
27
26
27
27
83
78
Number of
detect i ons
Ola)
Ola)
Ola)
2l|a)
23(3)
23
57(3)
I6(a)
I5(a)
22(a)
0(a)
18(8)
Ola)
23
2
26
1 1
19
17
1
1 1
7
27
1
1
81
9
15
6
lit
75
1
81
1
2
1
21
5
8
8
2
23
21
10
1
6
1
79
1
19
1
60
69
1
82
81
71
3
81
2
27
26
27
27
82(a)
78
Med ian
<50
<50
<2
9
370
150
21!
Itl
0.3
66
<50
9
<50
260
ND
5
ND
< 1 0
< 1 0
ND
ND
ND
< 1 0
ND
ND
37
ND
< 1 0
ND
<5
< 1 0
ND
13
ND
ND
ND
< 1 0
ND
ND
ND
ND
< 1 0
< 1 0
ND
ND
ND
ND
21
ND
ND
ND
< 1 0
< 1 0
ND
< 1 0
16
10
ND
1 1
ND
ISO
llltO
2140
130
0.05
140
Ranqe
<50
<50
<2
<2
63
35
< 1 0
<20
<0.2
< 1 0
<50
<2
<50
23
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
ND
< 1 0
ND
ND
ND
ND
ND
80
180
39
77
<0.006
18
- <50
- <50
- <2
- 140
- 1,1400
- 860
- 1,300
- 220
- 0.8
- 350
- <50
- 18
- <50
- 500
-
-------
TABLE 22-2. CONCENTRATIONS OF TOXIC AND CLASSICAL POLLUTANTS FOUND IN THE
RAW WASTEWATER ENTERING POTW B [2-61]
Pol lutant
Toxic pol lutant, ug/L
Metals and inorganics
Ant i mony
Arsen i c
Be ry 1 1 i urn
Cadm i urn
Chromi urn
Coppe r
Cyanide
Lead
Me rcury
Nickel
Se 1 en i urn
Si Iver
Tha 1 1 i urn
Zinc
Phtha 1 a tes
Bi s(2-ethylhexy 1 ) phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
Diethyl phthalate
Dimethyl phthalate
Di-n-octyl phthalate
Phenols
Pentachlorophenol
Phenol
Aroma t ics
Benzene
Ch 1 orobenzene
1 ,2-Dichl orobenzene
1 , 3-D ichl orobenzene
1 ,i)-Dichlorobenzene
2, 6-Di n i t roto 1 uene
Ethylbenzene
To 1 uene
Po 1 ycyc 1 i c aromatic hydrocarbons
Anthracene
F luoranthene
Naphtha lene
Phenanthrene
Pyrene
Halogenated aliphatics
Ch 1 orod i b romome thane
Ch 1 o reform
D ich 1 o rob romome thane
1 , 1 -D i ch 1 o roe thane
1 ,2-Dichloroethane
1, l-Dichloroethy1ene
1 , 2-D ich 1 oropropane
Methylene chloride
Tet rach 1 o roe thy lene
1, 1 ,2-Trichloroethane
Pesticides and metabolites
1 sophorone
Classical pollutants, mg/L
BOD
COD
TOC
TSS
Pheno 1 s, tota 1
Oil and grease
Number of
samples
7
7
7
7
7
7
Ml
7
7
7
7
7
7
7
6
6
6
6
6
6
6
6
142
142
6
6
6
6
142
142
6
6
6
6
6
142
142
142
M2
142
142
142
142
142
142
6
7
7
7
7
142
140
Number of
detect i ons
0(a)
0(a)
0(a)
6(a)
7
7
3i4(a)
2(a)
5(a)
7
0(a)
2(a)
Ola)
7
6
6
5
5
3
14
1
14
31
2
5
1
1
1
18
32
3
3
14
3
3
3
140
"4
2
2
16
1
39
141
114
1
7
7
7
7
i40(a)
140
Med i a n
<50
<5>0
<2
14
67
55
66
<20
0.2
31
<50
<2
<50
300
1
< | o
< 1 0
< 1 0
<5
-------
11.23 REFERENCES FOR VOLUME II
2-1. NRDC Consent Decree - Industry Summary
2-2. U.S. Environmental Protection Agency. Technical support
document for auto and other laundries industry. Contract
No. 68/03/2550. Prepared for Effluent Guidelines Divi-
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2-4. U.S. Environmental Protection Agency. Development docu-
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Prepared for Effluent Guidelines Division, Office of Water
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440/1-81/057-b. Prepared for Effluent Guidelines Divi-
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and Waste Management, Washington, D.C.; 1979. 934 pp.
