-------
6fr-IIIA
Operation Labor (Manhours/yr)
M M I-" >
o o o <
O U) it»
Ass
umpt
ion
s
1
2
)
)
16
26
Hours c
0 Days c
f Op
f Op
>er£
)erj
iti
iti
^
or
OI
^
*-
i/
i/
<••
*•
Da)
Ye;
, *
*
r
ir
X
^^ l*^*
• ^
^
/
,
/
^,
/
(.
* 4
jr
/
•$>
/
/
$
> f
,& f~
<£" f A
c
&
'/ jf
'.£•
tf1 ffg
y%
/*/
§
*/
4
y
I
4
V
>
f
ft*
J
}
'
*
--y—
f
f
\'
in 100 io3 io4 10* 10
Flow Rate (1/hr)
FIGURE 8-23
SLUDGE DRYING BED LABOR REQUIRED FOR OPERATION
-------
ID-
Assumptions 1) 16 Hours of Operation/Day
2) 260 Days of Operation/Year
O
O
10
100
io
3
Plow Rate (1/hr)
FIGURE 8-24
10-
10'
SLUDGE DRYING BED LABOR REQUIRED FOR MAINTENANCE
-------
10
W)
10-
O
Q
O
< U
I—1 -P
JS 100
10
Assumptions 1) 16 Hours of Operation/Day
260 Days of Operation/Year
^
10J 10
Flow Rate (1/hr)
FIGURE 8-25
SLUDGE DRYING BEDS ANNUAL MATERIAL COST
-------
TABLE 8-6
COUNTERCURRENT RINSE (FOR OTHER THAN RECOVERY
OF EVAPOPRATIVE PLATING LOSS)
Number of Rinse Tanks 345
Investment 10,794 13,88 16,978
Annual Costs:
Capital Cost 909 1,170 1,430
Depreciation 2,158 2,777 3,396
Operation & Maintenance
Costs (Excluding Energy
& Power Costs) 27 12 8
Energy & Power Costs 511 682 851
Total Annual Cost $3,605 $4,641 $5,685
VIII-52
-------
Countercurrent Rinse Used for Recovery of Evaporative Plating
Loss - The costs of countercurrent rinsing with a rinse flow rate
sufficient to replace plating tank evaporative losses are presented
in Table 8-7. The results are tabulated for various evaporative
rates which are equal to the rinse water flow rates. Costing assump-
tions are:
A. Unit cost is based on a sufficient number of rinse
stages to replace the evaporative loss from a
plating bath at approximately 43 degrees C while
also maintaining a rinse ratio of 8,180.
B. Investment costs include open top stainless steel
tanks with a depth of 0.91 meters (3 feet), length
of 1.22 meters (4 feet), and width of 1.22 meters
(4 feet). All water and air piping, a blower on each
rinse tank for agitation, a liquid level controller,
solenoid, and pump are also included in the invest-
ment cost. Operation is assumed to be programmed
hoist and line conversion costs are included.
C. Operation and maintenance costs include a cost for
electricity for the blowers based on a capacity of
1,219 liters/min/sq. meter of tank surface area (4
cfm/sq. ft.) at a discharge pressure of 1,538
kg/sq. meter/meter of tank depth (1 psi/18 in.). A
fan efficiency of 60 percent is assumed. A water
charge is also included. Rinse maintenance charges
are assumed to be neglibible when compared to
normal plating line maintenance and are ignored.
Submerged Tube Evaporation - Submerged tube evaporation invest-
ment costs are shown for double effect units in Figure 8-26.
Costing assumptions are:
A. Unit size, power requirements, and operational
expenses (less energy and power) are based on data
supplied by the manufacturer for standard size
units.
B. Investment cost includes the basic evaporator and
bath purification device.
C. Evaporative heat of 583 cal/gram of wastewater is
required for single effect units, and 292 cal/gram
is required for double effect units. The heating
value of fuel is assumed to be 10,140 cal/gram
(Lower Heating Value (LHV), API of 30) with a heat
recovery of 85 percent.
VIII-53
-------
TABLE 8-7
COUNTERCURRENT RINSE USED FOR RECOVERY OF
EVAPORATIVE PLATING LOSS
Evaporative Rate
(Liters/Hr) 15.3 24.0 50.8
Investment $15,430 $12,736 $10,042
Annual Costs:
Capital Costs 1,301 1,074 847
Depreciation 3,086 2,547 2,008
Operation & iMaintenance
Costs (Excluding Energy
& Power Costs) 4.54 6.8 16.0
Energy & Power Costs 714 572 428
Total Annual Cost $ 5,105 $ 4,200 $ 3,300
Note: Savings due to recovery of plating solution are not
presented in this table.
VIII-54
-------
10
Investment Cost (Dollars - Aug. 79)
i— ' t— ' i— >
o o o
OJ *> Ul
10
«
•••M^BI
1
•••»
•Hi
_!
H*
5
« •
i»
100
• ••
io3 io4 io5 i
Flow Rate (1/hr)
FIGURE 8-26
SUBMERGED TUBE (DOUBLE EFFECT) EVAPORATOR INVESTMENT COST
-------
D., A cooling water charge is not included in the
operation and maintenance cost. A cooling water
circuit is assumed to already exist for the plant.
E,. The condensate is assumed to be pure with the per-
centage of condensate and concentrate flow split
96.33% evaporate and 3.67% concentrate is left.
Contract Removal
Sludge,, waste oils, and in some cases concentrated waste .solutions
frequently result from wastewater treatment processes. These may
be disposed of on-site by incineration, landfill or reclamation,
but are most often removed on a contract basis for off-site dis-
posal. System cost estimates presented in this report are based
on contract removal of sludges and waste oils. In addition,
where only small volumes of concentrated wastewater are produced,
contract-removal of off-site treatment may represent the most cost-
effective approach to water pollution abatement. Estimates of so-
lution contract haul costs are also provided by this subroutine
any may be selected in place of on-site treatment on a least-cost
basis,
Investment Costs. The investment for contract removal is zero.
Operating Costs. Annual costs are estimated for contract removal
of total waste streams or sludge and oil streams as specified in
input data. Sludge and oil removal costs are further divided into
wet and dry haulage depending upon whether or not upstream sludge
dewatering is provided. The use of wet haulage or sludge de-
watering and dry haulage is based on least cost as determined by
annualized system costs over a five year period. Wet haulage costs
are always used in batch treatment systems and when the volume of
the sludge stream is less than 378 liters per day (100 gpd).
Both wet sludge haulage and total waste haulage differ in cost de-
pending on the chemical composition of the waste removed. Wastes
are classified as cyanide bearing, hexavalent chromium bearing, or
oily and assigned different haulage costs as shown below.
Wasjte Composition Haulage Cost
M).05 mg/1 CN~ $.16/liter ($.60/gallon)
X).l mg/1 Cr ° $.18/liter ($.56/gallon)
Oil & grease XTSS $.08/liter ($.08/gallon)
All others $.06/liter ($.24/gallon)
Dry sludge haul costs are estimated at $0.08/liter gallon and
40% dry solids in the sludge.
TREATMENT SYSTEM COST ESTIMATES
This section presents estimates of the total cost of wastewater
treatment and control systems for metal finishing process waste-
water incorporating the treatment and control components discussed
VIII-56
-------
above. Flows in the Metal Finishing Category vary from approxi-
mately 378 to 3,785,000 liters/day (100 gpd to 1,000,000 gpd).
This wide variation in flow rate necessitates the presentation
of treatment system total annual cost curves for each option.
Total annual costs have been plotted against flow in units enabling
the determination of cost for any flow rate. Implicit in these
curves is the fact that from zero to 1892 liters/day (500 gpd) it
is most economical for a plant to have all wastewater hauled to
a licensed treatment facility. From this flow rate to 946,250
liters/day (250,000 gpd) an on-site batch treatment system is
most economical and above this flow, an on-site continous system
is cost-effective. All available flow data from industry data
collection portfolios were used in defining the raw waste flows.
Raw waste characteristics were determined based on sampling data
as discussed in Section V.
The system costs presented include component costs as discussed
above and subsidiary costs including engineering, line segrega-
tion, administration, and interest expenses during construction.
In developing cost estimates for these option systems, it is as-
sumed that none of the specified treatment and control measures
are in place so that the presented costs represent total costs
for the systems.
System Cost Estimates (Option 1)
This section presents the system cost estimates for the Option 1
end-of-pipe treatment systems. The representative flow rates used
in this option system cost estimates were determined as being
typical based upon actually sampled flows and flow information
received in the data collection portfolios. The complete system
block diagram is shown in Figure 8-27.
At different industry plants, different subcategories of waste may
or may not be present. To present costs applicable to a variety
of plants, five cases corresponding to five combinations of sub-
category waste flows are modeled for Options 1, 2, and 3. Table
8-8 presents these cases and the percentage of the total plant ef-
fluent that is assumed to come from each subcategory. The flow
percentages are based on the average subcategory flows in collected
data. Where there is no flow in a subcategory, unnecessary down-
stream treatment components are not costed.
The costing assumptions for each component of the Option 1 system
were discussed above under Technology Costs and Assumptions. In
addition to these components, contractor sludge removal was in-
cluded in all cost estimates.
Table 8-9 presents costs for various treatment system influent flow
rates. The basic cost elements used in preparing these tables are
the same as those presented for the individual technologies: invest-
ment, annual capital costs, annual depreciation, annual operations
and maintenance cost (less energy cost), energy cost, and total annual
cost. These elements were discussed in detail earlier in this section,
VIII-57
-------
I
(ji
oo
Oily Raw Waste
P
Emulsion
Breaking
Skimmed Oil
Raw Waste Raw Waste Raw Waste
Cyanide
Oxidation
Chromium
Reduction
Common
Metals
Clarifier
Sludge Sludge
Treated
Effluent
Sludge
Drying Beds
Raw Waste
Complexed
Metals
Clarifier
Treated
Effluent
Contractor
Removal
FIGURE 8-27
OPTION 1 SYSTEM
-------
TABLE 8-8
FLOW SPLIT CASES FOR OPTIONS 1, 2, AND 3
Case Subcategory Flows (% of total plant flow)
1
2
3
4
5
Oily
3i.5
30
30
Cyanide
7
6
4.5
4
Chromium
13
12.5
9
9
Common
Metals
80
75. 5
55
70
52. 5
Complex
Metals
6
4.5
VIII-59
-------
TABLE 8-9
Option 1 Costs
I
o>
o
Case
Number
i
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
f.
5
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
CCNTNUOS
CONTNUOS
CCNTNUOS
BATCH
BATCH
BATCH
BATCH
BATCH .
BATCH
BATCH
BATCH
BATCH .. . .
BATCH
BATCH
B4TCH
BATCH
BATCH
BATCH
CONTNUOS
CONTNUDS -
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS...
CONTNUOS
CCNTN'JOS
CONTNUOS
CONTNUOS .
CCNTNUOS
CONTNUOS
CCNTNUOS
CONTNUQS
CONTNUOS
<^
112.
112.
96 .
60.
112.
9933.
9974.
9974.
9980.
9934.
9933.
9974.
9974.
9930.
9984.
49990.
49920.
49940.
50000.
49940.
499900.
499500.
..499500....
500000.
499500.
49990.
... 49920...
49940.
50000.
49940.
....250000. .
250200.
249400.
250000.
..249700.
499900.
499500.
499500.
...500000...
499500.
Oj"
^
26.49
26.49
22.71
13.92
26.49
2362.79
2359.47
2359.47
2360.89
2361.84
2362.79
2359.47
2359.47
2360.69
. ... 2361.84
11625.75
11609.20
11813.93
...11828.12
11813.93
118257.50
118162.87
..113162.87 .
118281.19
118162.87
11825.75
.... 11509.20
11813.93
11623.12
11813.93
. .59140.61 -
59137.92
53998.67
59140.62
... 59069.62.
113257.50
113162.87
113162.87
.118281.19 .
118162.37
V
2030
2311
2204
1575
2579
9719
11515
11515
7860
13283
105717
117139
171860
146209
182205
165434
203323
234423
244396
300921
653042
693373
. 903275
730753
942835
239930
273650
340831
255121
377953
414363
460006
599370
452535
. 641650
592316
6400SS
857717
6.3431.3
900905
<9*3>
^
.341
.236
.553
.539
.789
.328
.320
.320
.773
.020
.125
.750
.125
.000
.000
.937
.437
.250
.062.
.250
.875
.062
.500 .
.187
.562
.937
.250 -
.625
.312
.937
.125
.625
.562
.500
.437
.125
.125
.500
.500 ..
.250
CJ^v^
171.189
194.873
135.879
132.347
217.517
619.493
970.924
970.923'"
662.766
1119.969
8913.621
9876.773
14490.527
12327.719
15362.836
15635.012
17185.840
23981.227
2C648.539
25372.250
55061.687
53462.137
...76531.812. .
61613.375
79495.750
20234.062
23494.453
23737.312
21510. 4S8
31867.750
. 34937.312
33735.312
50536.250
33155.812
54101.125 .
49941.500
53969.375
72319.000
.. 53524.625
75960.375
"V <£*
? ^^
406.068
462.247
440.912
315.118
515.953
1943.865
..2303.064
2303.064
1572.155
2656.604
21143.422
23427.949
34372.023
29241.797
36441.000
37036.984
40765.687
56834.648
48979.211 .
60184.250
130608.562
136674.562
..181655.062.
146150.625
183567.062
47996.187
. 55730.047
68166.312
51024.262
75591.750
.. 62372.625
92001.312
119374.062
90507.062
. 126330.062
118463.187
123017.625
171543.500
126962.637
130181.000
"v *^*$
(V df5^
11456.066
11456.086
10740.527
6460.934
11723.371
823378.812
607664.562
807263.062
662929.250
COOC-26.187
12172.645
13906.711
13014.437
13153.102
14852.574
26464.777
27491.531
30439.703
23014.269
31514.512
195674.500
167330.750
240S66.1S7. .
140745.750
233598.562
27258.634
. 29744.953 .
32046.914
25897.957
34425.687
. 94406.062 .
99522.812-
121333.375
32815.250
120689.312
172930.875
168266.750
226793.375
. 148747.875
222268.750
^
<[
0.
0.
0.
0 ".'
0.
0.
0.
o.
0.
0.
357.
357.
364.
62.
363.
872.
853.
903.
511.
833.
6032.
6012.
. 6343.
5956.
6319.
323.
322.
355.
46.
352.
... 422.
414.
579.
233.
567.
545.
529.
859.
467 .
S35.
^
f
0
0
0
0
0
0
0
0
0
0
826
436
064
660
624
722
537
539
428
649
934
637
090.
230
098
941
306
356
732
939
435
413
711
660
508.
174
219
667
321
681
k /2>"s
^^
12033.340
12113.203
11367.316
6°CS.895
12456.844
826142.125
811133.500
810537.000
665164.187
804602.750
42587.512
47648.867
62241.051
54785.477
67019.937
60059.437
66296.500
112209.125
93153.375
117959.625
337377.687
390^30.125
505446.125
354466.437
507930.437
Q5S12.812
109291.687
129305.812
93479.375
142238.125
212633.375
230724.312
2°2323.375
211711.750
303688.000
341830.637
351332.937
471520.500
3 " ^ T 0 C. 500
479245.750
-------
For the cost computations, a least cost treatment system selection
was performed. This procedure calculated the costs for a batch
treatment system, a continuous treatment system, and haulaway of
the complete wastewater flow over a 5 year comparison period.
Figures 8-28 through 8-32 show the total annul costs for each case
shown in Table 8-8.
The various investment costs assume that the treatment system must
be specially constructed and include all subsidiary costs discussed
under the Cost Breakdown Factors segment of this section: It is
also assumed all plants operate 16 hours a day, 5 days per week, for
52 weeks per year (260 total days).
System Cost Estimates (Option 2)
System cost estimates of the effects of adding a multimedia filter
to the previously discussed end-of-pipe systems were developed
to provide Option 2 Treatment Cost Estimates. A schematic of the
System is shown in Figure 8-33. The cases used are the same as
those for Option 1 and are shown in Table 8-8. The costing assump-
tions for the multimedia filter were discussed above under the
technology costs and assumptions subsection.
Several flow rates were used for each case to effectively model a
wide spectrum of plant sites. Figures 8-34 through 8-38 present
the total annual costs for each case in Option 2.
Table 8-10 presents Option 2 treatment costs for construction of
the entire end-of-pipe system. These costs would be representative
of expenditures to be expected to attain Option 2 for a plant with
no treatment in place.
System Cost Estimates (Option 3)
The Option 3 system takes the Option 2 system and makes two signi-
ficant changes. First, a carbon adsorption bed is added after
the ultrafiltration to further reduce the discharge of oily wastes
and priority organics. The second change requires the closed loop
operation (zero discharge) of any processes using either cadmium
or lead. For costing purposes, an evaporative system has been
used with the condensate reused for rinsing and the concentrate
hauled for disposal. This may also be accomplished by other means
selected by the individual plants. Closed loop precipitation
with reuse of the treated water and licensed hauling of the sludge
or ion exchange, reuse of the water and treatment and hauling of
the regenerate solution are two possible options. The schematic
for the complete Option 3 is shown in Figure 8-39 and the total
annual cost curves for each case are shown in Figure 8-40 through
8-44. Table 8-11 presents a summary of the Option 3 costs.
VIII-61
-------
M
M
I
10
cr\
en
D
10
O
Q
-U
(fi
O
U
(0
D
c , n4
< 10
(0
-(J
O
10
100
io
10
10
10
10
Flow Rate (Ipd)
FIGURE 8-28
TOTAL ANNUAL COST vs FLOW RATE
FOR OPTION 1 TREATMENT SYSTEM, CASE 1
Haul
Batch
Continuous
-------
I
(Ti
00
o\
1 —
CTI
3
<
w 105
r-*
o
p
-p
o
u
rH
rtj
D
lio4
rH
4J
O
EH
103
1
00
/
X
/
/
/
^
y
X
^
^
103
x
y^
— •
/
w
i^*>
/
/
/
M
/
>
« •
X
/
>
.--^
104
... ^!
x
»
/
**•
^*
g^
1 ^
*
-^
_^^^
f *^
105
,«*»
^^
x*'
^
^
^
^
^
106
A
s
j*
*
/
10
Flow Rate (Ipd)
FIGURE 8-29
TOTAL ANNUAL COST VS FLOW RATE
FOR OPTION 1 TREATMENT SYSTEM, CASE 2
Haul
Batch
— — ————— Continuous
-------
CTl
cn
a
:,n5
rH
o
Q
O
a
rH
(13
a
? in4
4J
O
EH
in3
i
00
4
/
'
f
f
S
]
S
jr
i
LO3
J$
jf
S
j^
• «••
/
/
^
d •
]
>
/
/
. -^
LO4
A
^
y
**>*
^
**
*}P
rffl
^
«*
_^
j«rf^*
^ > **^
105
^.
r^
^
<
*•
^^
/^
» "
106
-------
10
X
.Ob
/
/
/x
^
y-
/
f
i
Flow Rate (Ipd)
FIGURE 8-31
TOTAL ANNUAL COST vs FLOW RATE
FOR OPTION 1 TREATMENT SYSTEM, CASE 4
Haul
Batch
Continuous
-------
J- W
*
r^
.
1
co IO5'
LJ i
m
M
r-H
o
5
4-1
lf\
0
u
M
m
D
c
£l04'
F-4j -*. VJ
m
5
o
tH
IO3
1
^^
r
:
zzz
1
—
_
i - ~:
— ,:
i __;
~ ~
ZZI
im
<^
_
~ -
—
~
::
: I
nn
~~\
.
^^**™^*^^^^
00
H
ZZI
~
HI
n
_
_
_
: ~
* ~
i :
±~
zz
^1
^
-.
j
unj
r^
~
~
_
_
_
••^•"•^™
EE
~
~
~
Z
I
__
.
zz
zz
Z
Z
Z
_
_
^
zz
H
__
__
,
_
_
B
~
~
_
_
_
_
_
ZI
ZH
~
~
-1
J
I
J
ZJ
~\
ZJ
ZJ
M
Z
_
_
.
E
u
i
_
_
_
_
.
_
z
~
_
_
_
_
^
.
~
~
__
_
__
_
.
,
.
R
;
_
_
.
_
.
Li
z
z
_
^
H
.
^
~
t
j
J
^
L
_
_
.
.
5
T
i
T
I
I
1
It
zt
i
T
i
I
T
1
It
If
±
T
T
I
T
I
I
5
t
t
I
I
t
I
£
r
r
I
I
I
I
I
£
r
r
r
I
I
r
1
t
i
^^
~ -I
i :
_ 7
HZ
m
~
^
~ i:
^
ZI2L
IZ^
±1
_
:" -
;
:
'
HH
.
, .
EZ
o3
B
•
H
_
_
^
r ~.
r~>
r?^:
±1
~
~
_
i —
"
~ :
HZ
: :
_
_
_
_
E3
~
~
_
Z
t
_
,
cz
_
~
~
~
z
_
,
zz
zz
~
_
—
__
__
__
_
R
z
~
_
_
_
_
-
,
z:
r:
_
_
-
_
_
.
~
_
_
_
__
_
_
.
B
~
~
_
_
:
_
:
_
~
L_
_
_
r
^
,
_
_
_
_
_
__
_
.
R
~
;
_
_
_
L
_
z
z
_
.
:
u.
r
_
_
_
_
_
_
.
.
B
;
~
L.
_
_
,
_
_
z
I
I
.
:
_
.
~
,
i
_
_
_
_
.
.
.
5
T
T
T
I
T
i
it
±
±
T
i
I
T
I
±
T
T
T
T
I
I
I
1
]
^3
1 -
I n
r ~
fcz
K
t
r
1 :
L i
L "
] -\
1— «rj
Cm
t
t
r
T —
J
]-
3 :
tzz
tzz
t
t
P
J
LO4
B
I~
~?
z_
_
_
_
_
:
: z
_
~
"^
~
_
_
_
~ ~
±H
cm
ZI
z:
_
_
_
j
3
2^
±;
~
z
_
_
.
.
zz
•M>
~
_
_
^
~
,
zz
_
__
__
_
^
j
3
HI
,
_
ZI
z:
~
~
~
__
^
r
~
n
_
z
__
_
_
.
.
3
3
J
_
_
_,
_
.
_
_
**
_
_
_
r
_
.
z
I
_
__
_
_
.
3
~
3
I
:
;
z
*•
_
u
r
.
z
I
:
.
_
a
±
31
T
±
I
I
I
zt
it
x
±
T
t
I
t
zt
±
±
i
T
±
I
I
1
T=g
T j
1
tul
t
D
-L- ****^^;
y "
n ^
1 i
tzz
tH
t
t
r
i —
3 —^
A
tzz:
tzz
tzz
t
t
t
io5
zzg
rn
^j
Zj
zj
IJ
^
z: ;
r^:
i ~
cz
ZI
_
_
_
_
:^z:
ZZZ
HZ
HJ
z:
_
_
L
L
3
ZJ
id
_j
i:
_
^
zz
zz
_
z
_
_
_
—
—
—
~
Z
__
[
3
^1
j
n
n
j
J
;
ZI
II
~
~
~
_
_
_
~
z:
~
t
t
f
[
3
J
J
1
I
:
-
:
z
z
z
d
1
,_
_
.