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Volume I.
Date: 1/24/83 R Change 2 II.23-1
-------
2-9. U.S. Environmental Protection Agency. Proposed develop-
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category, iron making subcategory. EPA-440/1-80/ 024-b.
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Volume II.
2-10. U.S. Environmental Protection Agency. Proposed develop-
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1980. 488 pp. Volume III.
2-11. U.S. Environmental Protection Agency. Proposed develop-
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1980. 374 pp. Volume IV.
2-12. U.S. Environmental Protection Agency. Proposed develop-
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Guidelines Division, Office of Water and Waste Management,
Washington D.C.; 1980. 512 pp. Volume V.
2-13. U.S. Environmental Protection Agency. Proposed develop-
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standards for the iron and steel manufacturing point
source category; cold forming subcategory, alkaline clean-
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1980. 576 pp. Volume VI.
2-14. U.S. Environmental Protection Agency. Proposed develop-
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standards for the leather tanning and finishing point
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Washington, D.C.; 1979. 381 pp.
Date: 1/24/83 R Change 2 II.23-2
-------
2-15. U.S. Environmental Protection Agency. Effluent guidelines
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1-80/073-a. Prepared for Effluent Guidelines Division,
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1980. 604 pp.
2-17. U.S. Environmental Protection Agency. Draft development
document for effluent limitations guidelines and standards
for the battery manufacturing point source category. EPA-
440/l-80/067a. Prepared for Effluent Guidelines Division,
Office of Water and Waste .Management, Washington, D.C.;
1980, 823 pp.
2-18. U.S. Environmental Protection Agency. Proposed develop-
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standards for the coil coating point source category.
EPA-440/l-81/071-b. Prepared for Effluent Guidelines
Division, Office of Water and Waste Management, Wash-
ington, D.C.; 1981. 481 pp.
2-19. U.S. Environmental Protection Agency. Draft development
document for effluent limitations guidelines and standards
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071-a. Prepared for Effluent Guidelines Division, Office
of Water and Waste Management, Washington, D.C.; 1979.
473 pp.
2-20. U.S. Environmental Protection Agency. Draft development
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for the electrical and electronic components point source
category. EPA-440/l-80/075-a. Prepared for Effluent
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Washington, D.C.; 1980. Variously paginated.
2-21. U.S. Environmental Protection Agency. Draft development
document for effluent limitations guidelines and standards
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category. EPA-440/l-80/070-a. Prepared for Effluent
Guidelines Division, Office of Water and Waste Management,
Washington, D.C.; 1980. 860 pp.
Date: 1/24/83 R Change 2 II.23-3
-------
2-22. U.S. Environmental Protection Agency. Draft development
document for effluent limitations guidelines and standards
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1-80/091-A. Prepared for Effluent Guidelines Division,
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1980. Variously paginated.
Updated with:
U.S. Environmental Protection- Agency. Proposed development
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1982.
2-23. U.S. Environmental Protection Agency. Proposed develop-
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standards for the electroplating point source category.
EPA-440/1-79/003. Prepared for Effluent Guidelines Divi-
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D.C.; 1979. 526 pp.
2-24. U.S. Environmental Protection Agency. Draft development
document for effluent limitations guidelines and standards
for the photographic equipment and supplies segment of the
photographic point source category. EPA-440/l-80/077-a.