~
I
I
t
L
t
[
s
|T
±r
it
±r
44
S
1
Ztt
Irt
zrt
±t
it
±[
jl
n
J
Ztr
zrr
nj
q~t
m
m
ffl
ffl
ffl
ji -t
T
j
1 j
1 jr\
W-\
t
t
4
4 ;
J
itzz
Bzzz
4tm
tt
t
t
j —
IJ ;
4tZZZZ
TI ~
JtZZ
JEZH
It
t
t
IO6
3
Z]
~?\
23
±J
Z1
_
_
~
~z
L '
~
~
H
_
_
_
—
izz
ZI
LZ
~
t
t
3
2
±j
Z]
IJ
J
_
_
zz
zz
zz
z
z
_
_
tzz
zz
•
Zj
±
t
_:
^
t
3
j
j
n
J
I
_
.
~
~
~
__
__
j
_
—
~
~
~
~
~
L
3
j
j
1
J
:
.
.
_
z
z
I
^
_
_
~
z
I
I
t
L
[
[
35
n:
j:
±
T
I
J
J
_T
^i
T
II
-i
4
ii
3
i
—id
Zn
zn
iti
jj
±
±
ffl
ffl
"
J
±1
ij
t]
jj
4\
11
jj
ti
±j
±1
4J
jj
B
It
n
J
1
10
Flow Rate (Ipd)
FIGURE 8-32
TOTAL ANNUAL COST vs FLOW RATE
FOR OPTION 1 TREATMENT SYSTEM, CASE S
Haul
Batch
Continuous
-------
Oily Raw Waste
Raw Waste Raw Waste Raw Waste
Skimmed Oil
M
M
I
Emulsion
Breaking
Cyanide
Oxidation
Ultrafi1trat ion
Oil
Chromium
Reduction
Common
Metals
Clarifier
Sludge Sludge
Multimedia
Filter
Sludge
Sludge
Drying Beds
Treated
Effluent
Raw Waste
Complexed
Metals
Clarifier
Sludge
Multimedia
Filter
Contractor
Removal
Treated
Effluent
FIGURE 8-33
OPTION 2 SYSTEM
-------
10'
IJI
o
10-
X
I
o
EH
10
100
io
10
10
10
10
Flow Rate (Ipd)
FIGURE 8-34
TOTAL ANNUAL COST vs FLOW RATE
FOR OPTION 2 TREATMENT SYSTEM, CASE 1
Haul
Batch
Continuous
-------
a\
F-
^
en
3
<
to 105
u
(0
r-H
rH
O
Q
4J
Ul
O
U
rH
03
D
c , n4
< 10
1-1
nj
jJ
O
EH
103
1
4
/
/
/
/
/
A
y
S
S
S
r
^
/
r
BV>
/
i—
/
«
/
/
^
»<
X
/
r
t
*~~*
/
/
• •""
/
^f
rf*1
^
1
—
J
«
;5
?>
00 103 104 105
Flow Rate (Ipd)
FIGURE 8-35
**
,
^
i
/
#*
X
106
"— Ba
s
_^i
f
t
107
ul
tch
TOTAL ANNUAL COST vs FLOW RATE
FOR OPTION 2 TREATMENT SYSTEM, CASE 2
-------
M
I
10
3
-------
10
O
Q
^
io5
103
1
A
y
'
/
/
/
/
/
/
^-
^
f
f
•— •
•-J
/
^»
/
^
A
.. •
00 IO3
y
S
A
- - -
• *"•"
S
/
^~
^^
^
„
^P
•*•
^
1
IO4 IO5
Flow Rate (Ipd)
FIGURE 8-37
s
^
^
^f
s
s
t
IO6
. ~ Ba
— — — — Co
-f-
10
ul
tch
ntinuous
TOTAL ANNUAL COST VS FLOW RATE
FOR OPTION 2 TREATMENT SYSTEM, CASE 4
-------
10'
Vf
en
10
a
0
EH
10
10
10
Flow Rate (Ipd)
FIGURE 8-38
TOTAL ANNUAL COST vs FLOW RATE
FOR OPTION 2 TREATMENT SYSTEM, CASE 5
Haul
Batch
Continuous
-------
I
-o
TABLE 8-10
Option 2 Costs
&
Case
Number
i
2
3
4
5
1 „
2
3
4
5..
1.
c
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
1
2
3
4
5
CONTNUOS
CONTKUOS .
CONTNUOS
CONTNUOS
CONTNUOS
CQNTKUOS
CONTKUOS
CONTNUOS
CONTNUOS
„ .... CCNTNUOS .
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
CCNTNUOS
CONTKUOS '"
CONTNUOS
CONTNUOS
CONTNUOS .
CONTNUOS
CCNTNUOS
CONTNUOS
CCNTNUOS
CONTNUOS
CONTNUOS
£?
112.
112. .
96.
80.
112.
Q9SS
9974.
9974.
9980.
9984..
9963.
9974.
9974.
.9960.,...
9984.
49990.
49920.
4°940....
50000.
49940.
499900.
. .493500...
499500.
500000.
499500.
.... 49990.
49920.
49940.
50000.
49940.
250000.'"
250200.
249400.
..250000.
249700.
499900.
499500.
...499500.
500000.
499500.
#
g&
26.49
26.49.
22.71
18.92
26.49
2362-.79
2359.47
2359.47
2360.89
2361.64
2362.79
2359.47
2359.47
2360 .69.
2361.84
11825.75
11809.20
... 11813.93
11828.12
11813.93
113257.50
118162.87
118162.87
113261.19
118162.87
11825.75
11809.20
11813.93
11828.12
11813.93
59140. 6f
59167.92
58998.67
.. 59140.62
59069.62
118257.50
118162.87
118162.67
118281.19
116162.87
\
^ .4?
*y
cr ^
171.189
.. .194.873
185.679
132.647
217.517
81Q 4°3
970.924
970.923
662.786
,. 1119.969..
10781.766
12004.133
20353.687
•15151,977
21358.641
20842.812
23057.953
... 37996,625
32226.750
39776.562
73341.812
75726.812
171052.125
146026.562
173027.937
25428.125
29350.437
43229.637
32258.750
46735.312
""46746.125"'
52550.625
100581.375
81529.000
103970.625
68221.000
75232.250
163537.500
140531.937
171199.750
ys-f
*Y
rSi
V
406
462
440
315
515
1Q43
2303
2303
1572
2656
25574
26474
48279
35.940
50663
49440
54694
....90129
76443
94351
173969
189114
405744
346332
410428
60316
69620
102543
76519
110353
110883
124652
238583
193391
246624
161322
178^54
399779
333346
406093
ti
&<$
.063
.247..
.912
.118
.953
.865..
.064
.064
.155
.604...
.699
.137
.625
.934
.359
.250
.464
.625.
.375
.750
.637
.937
.375
.137
.375
.750
.500
.000
.125
.062
.500
.250
.562
,500
.000
.812
.187
.000
.187
.750
•& <> V
7 •&•£
d^^
11456.086
... 11456.086
10740.527
6460.934
11723.371
623378.812...
807864.562
807263.062
662929.250
. 600826.187....
16699.363
27020.547
30366.090
24947,555
33543.395
33069.832
40603.656
54657.434
45006.223
62093.395
214803.687
212275.250
276321.000
174366.437
275397.625
33363.754
42357.062
56284.410
46751.320
65028.461
106640.125
117828.250
152902.937
111936.375
158453.437
192060.062
193611.250
262950.937
181400.062
264756.750
j
4
0
0
0
0
0
o
0
0
0
0
696
1034
803
497
1136
1211
1530
1653
1331
1963
6969
7251
11243
10689
11351
662
999
1282
947
1592
1029
1337
4007
3536
4182
1481
1767
7483
6347
7514
*cP^
.0
.0 ,
.0
.0
.0
.0
.0
.0
.0
.0
.499
.731
.530
.55.9.
.995
.395
.832
.354
.639
.534
.145
.406
.035
.660
.078
.613
.652
.473
.615
.542
.454
.344
.601
.147
.660
.336
.991
.133
.422
.332
^ N^v
^V
12033.340
.. 12113.203
11367.316
6903.695
12456.844
626142.125
811136.500
610537.000
665164.137
804602.750
55752.324
63533.562
99G02.937
76533 ,000
111707.312
104564.250
119386.937
184441.937
155008.125
198190.187
469034.312
438368.375
664360.500
677-464.812
370705.000
120271.137
142327.625
203339.500
156476.750
224214.312
265299.137
296363.437
496075.437
390393.000
513230.687
423535.137
4'4Q265.625
838750.562
662125.562
849564.562
-------
Oily Raw Waste
Raw Waste Raw Waste Raw Waste
Skimmed Oils
Emulsion
Breaking
Cyanide
Oxidation
Ultrafiltration
Oil
Carbon
Adsorption
I
Chromium
Reduction
Common
Metals
Clarifier
Sludge
Multimedia
Filter
Sludge
Sludge
Sludge
Drying Beds
Raw Waste
Complexed
Metals
Clarifier
Sludge
Multimedia
Filter
Treated
Effluent
Contractor
Removal
Treated
Effluent
FIGURE 8-39
OPTION 3 SYSTEM
-------
CTl
r~
en
D
X
>x
1 ^"IT*1**11"* •
103
s
jf
jr
m <^"
jr
— —
x
^»
/
«
/
.
^
«i»
>
/
s
^
.— •"
104
jt
^*"
-f
-,
^
"
r.-
^
.^
^^
X
io5
'P
x^
^
•
^
4
]
4 4
f
LO6
^
j^-
1
Flow Rate (Ipd)
FIGURE 8-40
TOTAL ANNUAL COST VS FLOW RATE
FOR OPTION 3 TREATMENT SYSTEM, CASE 1
Haul
Batch
Continuous
-------
en
cn
in 105
o
Q
o
u
D
?m«
4J
O
E-i
in3
i
00
*
/
/
/
/
.t
'
jt
/
s—
t
103
/
/"
/"
x1^
/
/
/
^
]
/
/
'
. — ••
LO4
X
/
— •
yX
^ -
^>
^"
^
^^*
^^"
LO5
^x^1
^*»
X
^
-^
*x
4
^
^ ^
y*'
x
»
106
.
/
/
f
10
Flow Rate (Ipd)
FIGURE 8-41
TOTAL ANNUAL COST vs FLOW RATE
FOR OPTION 3 TREATMENT SYSTEM, CASE 2
Haul
Batch
Continuous
-------
CTv
r~
CT>
D
<
1 ,.
W 10
iH
0
Q
4J
< 8
M
H rH
w (0
1 D
-> C
"*J r* A
< IQ
4J
o
E-<
103
1
00
X
/
/
'
'
]
____^__
X
X
LO3
./
S
/*—
f
/
'
_
x
]
y
y^
— •— •
LO4
S
x
~~
f
—
^
^
X
f***'
-**
^ '^
105
-
«*
4
K
X
4
^
]
— ^2-
9^
^*
.O6
10'
Flow Rate (Ipd)
FIGURE 8-42
TOTAL ANNUAL COST VS FLOW RATE
FOR OPTION 3 TREATMENT SYSTEM, CASE 3
Haul
Batch
Continuous
-------
00
-------
O>
cn
D
cn 105
O
4-1
O
rH
D
1 in4
4-1
0
E-t
3 0
1
00
4
/
/
,
/
/
\
*
s
/
s
103
X
>*•
f
f
,
/
^
^
/
/
/
<'
,
*•
104
_/
yT
..--
yr
'
-"
**
,
*«
.'^
105
r>>
^
^»
^
^
/
^
106
10'
Flow Rate (Ipd)
FIGURE 8-44
TOTAL ANNUAL COST vs FLOW RATE
FOR OPTION 3 TREATMENT SYSTEM, CASE 5
Haul
Batch
——«•——• Continuous
-------
I
oo
o
TABLE 8-11
Option 3 Costs
~.
Case
Number
i
2
3
^
5
1
2
3
4
5
1
i>
3
4
5
1
2
3
4
5
1
2
3
^
5
1
2
3
5
1
2
3
4
5
1
2
3
4
5
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
CCNTNUOS
„ CONTNUOS
CONTNUOS
CONTNUOS
BATCH
_ ,,. ..BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
BATCH
CONTNUOS
CONTNUOS
CQNTNUQS
CONTNUOS
CONTNUOS
CONTNUOS
CQNTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
CONTNUOS
<£yd
112.
112.
96.
80.
112.
9988.
9974.
.- -9-974...
9980.
9984.
9938.
...9974....
9974.
9930.
9984.
...49990*
49920.
49940.
50000.
49940.
499900.
499500.
499500.
500000. .
499500.
49990.
49920.
, .,.49940....
50000.
49940.
250000.
...250200...
249400.
250000.
249700.
...,49.9900......
499500.
499500.
500000.
499500.
Of
<^
26.49
£6.49
22.71
.18.92
26.49
2362.79
2359.47
... -2359.47
2360.89
2361.84
2362.79
2359.47.
2359.47
2360.89
2361.84
11825.75.
11809.20
11813.93
11828.12
11813.93
118257.50
118162.67
118162.87
...118281.19
118162.87
11825.75
11609.20
.„, 11813.93
11828.12
11813.93
59140.61
59187.92
58998.67
59140.62
59069.62
...118257.50.
118162.87
118162.87
118281.19
.....11816..2..8..7.
V Cy ' ^t
'/'^
2030.341
2311.236
2204.558
.... ..1575.589
2579.789
9719.328
11515.320
,- 11515.320
7860.773
13283.020
127873.500
...142370.687
313763.875
270967.437
324203.000
... 2472C1.250.
273472.437
591507.875
561072.875
..609319.187 .
869648.562
945574.937
2428303.00
2257360.00...
2442890.00
301583.750
343102.562
.643282.. 625..
572133.312
687192.375
554417.500
623261.437...
1462392.00
1333791.00
1496435.00
... 809114.312
892270.937
2379909.00
2164152.00
240 g.6 2 3.. 00...
?
c
171
194
185
132
217
819
970
970
662
1119
10781
.. 120C4
26455
22346
27335
. 20642
23057
49873
47307
.... 51417
73341
79726
204735
..1.S0330
205973
25428
29350
5466Q
43239
57940
46746
.525.50
123302
112830
126177
68221
75232
200663
182472
,.g.02578
.'
$<$
.189
.873
.879
.847 .
.517
.493
.924
.923
.786
.969
.766
.133
.227
.828
.902
.812..
.953
.137
.062
.187..
.812
.812
.562
.500
.125
.125
.437
.250...
.625
.937
.125
.625
.500
.812
.125
.000..
.250
.312
.125
,000
^f fr^
* <^^
406.068
462.247
440.912
315.118
515.958
1943.865
2303.064
... 2303.064
1572.155
2656.604
25574.699
£8474.137...
62752.773
54193.484
64841.593
. 49440.250
54694.484
118301.562
112214.562
, 121963.312
173969.687
169114.937
485760.562
..451472.. 000
433578.000
60316.750
69620.500
. 12.9656.500..
114426.625
137438.437
110833.500
124652.250 .
292478.375
267753.187
299297.000
...161822.812
178454.187
475981.750
432830.375
4805.24. 562 .
V
V c/
\_JV
11456.
11456.
10740.
.. 6460.
11723.
823378.
607664.
.607263.
662929.
600326.
18699.
.. 27020.
31335.
35713.
39540.
. .33069.
40603.
57509.
56291.
64857.
214S03.
212275.
fr<
'J?
N
086
066
527
.934 .
371
812
562
062
250
187
363
547
266
859
457
832 ..
656
246
371
305 ..
667
250
301051.625
..£04641.
299182.
33363.
42857.
59U3.
59176.
67770.
106640.
.. 117828.
166267.
131591.
171289.
192060,
193811.
237003.
212662.
287872.
375
937
754
062
398....
922
312
125
250...
500
187
375
062
250
562
437
000
/ •&
-------
Use of ccrglE: Estimation Results
Cost estimates presented in the tables and figures in this section are
representative of costs typically incurred in implementing treatment
and control equivalent to the specified options. They will not, in
general, correspond precisely to cost experience at any individual
plant. Specific plant conditions such as age, location, plant layout,
or present production and treatment practices may yield costs which
are either higher or lower than the presented costs. Because the costs
shown are total system costs and do not assume any treatment in place,
it is probable that most plants will require smaller expenditures to
reach the specified levels of control from their present status.
The actual costs of installing and operating a system at a particular
plant may be substantially lower than the tabulated values. Reductions
in investment and operating costs are possible in several areas. De-
sign and installation costs may be reduced by using plant workers.
Equipment costs may be reduced by using or modifying existing equip-
ment instead of purchasing all new equipment. Application of an excess
capacity factor, which increases the size of most equipment foundation
costs could be reduced if an existing concrete pad or floor can be uti-
lized. Equipment size requirements may be reduced by the use of treat-
ment (for example, shorter retention time) of particular waste streams.
Substantial reduction in both investment and operating cost may be
achieved if a plant reduces its water use rate below that assumed in
costing.
IN-PROCESS FLOW REDUCTIONS
The use of in-process techniques to achieve reductions in waste flows
can result in significantly reduced operating and maintenance costs.
Although an additional initial investment will be required for a
countercurrent rinse or other flow reducing equipment, downstream
treatment components may be sized for smaller flows. This reduces the
initial investment for downstream treatment components.
ENERGY AND NON-WATER QUALITY ASPECTS
Energy and non-water quality apsects of the wastewater treatment tech-
nologies described in Section VII are summarized in Tables 8-12 and 8-13.
Energy requirements are listed, the impact on environmental air and noise
pollution is noted, and solid waste generation characteristics are sum-
marized. The treatment processes are divided into two groups, waste-
water treatment processes on Table 8-12 and sludge and solids handling
processes on Table 8-13.
Energy Aspects
Energy aspects of the wastewater treatment processes are important
because of the impact of energy use on our natural resources and on
the economy. Electrical power and fuel requirements (coal, oil, or gas)
are listed in units of kilowatt hours per ton of dry solids for sludge
and solids handling. Specific energy uses are noted in the "Remarks"
column.
VIli-81
-------
TABLE 8-12
NON-WATER QUALTY ASPECTS OF WASTEWATER TREATMENT
PROCESS
ENERGY REQUIREMENTS
NON-WATER QUALITY IMPACT
Chemical Reduction
Skimming
Clarification
Chemical Precipitation
Sedimentation
Reverse Osmosis
Ultraf iltrat ion
Electrochemical
Chromium Reduction
Chemical oxidation
by Chloride
Chemical Emulsion
Breaking
Deep Bed Filtration
Carbon Adsorption
Throwaway
Evaporation
Countercurrent Rinse
Power
kwh
00 liters
1.0
0.01-.3
0.1-3.2
1.02
0.1-3.2
3.0
1.25-3.0
0.2-0.8
4.4-9.6
.1-3.2
.02-1.0
Fuel Energy
kwh use
1000 liters
— ' — Mixing
Skimmer Drive
Sludge Collec-
tor Drive
Flocculation
Paddles
Sludge Collector
Drive
High Pressure
Pump
High Pressure
Pump
— Reactifier, Pump
Mixing
Mixer, Skimmer,
Sludqe Pump
ue.;u, jJackwash
Air
Pollution
Impact
None
None
None
None
None
None
None
None
None
None
None
Noise
Pollution
Impact
None
None
None
None
None
Not
Objectionable
Not
Objectionable
None
None
Hot
Objectionable
None
Solid
Waste
None
Concentrated
Concentrated
Concentrated
Concentrated
Dilute
Concentrate
Dilute
Concentrate
Concentrate
None
Concentrated
Concentrated
Solid Waste
Concentration
* Dry Solids
5-50 (oil)
1-10
3-10
1-3
1-40
1-40
1-3
1-3 (TSS)
Variable
.'U8
Pumps
Head, Backwash
Pumps
2,500,000 Evaporation
Negligible
None None
Depends On
Volatiles
Present
None
None
Concentrated
Concentrated
None
Variable
50-100
-------
TABLE 8-13
NON-WATER QUALITY ASPECTS OF SLUDGE AND SOLIDS HANDLING
PROCESS
ENERGY REQUIREMENTS
NON-WATER QUALITY IMPACT
<2
M
M
l-l
1
00
OJ
Sludge
Thickening
Pressure
Filtration
Vacuum
Filter
Centrifugation
Landfill
Lagooning
Sand Bed Drying
rower
kwh
ton dry solids
29-930
21
16.7-
66 .*8
0.2-
98.5
- —
Fuel Energy
kwh Use
ton dry solids
— Skimmer,
Sludge Rake
Drive
High Pressure
Pumps
Vacuum Pump,
Rotation
Rotation
20-980 Haul, Land-
fill 1-10
Mile Trip
36 Removal
Equipment
25 Removal
Equipment
Air
Pollution
Impact
None
None
None
None
None
None
None
Noise
Pollution
Impact
None
None
Not
Objectionable
Not
Objectionable
None
None
None
Solid
Waste
Concentrated
Dewatered
Dewatered
Dewatered
Dewatered
Dewatered
Dewatered
Solid Wa
Concentr
* Ttrv Sf
o LJLy tj*—
4-27
25-50
12-40
15-50
N/A
3-5
15-40
Solid Waste
Disposal
Technique
Dewater & Landfill
or Incinerate
Landfill or Incinerate
Landfill or Incinerate
Landfill or Incinerate
N/A
Dewater & Landfill
Landfill
-------
Energy requirements are generally low, although evaporation can be
an exception if no waste heat is available at the plant. Thus,
if evaporation is used to avoid discharge of pollutants, the in-
fluent water rate should be minimized. For example, an upstream
reverse osmosis or ultrafiltration unit can drastically reduce
the flow rate of wastewater to an evaporation device.
Non-Water Quality Aspects
It is important to consider the impact of each treatment process
on air, noise, and radiation pollution of the environment to pre-
clude the development of a more adverse environmental impact.
In general, none of the liquid handling processes causes air pol-
lution. Alkaline chlorination for cyanide destruction and chromium
reduction using sulfur dioxide also have potential atmospheric
emissions. With proper design and operation, however, air pollu-
tion impacts are eliminated. Incineration of sludges or solids
can cause significant air pollution which must be controlled by
suitable bag houses, scrubbers, or stack gas precipitators as well
as proper incinerator operation and maintenance. Care must be taken
to insure that solids collected in air pollution control do not
become a water pollution threat. None of the wastewater treatment
processes causes objectionable noise and none of the treatment
processes has any potential for radioactive radiation hazards.
The solids waste impact of each sludge dewatering process is
indicated in two columns on Table 8-13 . The first column shows
whether effluent solids are to be expected and, if so, the solids
content in qualitiative terms. The second column lists typical
values of percent solids of sludge or residue. The third column
indicates the ususal method of solids disposal associated with
the process.