Prepared for Effluent Guidelines Division, Office of Water
and Waste Management, Washington, D.C.; 1980. Variously
paginated.
2-25. U.S. Environmental Protection Agency. Proposed develop-
ment document for effluent limitations guidelines and
standards for the porcelain enameling point source cate-
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lines Division, Office of Water and Waste Management,
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2-26. U.S. Environmental Protection Agency. Draft development
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41FR10180, 1976.
Date: 1/24/83 R Change 2 II.23-4
-------
2-29. U.S. Environmental Protection Agency. Final development
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agents, dynamite, and pyrotechnics. Performed by Hydro-
science for the Effluent Guidelines Division, U.S. Environ-
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the best available technology, best demonstrated tech-
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chemicals point source category. Prepared by Environ-
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U.S. Environmental Protection Agency. Proposed develop-
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1980. Variously paginated.
2-33. U.S. Environmental Protection Agency. Effluent limita-
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1977.
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Bate: 1/24/83 R Change 2 II.23-5
-------
Guidelines Division, Office of Water and Waste Management,
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and standards for nonferrous metals. 40CFR421; 39FR12822,
April 8, 1974; Amended by 40FR8514, February 27, 1975;
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1976.
2-37. U.S. Environmental Protection Agency. Development docu-
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of Water and Hazardous Materials, Washington, D.C.; 1978.
913 pp.
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development document for BAT effluent limitations guide-
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2-41. U.S. Environmental Protection Agency. Draft engineering
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Date: 1/24/83 R Change 2 II.23-6
-------
Updated with:
U.S. Environmental Protection Agency. Proposed develop-
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July 28, 1975.
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Date: 1/24/83 R Change 2 II.23-7
-------
2-49. U.S. Environmental Protection Agency. Effluent guidelines
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[effective May 27, 1975]; and 43FR6230, February 14,
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Date: 1/24/83 R Change 2 II.23-8
-------
2-58. U.S. Environmental Protection Agency. Technical study
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U.S. Environmental Protection Agency. Final development
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pp.
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organic chemicals and plastics and synthetics. Prepared
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2-63. JRB Associates, Inc. Organic chemicals industry priority
pollutant data; data listings, descriptive statistics and
percent reduction. Memorandum, J. Ackermann, JRB, to C.
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Date: 1/24/83 R Change 2 II.23-9
-------
Chemical Society National Meeting, Division of Industrial
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classical pollutants. Contract 68-01-5011. Prepared for
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Management, Washington, D.C.; 1981. 10 pp.
2-67. JRB Associates, Inc. Priority pollutant analysis (with
supplemental data listing). Memorandum, J. Ackerman, JRB,
to M. Irizarry, EPA, 22 May, 1981; supplemented with
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2-68. Gile, Rexford R. 1982. Letter, Rexford R. Gile, EGD, to
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document for effluent limitations guidelines and standards
for the electrical and electronic components point source
category. EPA 440/1-82/075-b. Prepared for Effluent
Guidelines Division, Office of Water and Waste Management,
Washington, D.C.; 1982.
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guidelines and standards of performance for the ore mining
and dressing industry point source category - chemical
analyses data supplement B-l. Prepared for Effluent
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Washington, D.C.; 1978.
2-71. Jordan, J. William. 1975. Memorandum, J. William Jordan,
EGD, to Bruce P. Smith, 17 June 1975. 4 pp.
2-72. Miskimen, Thomas A. 1982. Letter, Thomas A. Miskimen,
Utility Water Act Group, to William A. Cawley, USEPA,
8 December 1982. 4 pp.
2-73. Utility Water Act Group. 1982. Utility Water Act Group
Comments on the draft revised treatability manual, 14 July
1982. Variously paginated.
U.S. GOVERNMENT PRINTING OFFICE : 1984 O - 432-454(Vol II)
Date: 1/24/83 R Change 2 11.23-10
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