The processes for treating the wastewaters from this category pro-
duce considerable volumes of sludges. In order to ensure long-term
protection of the environment from harmful sludge constituents,
special consideration of disposal sites should be made by RDRA and
municipal authorities where applicable. All landfill sites should
be selected to prevent horizontal and vertical migration of these
contaminants to ground or surface waters. In cases where geologi-
cal conditions may not be expected to prevent this, adequate me-
chanical precautions (e.g., impervious liners) should be used for
long-term protection of the environment. A program of routine
periodic sampling and analysis of leachates is advisable. Where
appropriate, the location of solid hazardous materials disposal
sites should be permanently recorded in the appropriate office of
legal jurisdiction.
VIII-84
-------
SECTION IX
BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
AVAILABLE, GUIDELINES AND LIMITATIONS
These limitations will be developed at a later date,
IX-1
-------
SECTION X
BEST AVAILABLE TECHNOLOGY ECOMONICALLY
ACHIEVABLE, GUIDELINES AND LIMITATIONS
These limitations will be developed at a later date.
X-l
-------
SECTION XI
NEW SOURCE PERFORMANCE STANDARDS
These limitations will be developed at a later date.
XI-1
-------
SECTION XII
PRETREATMENT
These limitations will be developed at a later date,
XII-1
-------
SECTION XIII
ACKNOWLEDGEMENTS
The Environmental Protection Agency was aided in the preparation
of this Development Document by Hamilton Standard, Division of
United Technologies Corporation. Hamilton Standard's effort was
managed by Mr. Daniel J. Lizdas, Mr. Walter M. Drake and Mr.
Robert W. Blaser. Mr. Jeffrey M. Wehner and Mr. Kenneth J.
Dresser directed the engineering activities and field operations
were under the direction of Mr. Richard Kearns.
Significant contributions were made by Eric Auerbach, Steven
Bauks, Lewis Hinman, Robert Lewis, Joel Parker, James Pietrzak,
Donald Smith, and Stephen Wendt. Data and information acquisition,
analysis, and processing were performed by Clark Anderson,
Michael Derewianka, Remy Halm, Robert Patulak, and John Vounatso.
Mr. Devereaux Barnes, Mr. J. Bill Hanson, and Mr. Richard Kinch
of the EPA's Effluent Guidelines Division served as Project
Officers during the preparation of limitations and the prepara-
tion of this document. Mr. Robert Schaffer, Director, Effluent
Guidelines Division, and Mr. G. Edward Stigall, Chief, Inorganics
Chemicals and Services Branch, offered guidance and suggestions
during this project.
Acknowledgement and appreciation is also given to Ms. Kaye Starr
and Ms. Carol Swann of the word processing staff, Mrs. Lynne
McDonnell, Ms. Lori Kucharzyk, and Ms. Kathy Maceyka of Hamilton
Standard, and those of the secretarial and administrative staff
of the Effluent Guidelines Division who worked so diligently to
prepare, edit, publish and distribute the manuscript.
Finally, appreciation is also extended to those metal finishing
industry associations and plants that participated in and con-
tributed data for the formulation of this document.
XIII-1
-------
SECTION XIV
REFERENCES
XIV-1
-------
OIL, SOLVENT, AND CHEMICAL RECOVERY
"A Low-Cost Answer to Oil Recycling?"
Factory Management, January 1977, pp. 32-33.
Bech, B.C., Giannini, A.P., and Ramirez, E.R.,
"Electrocoagulation Clarifies Food Wastewater", Reprinted
from Food Technology, Vol. 28, No. 2, 1974, pp. 18-22.
Belinke, Robert J., "Central Filtration for Coolants",
American Machinists, December 1976, pp. 86-88.
Bolster, Maurice, "How to Maintain Emulsion Coolant Systems",
Modern Machine Shop, March 1977, pp. 112-115.
Bowes, H. David, "In-House Solvent Reclamation Eliminates
Quality Problems at Low Cost", Plastics Design & Processing,
May 1978, pp. 20-32.
Chonisby, J. and Kuhn, D., "Practical Oil Reclamation,
Purification", Hydraulics & Pneumatics, April 1976, pp. 71-73.
Chua, John P-, "Coolant Filtration Systems",
Plant Engineering, December 23, 1976, pp. 46-51.
"Coolant Failure and How to Prevent It", Sun Coolant
Control Inc., Southfield, Mich.
"Coolant Tripler Tool Life", Modern Machine Shop,
June 1979, pp. 140-141.
Cutting and Grinding Fluids; Selection and Application,
American Society of Tool and Manufacturing Engineers,
Dearborn, Mich. 1967.
Dinius, B., "How to Choose an In-Plant Oil Reclamation System",
Hydraulics and Pneumatics, July 1978, pp. 62-64.
"Economic Impact of the Proposed Illinois Special Waste Hauling
Regulations (R76-10)", Illinois Institute of Environmental
Quality, Project No. 80.089, IIEQ Document No. 77/26,
October 1977.
Electrostatic Separation of Solids from Liquids", Filtration &
Separation, March/April 1977, pp. 140-144.
Ford, Davis L. , and Elton, Richard L., "Removal of Oil and Grease
from Industrial Wastewaters", Chemical Engineering/Deskbook Issue,
October 17, 1977, pp. 49-56.
XIV-2
-------
Hura, LCdr Myron, USN and Mittleman, John,
"High Capacity Oil-Water Separator", Naval Engineers Journal,
December 1977, pp. 55-62.
Johnson, Ross E. Jr., Wastewater Treatment and Oil Reclamation
at General Motors, Sb. Catherines, pp. 345-357.
Kellogg, Jack, "Cutting Oil and Coolant Reclamation Pays Its
Way at Twin Disc".
Kelley, Ralph, "The Use of Cutting Fluids and Their Effect on
Cutting Tools and Grinding Wheels in Solving Production Problems",
Cincinnati Milacron/Products Division.
Koury, Anthony J., and Gabel, M.K., and Wijenayake, Anton P.,
"Effect of Solid Film Lubricants on Tool Life", Journal of the
American Society of Lubrication Engineers, June 1979 Volume 35,6.,
pp. 315-316, "329-338.
Luthy, Richard G., and Sellech, Robert E., and Galloway, Terry R.,
"Removal of Emulsified Oil with Organic Coagulants and Dissolved
Air Flotation", Journal WPCF, February 1978, pp. 331-346.
Lutz-Nagey, Robert C., "Detroit Experimenters Reveal New Ways
to Save Cutting Oil", Production Engineering, June 1977, pp. 54-55,
"Making Recycling Work for You Through Proper Process Selection",
IBID, p. 10.
McNutt, J.E. and Swalheim. D.A., "Recovery and Re-use of Chemicals
in Plating Effluents", AES Illustrated Lecture Series,
American Electroplaters Society, Inc., Winter Park, FL, 1975.
Miranda, Julio G., "Designing Parallel-Plates Separators",
Chemical Engineering, January 31, 1977.
"Oil Audit and Reuse Manual for the Industrial Plant", Illinois
Institute of Natural Resources, Project No. 80.085, Document
No. 78/35, November 1978.
"Oil/Water Splitter Snags Emulsified Oil", Chemical Engineering.
July 18, 1977, p. 77.
Quanstrom, Richard L., "Central Coolant Systems-Closing the Loop
on Metalworking Fluids", Lubrication Engineering, January 1977,
Volume 33,1, pp. 14-19.
Rasquin, Edgar A. and Lynn, Scott and Hanson, Donald N.,
"Vacuum Steam Stripping of Volatile, Sparing Soluble Organic
Compounds from Water Streams", Indo Eng. Chemical Fundam.,
Vol. 17, No. 3, 1978, pp. 170-174.
"Recycling Etchant for Printed Circuits", Metal Finishing,
Metals and Plastics Publications Inc., Hackensack, NJ,
March 1972, pp. 42-43.
XIV-3
-------
Reininga, O.G. and Wagner, R.H. and Bonewitz,
"Thermopure for Processing Water-Oil Emulsions",
Wire Journal, October 1976, pp. 48-53.
"Selection of Lubricants for Drawing and Cleaning", Daniel Brewer,
Ceramic Industry Magazine, June 1978, pp. 34-35.
Seng, W.C. and Kreutzer, G.M., "Resume of Total Operation of
Waste Treatment Facility for Animal and Vegetable Oil Refinery",
Reprinted from the Journal of the American Oil Chemists' Society,
Volume 52, No. 1, 1975, pp. 9A-13A.
Shah, B. and Langdon, W., and Wasan, D., "Regeneration of Fibrous
Bed Coalescers for Oil-Water Separation", Environmental Science
and Technology, Volume 11, No. 2, February 1977, pp. 167-170.
Sutcliffe, T. and Barber, S.J., "How to Select a Water-Base
Coolant", American Machinist, April 1977.
"System Strips Solvents, Separates Solids Simultaneously",
Chemical Engineering, November 22, 1976, pp. 93-94.
Taylor, J.W., "Evaluation of Filter/Separators and Centrifuges
for Effects on Properties of Steam Turbine Lubricating Oils",
Journal of Testing and Evaluation, Volume 5, No. 5, September 1977,
pp. 401-405.
Teale, James M., "Fast Payout from In-Plant Recovery of Spent
Solvents", Chemical Engineering, January 31, 1977, pp. 98-100.
"The First Step-Reducing Waste Oil Generation", IBID, p. 16.
"Used Oil Recycling in Illinois", Data Book, Illinois Institue
of Natural Resources, Project No. 80.085, Document No. 78/34,
October, 1978.
"Waste Oil Reclamation", The Works Managers Guide to Working
Fluid Economy, Alfa-Laval No. 1B40494 E2.
"Waste Oil Recycling - Coming Up a Winner", Fluid and Lubricant
Ideas, Volume 2, Issue 3, Summer 1979, p. 8.
Vucich, M.G., "Emulsion Control and Oil Recovery on the Lubricating
System of Double-Reduction Mills", Iron and Steel Engineer,
December 1976, pp. 29-38.
XIV-4
-------
PLATING AND COATING
Adams, F. "Getting the Most Out of Vacuum Metalizing",
Products Finishing, Gardner Publications Inc., Cincinnati,
Ohio, November,1917, pp. 43-51.
Allied Chemical Company and Aluminum Company of America,
"Chromic Acid Anodizing of Aluminum", AES Illustrated
Lecture Series, American Electroplaters Society, Inc.,
Winter Park, FL, 1973.
Baker, R. G. et al, "Gold Electroplating Part 2", AES
Illustrated Lecture Series, American Electroplaters Society,
Inc., Winter Park, FL, 1978.
Bellis, H.E. and Pearlstein, F., "Electroless Plating of Metals",
AES Illustrated Lecture Series, American Electroplaters Society
Inc., Winter Park, FL, 1972.
"Cheminator", Chemical Engineering, McGraw Hill, New York, NY,
Septermber, 1975, p. 26.
"Developments to Watch", Product Engineering, Morgan-Grampian,
New York, NY, October 1976, p. 5.
DiBari, G.A., "Practical Nickel Plating", AES Illustrated
Lecture Series, American Electroplaters Society, Inc., Winter
Park, FL, 1977.
Duva, R., "Gold Electroplating Part 1", AES Illustrated
Lecture Series, American Electroplaters Society, Inc., Winter
Park, FL, J977.
"Electroplating Engineering Handbook", Third Edition, edited
by A. Kenneth Graham, Van Nostrand Reinhold Company, New York,
NY, 1971.
"Electroplating - Fundamentals of Surface Finishing", Frederick
A. Lowenheim, McGraw-Hill, Inc., New York, NY, 1978.
General Motors Research Laboratories, "Factors Influencing
Plate Distribution", AES Illustrated Lecture Series, American
Electroplaters Society, Inc., Winter Park, FL, 1975.
Halva, C.J. and Rothschild, B.F., "Plating and Finishing of
Printed Wiring/Circuit Boards", AES Illustrated Lecture Series,
American Electroplaters Society, Inc., Winter Park, FL, 1976.
XIV-5
-------
Hubbell, F.N., "Chemically Deposited Composites - A new Gener-
ation of Electroless Coatings", Plating and Surface Finishing,
American Electroplaters Society, E. Orange, NJ, Vol. 65, Dec.
1978, p. 48.
"Ion Transfer Method Developed for Metal Plating", Industrial
Finishing, Hitchcock Publishing Co., Wheaton, Ohio, April 1979,
p. 95.
Logozzo, Arthur W., "Hard Chromium Plating", AES Illustrated
Lecture Series, American Electroplaters Society, Inc., Winter
Park, FL, 1973.
MacDermid, Inc., "Chromate Conversion Coatings" AES Illus-
trated Lecture Series, American Electroplaters Society, Inc.,
Winter Park, FL, 1970.
Mazzeo, D.A., "Energy Conservation In Plating and Surface
Finishing", Plating and Surface Finishing, American Electroplaters
Society, Inc., Winter Park, FL, July, 1979, pp. 10-12.
M&T Chemical Inc., "Decorative Chromium Plating", AES Illus-
trated Lecture Series, American Electroplaters Society, Inc.,
Winter Park, FL, 1972.
Mohler, J.B., "The Art and Science of Rinsing", AES Illustrated
Lecture Series, American Electroplaters Society, Inc., Winter
Park, FL, 1973.
Montgomery, D.C., "The Coloration of Anodic Coatings for
Architectural Applications by Using Organic Dyes", Plating
and Surface Finishing, American Electroplaters Society, E.
Orange, NJ, Vol. 65, Dec. 78, p. 48.
Ostraw, R. and Kessler, R.B., "A Technical and Economic Com-
parison of Cyanide and Cyanide-Free Zinc Plating", Plating,
American Electroplaters Society, Hackensack, NJ, April 1970.
Pearlstein, F., "Selection and Application of Inorganic Fini-
shes - Part 1", Plating and Surface Finishing, American Elec-
troplaters Society, E. Orange, NJ, Vol. 65, Dec. 1978., p. 32.
Pearlstein, F. et al, "Testing and Evaluation of Deposits",
AES Illutrated Lecture Series, American Electroplaters Society
Inc., Winter Park, FL, 1974.
Rajagopal, I., and Rajam, K.S., "A New Addition AgenV for
Lead Plating", Metal Finishing, Metals and Plastics Publi-
cation Inc., Hackensack, NJ, December, 1978.
XIV-6
-------
SURFACE PREPARATION
Axelson, William, "Specialized Cleaning Equipment Supports
Efficient Maintenance", Pit & Quauy, October 1976, pp. 95-98.
Bauks, S.V., and Dresser, K.J., Cleaning Alternatives to Solvent
Degreasing, EPA, December 7, 1878.
Jackson, Lloyd, C., "How to Select a Substrate Cleaning Solvent",
Adhesives Age, April 1977, pp. 23-31.
Jackson, Lloyd C., "Removal of Silicone Grease and Oil
Contaminants", Adhesives Age, April 1977, pp. 29-32.
Jackson, Lloyd C., "Solvent Cleaning Process Efficiency",
Adhesives Age, July 1976, pp. 31-34.
Maloney, J.E., "Low Temperature Cleaning", Metal Finishing,
June 1976, pp. 33-35.
Metal Cleaning Fundamentals, Materials and Methods, Oak'ite
Products, Inc., F 10646R13-379.
Metals Handbook, American Society for Metals, 8th Edition, Volume
2, "Heat Treating, Cleaning, and Finishing", 1964, pp. 307-314.
Mohler, J.B., "Guidelines for Cleaning Metal Parts", Plant
Engineering, October 2, 1975, pp. 93-95.
Obrzut, John J., "Metal Cleaning Bends with Social Presures",
Iron Age, February 17, 1974,, pp. 41-44.
Taller, R.A. and Koleske, J.V., "Energy Conservation in Metal
Pretreatment and Coating Operations", Metal Finishing,
August 1977, pp. 18-19.
Tonis, Paul G., "Try Steam Cleaning/Phosphatizing", Products
Finishing, January 1979, pp. 56-57.
SURFACE PREPARATION - ACID CLEANING
Frey, S.S. and Swalheim, D.A., "Cleaning and Pickling for
Electroplating", AES Illustrated Lecture Series, American
Electroplaters Society, Inc., Winter Park, FL, 1970.
Metals Handbook, American Society for Metals, 8th edition,
Volume 2, "Heat Treating, Cleaning and Finishing", 1964.
Rodzewich, Edward A., "Theory and Practice of Phosphating",
AES Illustrated Lecture Series, American Electroplaters
Society, Inc., Winter Park, FL, 1974.
Roebuck, A.H., "Safe Chemical Cleaning - The Organic Why",
Chemical Engineering, July 31, 1978, pp. 107-110. '
XIV-7
-------
SURFACE PREPARATION - ALKALINE CLEANING
Erichson, Paul R. and Throop, William M., "Alkaline Treatment
System Reduces Pollution Problems", Industrial Wastes, March/
April 1977.
Erichson, Paul R. and Throop, William M., "Improved Washing of
Machined Parts", Production Engineering, March 1977-
Graham, A. Kenneth, Electroplating Engineering Handbook, 1971,
pp. 152-176.
Metals Handbook, American Society for Metals, 8th Edition,
Volume 2, "Heat Treating, Cleaning and Finishing", 1964,
pp. 317-325.
SURFACE PREPARATION - EMULSION CLEANING
Connolly, James T., "Metal Cleaning with Emulsions - An Update",
Lubrication Engineering, December 1976, pp. 651-654.
Glover, Harry C., "Are Emulsified Solvents Safer Cleaners?",
Production Engineering, July 1978, pp. 41-43.
Metal Handbook, American Society for Metals, 8th Edition,
Volume 2, "Heat Treating, Cleaning and Finishing", 1964,
pp. 326-330.
SURFACE PREPARATION - VAPOR DECREASING
Bauks, S.V. and Dresser, K.J., Solvent Degreasing Unit Operation
Report, EPA, September 17, 1979.
Metals Handbook, American Society for Metals, 8th Edition,
Volume 2, "Heat Treating, Cleaning and Finishing", 1964,
pp. 334-340.
"Organic Solvent Cleaning-Background Information for Proposed
Standards", US EPA, EPA-450/2-78-045; May 1979.
Suprenant, K., "Vapor Degreasing or Alkaline Cleaning?",
Products Finishing, March 1979, pp. 67-71.
XIV-8
-------
TREATMENT
Barrett, F., "The Electroflotation of Organic Wastes",
Chemistry and Industry, October 16, 1976, pp. 880-882.
Chin, D.T., and Echert, B., "Destruction of Cyanide Wastes
with a Packed-Bed Electrode", Plating and Surface Finishing,
October 1976, pp. 38-41.
DeLatour, Christopher, "Magnetic Separation in Water Pollution
Control", IEEE Transactions on Magnetics, Volume Mag-9, No. 3,
September 1973, p. 314.
"Development Document for Proposed Exisiting Source Pretreat-
ment Standards for the Electroplating Point Source Category",
EPA 440/1-78/085. United States Environmental Protection
Agency, Washington, DC, 1978.
"Economic Analysis of Proposed Pretreatment Standards for
Existing Sources of the Electroplating Point Source Category",
EPA 230/1/78-001, United States Environmental Protection
Agency, Washington, DC. 1977.
"Electrotechnology Volume 1, Wastewater Treatment and Separation
Methods", Cheremisinoff, Paul N., King, John A., Oullette, Robert P.,
Ann Arbor Science Publishers, Inc., Ann Arbor, MI, 1978.
"Emerging Technologies for Treatment of Electroplating
Wastewaters", for presentation by Stinson, M.K., at AICHE
71st Annual Netting, Session 69, Miami Beach, Florida,
November 15, 1978.
Flynn, B.L. Jr., "Wet Air Oxidation of Waste Streams", CEP,
April 1979, pp. 66-69.
Grutsch, James F., "Wastewater Treatment: The Electrical
Connection", Environmental Science and Technology, Volume 12,
No. 9, Sept. 1978, pp. 1022-1027.
Grutsch, James F., and Mallatt, R.C., "Optimizing Granular
Media Filtration", GEP, April 1977, pp. 57-66.
"Handbook of Environmental Data on Organic Chemicals", Karel
Verschueren, Van Nostrand Reinhold Company, New York, NY 1977.
Henry, Joseph D. Jr., Lowler, Lee F., and Kuo, C.H. Alex,
"A Solid/Liquid Separation Process Based on Cross Flow and
Electrofiltration", AIChE Journal, Volume 23, No. 6, November
1977, pp. 851-859.
XIV-9
-------
Hochenberry, H.R. and Lieser, J.E., Practical Application
of Membrane Techniques of Waste Oil Treatmentf presented
at the 31st Annual Meeting in Philadelphia, Pennsylvania,
May 10-13, 1976, American Society of Lubrication Engineers,
Reprint Number 76-AM-28-2.
Humenich, Michael J. and Davis, Barry J., "High Rate
Filtration of Refinery Oily Wastewater Emulsions",
Journal WPCF, Agusut 1978, pp. 1953-1964.
"In Process Pollution Abatement - Upgrading Metal Finishing
Facilities to Reduce Pollution", EPA Technology Transfer Semi-
mar Publication, Environmental Protection Agency, July 1973.
Kaiser, Klaus L.E. and Lawrence, John, Polyelectrolytes;
Potential Chloroform Precursors, Environment Canada, Canada
Centre for Inland Waters, Burlington, Ontario, January 25, 1977.
Kitagewa, T. and Nishikawa, Y. and Frankenfeld, J.W. and Li,
N.N., "Wastewater Treatment by Liquid Membrane Process",
Environmental Science and Technology, Volume 11, No. 6,
June 1977, pp. 602-605.
Kolm, Henry H., "The Large-Scale Manipulation of Small Particles",
IEEE Transactions on Magnetics, Vol. Mag-11, No. 5, Sept. 1975,
pp. 1567-1569.
Lancy, L. E., "Metal Finishing Waste Treatment Aims Accomplished
by Process Changes", Chemical Engineering Progress Symposium
Series, Vol. 67, 1971, pp. 439-441.
Lancy, L.E. and Steward, F.A., "Disposal of Metal Finishing
Sludges - The Segregated Landfill Concept", Plating and Surface
Finishing, American Electroplaters Society, E. Orange, NJ,
Vol. 65, Dec. 1978. p. 14.
Lawes, B.C. and Stevens, W.F., "Treatment of Cyanide and
Chromate Rinses", AES Illustrated Lecture Series, American
Electroplaters Society, Inc., Winter Park, PL, 1972.
Lowder, L.R., "Modifications Improve Treatment of Plating Room
Wastes", Water and Sewage Works, Plenum Publishing Corp, New
York, NY, December, 1968. p. 581.
Oberteuffer, John A., "High Gradient Magnetic Separation",
IEEE Transaction on Magnetics, Volume Mag-9, No. 3,
September 1973, pp. 303-306.
Okamato, S., "Iron Hydroxide as Magnetic Scavengers",
Institute of Physical and Chemical Research, Waho-shi,
Saitama-hen, 351 Japan.
XIV-10
-------
Oulman, Charles S. and Baumann, Robert E., "Polyelectrolyte
Coatings for Filter Media", Industrial Water Engineering,
May 1971, pp. 22-25.
Pietrzak, J., Unit Operation Discharge Summary for the Mechanical
Products Category, EPA, September 7, 1979.
Pinto, Steven, D., Ultrafiltration for Dewatering of Waste
Emulsified Oils, Lubrication Challenges in Metalworking and
Processing Proceedings, First International Conference, IIT
Research Institute, Chicago, Illinois 60616, USA, June 7-9, 1978.
"Physiochemical Processes for Water Quality Control", Wiley-
Interscience Series, Walter, J. Weber, Jr., John Wiley and Sons
Inc., New York, NY 1972.
"Pollution Control 1978", Products Finishing, Gardner Publica-
tions, Inc., Cincinnati, Ohio, August, 1978, pp. 39-41.
Read, H.J., "Principles of Corrosion", AES Illustrated Lecture
Series, American Electroplaters Society, Inc., Winter Park,
FL, 1971.
Sachs, T.R., "Diversified Finisher. Handles Complex Waste
Treatment Problem", Plating and Surface Finishing, American
Electroplaters Society, E. Orange, NJ, Vol. 65, Dec. 1978, p. 36.
Shambaugh,Robert T. and Melhyh, Peter B., "Removal of Heavy
Metals via Ozonation", Journal WPCF, Jan. 1978, pp. 113-121.
Staebler, C.J. and Simpers, B.F., "Corrosion Resistant Coatings
with Low Water Pollution Potential", presented at the EPA/AES
First Annual Conference on Advanced Pollution Control for the
Metal Finishing Industry, Lake Buena Vista, FL, January 17-19, 1978,
Sundaram, T.R. and Santo, J.E., "Removal of Suspended and
Colloidal Solids from Waste Streams by the Use of Cross-Flow
Microfiltration", American Society of Mechanical Engineers,
77-ENAS-51.
"The Electrochemical Removal of Trace Metals for Metal Wastes
with Simultaneous Cyanide Destruction", for presentation by
H.S.A. Reactors Limited at the First annual EPA/AES Conference
on Advanced Pollution Control for the Metal Finishing Industry,
Dutch Inn, Lake Buena Vista, FL, Jan. 18, 1978.
Wahl, James R., Hayes, Thomas C., Kleper, Myles H., and Pinto,
Steven D., Ultrafiltration for Today's Oily Wastewaters;
A Survey of Current Ultrafiltration Systems, presented at the
34th Annual Purdue Industrial Waste Conference, May 8-10, 1979.
XIV-11
-------
Ukawa, Hiroshi, Koboyashi, Kaseimaza, and Iwata, Minoru
"Analysis of Batch Electrokinetic Filtration", Journal of
Chemical Engineering of Japan, Volume 9, No. 5, 1976,
pp. 396-401.
Robinson, G.T., "Powder Coating Replaces Zinc Plating for
Pulleys", Products Finishing, Gardner Pubications Inc.,
Cincinnati, OH, Feb. 1974, pp. 79-81.
"Semiconductor Technique Now to Plate Auto Parts", Machine
Design, Penton Publishing, Cleveland, OH, p. 18.
Spooner, R.C., "Sulfuric Acid Anodizing of Aluminum and Its
Alloys", AES Illustrated Lecture Series, American Electro-
platers Society, Inc., Winter Park, FL, 1969.
Swalheim, D.A. et al, "Cyanide Copper Plating", AES Illustrated
Lecture Series, American Electroplaters Society, Inc., Winter
Park, FL, 1969.
Swalheium, D.A. et al, "Zinc and Cadmium Plating", AES
Illustrated Lecture Series, American Electroplaters Society,
Inc., Winter Park, FL.
"Wooing Detroit with Cheaper Plated Plastic", Business Week,
McGraw-Hill Inc., New York City, NY, May 9, 1977, pp. 44c-44d.
Udylite Corporation, "Bright Acid Sulfate Copper Plating",
AES Illustrated Lecture Society, American Electroplaters Society,
Inc., Winter Park, FL, 1970.
XIV-12
-------
SECTION XV
GLOSSARY
Abrasive Belt Grinding - Roughing and/or finishing a workpiece by
means of a power-driven belt coated with an abrasive, usually
in particle form, which removes material by scratching the
surface.
Abrasive Belt Polishing - Finishing a workpiece with a power-driven
abrasive-coated belt in order to develop a very good finish.
Abrasive Blasting - (Surface treatment and cleaning.) Using dry or
wet abrasive particles under air pressure for short durations
of time to clean a metal surface.
Abrasive Cutoff - Severing a workpiece by means of a thin abrasive
wheel.
Abrasive Jet Machining - Removal of material from a workpiece by a
high-speed stream of abrasive particles carried by gas from a
nozzle.
Abrasive Machining - Used to accomplish heavy stock removal at high
rates by use of a free-cutting grinding wheel.
Acceleration - See Activation.
Acceptance Testing - A test, or series of tests, and inspections
that confirms product functioning in accordance with specified
requirements.
Acetic Acid - (Ethanoic acid, vinegar acid, methanecarboxylic acid)
CH3_COOH. Glacial acetic acid is the pure compound (99.8% rain.),
as distinguished from the usual water solutions known as acetic
acid. Vinegar is a dilute acetic acid.
Acid Cleaning - Using any acid for the purpose of cleaning any mater-
ial. Some methods of acid cleaning are pickling and oxidizing.
Acid Dip - An acidic solution for activating the workpiece surface
prior to electroplating in an acidic solution, especially after
the workpiece has been processed in an alkaline solution.
Acidity - The quantitative capacity of aqueous solutions to react
with hydroxyl ions. It is measured by titration with a standard
solution of a base to a specified end point. Usually expressed
as milligrams per liter of calcium carbonate.
XV-1
-------
Act - Federal Water Pollution Control Act Amendments of 1972.
Activitated Sludge Process - Removes organic matter from sewage by
saturating it with air and biological active sludge.
Activation - The process of treating a substance by heat, radiation
or the presence of another substance so that the first mentioned
substance will undergo chemical or physical change more rapidly
or completely.
Additive Circuitry - 1. Full - Circuitry produced by the buildup of
an electroless copper pattern upon an unclad board. 2. Semi -
Circuitry produced by the selective "quick" etch of an electro-
less layer; this copper layer was previously deposited on an
unclad board.
Administrator - Means the Administrator of the United States Environ-
mental Protection Agency.
Adsorption - The adhesion of an extremely thin layer of molecules
(as of gas, solids or liquids) to the surface of solid or
liquids with which they are in contact.
Aerobic - Living, active, or occurring only in the presence of oxygen.
Aerobic Biological Oxidation - Any waste treatment process utilizing
organisms in the presence of air or oxygen to reduce the pol-
lution load or oxygen demand of organic substance in water.
Aerobic Digestion - (Sludge Processing) The biochemical decomposition
of organic matter, by organisms living or active only in the
presence of oxygen, which results in the formation of mineral and
simpler organic compounds.
Aging - The change in properties (eg. increase in tensile strength and
hardness) that occurs in certain metals at atmospheric temperature
after heat treatment.
Agitation of Parts - The irregular movement given to parts when they
have been submerged in a plating or rinse solution.
Air Agitation - The agitation of a liquid medium through the use of
air pressure injected into the liquid.
Air Flotation - See Flotation
Air Pollution - The presence in the outdoor (ambient) atmosphere of one
air pollutants or any combination thereof in such quantities and
of such characteristics and duration as to be, or be likely to be,
injurious to public welfare, to the health of human, plant or
animal life, or to property, or as unreasonably to interfere with
the enjoyment of life and property.
XV-2
-------
Air-Liquid Interface - The boundary layer between the air and the
liquid in which mass transfer is diffusion controlled.
Aldehydes Group - A group of various highly reactive compounds
typified by actaldehyde and characterized by the group CHO.
Algicides - Chemicals for preventing the growth of algae.
Alkaline Cleaning - A process for cleaning basis material where
mineral and animal fats and oils must be removed from the
surface. Solutions at high temperatures containing casutic
soda, soda ash, alkaline silicates and alkaline phosphates
are commonly used.
Alkalinity - The capacity of water to neutralize acids, a property
imparted by the water's content of carbonates, bicarbonates,
hydroxides, and occasionally borates, silicates, and phosphates.
Alloy Steels - Steels with carbon content between 0.1% to 1.1% and
containing elements such as nickel, chromium, molybdenum and
vanadium. (The total of all such alloying elements in these type
steels is usually less than 5%.)
Aluminizing - Forming an aluminum or aluminum alloy coating on a metal
by hot dipping, hot spraying or diffusion.
Amines - A class of organic compounds of nitrogen that may be considered
as derived from ammonia (NH^) by replacing one or more of the
hydrogen atoms by organic radicals, such as CH^ or Cj>H_5, as in
methylamine and aniline. The former is a gas at ordinary tempera-
ture and pressure, but other amines are liquids or solids. All
amines are basic in nature and usually combine readily with hydro-
chloric or other strong acids to form salts.
Anaerobic Biological Treatment - Any waste treatment process utilizing
anaerobic or facultative organisms in the absence of air to
reduce the organic matter in water.
Anaerobic Digestion - The process of allowing sludges to decompose
naturally in heated tanks without a supply of oxygen.
Anaerobic Waste Treatment - (Sludge Processing)' Waste stabilization
brought about through the action of microorganisms in the absence
of air or elemental oxygen.
Anhydrous - Containing no water.
Anions - The negatively charged ions in solution, e.g., hydroxyl.
Annealing - A process for preventing brittleness in a metal part.
The process consists of raising the temperature of the metal
to a pre-established level and slowly cooling the steel at a
prescribed rate.
XV-3
-------
Annual Capital Recovery Cost - Allocates the initial investment and
the interest to the total operating cost. The capital recovery
cost is equal to the initial investment multiplied by the capital
recovery factor.
Anode - The positively charged electrode in an electrochemical process.
Anodizing - The production of a protective oxide film on aluminum or
other light metal by passing a high voltage electric current
through a bath in which the metal is suspended.
Aquifer - Water bearing stratum.
Ash - The solid residue left after complete combustion.
Assembly - The fitting together of manufactured parts into a complete
machine, structure, or unit of a machine.
Atmospheric Evaporation - Evaporation at ambient pressure utilizing
a tower filled with packing material. Air is drawn in from
the bottom of the tower and evaporates feed material entering
from the top. There is no recovery of the vapors.
Atomic Absorption - Quantitative chemical instrumentation used for the
analysis of elemental constituents.
Automatic Plating - 1. Full - Plating in which the workpieces are
automatically conveyed through successive cleaning and plating
tanks. 2. Semi - Plating in which the workpieces are conveyed
automatically through only one plating tank.
Austempering - Heat treating process to obtain greater toughness and
ducticity in certain high-carbon steels. The process is charac-
terized by interrupted quenching and results in the formation of
bainite grain structure.
Austenitizing - Heating a steel to a temperature at which the structure
transforms to a solution of one or more elements in face-centered
cubic iron. Usually performed as the essential preliminary of
heat treatment, in order to get the various alloying elements
into solid solution.
Barrel Finishing - The process of polishing a workpiece using a rotat-
ing or vibrating container and abrasive grains or other polishing
materials to achieve the desired surface appearance.
Barrel Plating - Electroplating of workpieces in barrels (bulk).
Basis Meta-1 or Material - That substance of which the workpieces are
made and that receives the electroplate and the treatments in
preparation for plating.
XV-4
-------
Batch Treatment - A waste treatment method where wastewater is collect-
ed over a period of time and then treated prior to discharge.
Bending - Turning or forcing by a brake press or other device from a
straight or even to a curved or angular condition.
Best Available Technology Economically Achievable (BAT) - Level of
technology applicable to effluent limitations to be achieved
by 1984 for industrial discharges to surface waters as defined
by Section 301(b) (2) (A) of the Act.
Best Practicable Control Technology Currently Available - Level of
technology applicable to effluent limitations to be achieved
for industrial discharges to surface waters as defined by
Section 301 (b) (1) (A) of the Act.
Biochemical Oxygen Demand (BOD) - The amount of oxygen in milligrams
per liter used by microorganisms to consume biodegradable organics
in wastewater under aerobic conditions.
Biodegradability - The susceptibility of a substance to decomposition
by microorganisms; specifically, the rate at which compounds may
be chemically broken down by bacteria and/or natural environmental
factors.
Blanking - Cutting desired shapes out of sheet metal by means of dies.
Slowdown - The minimum discharge of recirculating water for the purpose
of discharging materials contained in the water, the further build-
up of which would cause concentration in amounts exceeding limits
established by best engineering practice.
BODS - The five-day Biochemical Oxygen Demand (BODS) is the quantity
of oxygen used by bacteria in consuming organic matter in a sample
of wastewater over a five-day period. BOD from the standard five-
day test equals about two-thirds of the total BOD. See Biochem-
ical Oxygen Demand.
Bonding - The process of uniting using an adhesive or fusible
ingredient.
Boring - Enlarging a hole by removing metal with a single or occasion-
ally a multiple point cutting tool moving parallel to the axis of
rotation of the work or tool. 1. Single-Point Boring - Cutting
with a single-point tool. 2. Precision Boring - Cutting to
tolerances held within narrow limits. 3. Gun Boring - Cutting
of deep holes. 4. Jig Boring - Cutting of high-precision and
accurate location holes. 5. Groove Boring - Cutting accurate
recesses in hole walls.
XV 5
-------
Brazing - Joining metals by flowing a thin layer, capillary thickness,
of non-ferrous 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).
Bright Dipping - The immersion of all or part of a workpiece in a
media designed to clean or brighten the surface and leave a
protective surface coating on the workpiece.
Brine - An aqueous salt solution.
Broaching - Cutting with a tool which consists of a bar having a
single edge or a series of cutting edges (i.e., teeth) on its
surface. The cutting edges of multiple-tooth, or successive
single-tooth, broaches increase in size and/or change in shape.
The broach cuts in a straight line or axial direction when
relative motion is produced in relation to the workpiece, which
may also be rotating. The entire cut is made in single or
multiple passes over the workpiece to shape the required surface
contour. 1. Pull Broaching - Tool pulled through or over work-
piece. 2. Push Broaching - Tool pushed over or through work-
piece. 3. Chain Broaching - A continuous high production
surface broach. 4. Tunnel Broaching - Work travels through an
enclosed area containing broach inserts.
Bromine Water - A nonmetallic halogen liquid, normally deep red,
corrosive and toxic, which is used as an oxidizing agent.
Buffing - An operation to provide a high luster to a surface. The
operation, which is not intended to remove much material,
usually follows polishing.
Buffing Compounds - Abrasive contained by a liquid or solid binder
composed of fatty acids, grease, or tallow. The binder serves
as lubricant, coolant, and an adhesive of the abrasive to the
buffing wheel.
Burnishing - Finish sizing and smooth finishing of a workpiece
(previously machined or ground) by displacement, rather than
removal, of minute surface irregularities with smooth point or
line-contact, fixed or rotating tools.
Calendering - Process of forming a continuous sheet by squeezing the
material between two or more parallel rolls to impart the desired
finish or to insure uniform thickness.
Calibration - The application of thermal, electrical, or mechanical
energy to set or establish reference points for a part, assem-
bly or complete unit.
XV-6
-------
Calibration Equipment - Equipment used for calibration of instruments.
Capital Recovery Costs - Allocates the initial investemnt and the inter-
est to the total operating cost. The capital recovery cost is
equal to the initial investment multiplied by the capital recovery
factor.
Capital Recovery Factor - Capital Recover Factor is defined as:
i + i/(a - 1) where i = interest rate, a = (1 + i) to the power n,
n = interest period in years.
Captive Operation - A manufacturing operation carried out in a facility
to support subsequent manufacturing, fabrication, or assembly
operations.
Carbides - Usually refers to the general class of pressed and sintered
tungsten carbide cutting tools which contain tungsten carbide plus
smaller amounts of titanium and tantalum carbides along with
cobalt which acts as a binder. (It is also used to describe hard
compounds in steels and cast irons.)
Carbon Adsorption - Activated carbon contained in a vessel and
installed in either a gas or liquid stream to remove organic
contaminates. Carbon is regenerable when subject to steam which
forces contaminant to desorb from media.
Carbon Bed Catalytic Destruction - A non-electrolytic process for the
catalytic oxidation of cyanide wastes using filters filled with
low-temperature coke.
Carbon Steels - Steel which owes its properties chiefly to various
percentage of carbon without substantial amounts of other alloying
elements.
Carbonate - A compound containing the acid radical of carbonic acid
(C0_3 group) .
Carbonitriding - Process for case or core hardening of metals. The
heated metals absorb carbon in a gaseous atmosphere.
Carburizing - (Physical Property Modification) Increasing the carbon
content of a metal by heating with a carburizing medium (which
may be solid, liquid or gas) usually for the purpose of producing
a hardened surface by subsequent quenching.
Carcinogen - Substance which causes cancerous growth.
Case Hardening - A heat treating method by which the surface layer of
alloys is made substantially harder than the interior. (Carburiz-
ing and nitriding are common ways of case hardening steels.)
Cast - A state of the substance after solidification of the molten
substance.
XV-7
-------
Casthquse - The facility which melts metal, holds it in furnaces for
degassing (fluxing) and alloying and then casts the metal into
pigs, ingots, billets, rod, etc.
Casting - The operation of pouring molten metal into a mold.
Catalytic Bath - A bath containing a substance used to accelerate the
rate of chemical reaction.
Category - Also point source category. A segment of industry for
which a set of effluent limitations has been established.
Cathode - The negatively charged electrode in an electrochemical
process.
Cation - The positively charged ions in a solution.
Caustic - Capable of destroying or eating away by chemical action.
Applies to strong bases and characterized by the presence of
hydroxyl ions in solution.
Caustic Soda - Sodium hydroxide, NaOH, whose solution in water is
strongly alkaline.
Cementation - The electrochemical reduction of metal ions by contact
with a metal of higher oxidation potential. It is usually used
for the simultaneous recovery of copper and reduction of
hexavalent chromium with the aid of scrap iron.
Centerless Grinding - Grinding the outside or inside of a workpiece
mounted on rollers rather than on centers. The workpiece may be
in the form of a cylinder or the frustrum of a cone.
Central Treatment Facility - Treatment plant which co-treats process
wastewaters from more than one manufacturing operation or co-
treats process wastewaters with non-contact cooling water, or
with non-process wastewaters (e.g., utility blowdown, miscellan-
eous runoff, etc.).
Centrifugation - An oil recovery step employing a centrifuge to remove
water from waste oil.
Centrifuge - A device having a rotating container in which centrifugal
force separates substances of differing densities.
Chelated Compound - A compound in which the metal is contained as an
integral part of a ring structure and is not readily ionized.
XV-8
-------
Chelating Agent - A coordinate compound in which a central atom
(usually a metal) is joined by covalent bonds to two or more
other molecules or ions (called ligands) so that heterocyclic
rings are formed with the central (metal) atom as part of each
ring. Thus, the compound is suspending the metal in solution.
Chemical Brightening - Process utilizing an addition agent that leads
to the formation of a bright plate or that improves the brightness
of the deposit.
Chemical Deposition - Process used to deposit a metal oxide on a
substrate. The film is formed by hydrolysis of a mixture of
chlorides at the hot surface of the substrate. Careful control
of the water mixture insures that the oxide is formed on the
substrate surface.
Chemical Etching - To dissolve a part of the surface of a metal or
all of the metal laminated to a base.
Chemical Machining - Production of derived shapes and dimensions
through selective or overall removal of metal by controlled
chemical attack or etching.
Chemical Metal Coloring - The production of desired colors on metal
surfaces by appropriate chemical or electrochemical action.
Chemical Milling - Removing large amounts of stock by etching
selected areas of complex workpieces. This process entails
cleaning, masking, etching, and demasking.
Chemical Oxidation - (Including Cyanide) The addition of chemical
agents to wastewater for the purpose of oxidizing pollutant
material.
Chemical Oxygen Demand (COD) - The amount of oxygen in milligrams per
liter to oxidize both organic and oxidizable inorganic compounds.
Chemical Precipitation - A chemical process in which a chemical in
solution reacts with another chemical introduced to that solution
to form a third substance which is partially or mainly insoluble
and, therefore, appears as a solid.
Chemical Recovery Systems - Chemical treatment to remove metal or
other materials from wastewater for later reuse.
Chemical Reduction - A chemical reaction in which one or more electrons
are transferred to the chemical being reduced from the chemical
initiating the transfer (reducing agent).
XV-9
-------
Chemical Treatment - Treating contaminated water by chemical means.
Chip Dragout - Cutting fluid or oil adhering to metal chips from a
machining operation.
Chlorinated Hydrocarbons - Organic compounds containing chlorine
such as many insecticides.
Chlorination - The application of chlorine to water generally for
purposes of disinfection, but frequently for accomplishing
other biological or chemical results.
Chromate Conversion Coating - Protective coating formed by immersing
metal in an aqueous acidified solution consisting substantially
of chromic acid or water soluble salts of chromic acid together
with various catalysts or activators.
Chromatizing - To treat or impregnate with a chromate (salt of ester
of chromic acid) or dichromate, especially with potassium
dichromate-
Chrome-Pickle Process - Forming a corrosion-resistant oxide film on
the surface of magnesium base metals by immersion in a bath of
an alkaline bichromate.
Clarification - The composite wastewater treatment process consisting
of flash mixing of coagulants, pH adjusting chemicals, and/or
polyelectrolytes, flocculation, and sedimentation.
Clarifier - A unit which provides for settling and removal of solids
from wastewater.
Cleaning - The removal of soil and dirt (including grit and grease)
from a workpiece using water with or without a detergent or
other dispersing agent.
See Vapor Degreasing
Solvent Cleaning
Contaminant Factor
Acid Cleaning
Emulsion Cleaning
Alkaline Cleaning
Salt Bath Descaling
Pickling
Passivate
Abrasive Blast Cleaning
Sonic and Ultrasonic Cleaning
Closed-Loop Evaporation System - A system used for the recovery of
chemicals and water from a chemical finishing process. An
evaporator concentrates flow from the rinse water holding tank.
The concentrated rinse solution is returned to the bath, and
distilled water is returned to the final rinse tank. The
system is designed for recovering 100 percent of chemicals nor-
mally lost in dragout for reuse in the process.
XV-10
-------
Closed Loop Rinsing - The recirculation of rinse water without the
introduction of additional makeup water.
Coagulation - A chemical reaction in which polyvalent ions neutralize
the repulsive charges surrounding colloidal particles.
Coating See Aluminum Coating
Hot Dip Coating
Ceramic Coating
Phosphate Coating
Chromate Conversion Coating
Rust-Preventive Compounds
Porcelain Enameling
COD - See Chemical Oxygen Demand
Cold Drawing - A process of forcing material through dies or other
mandrels to produce wire, rod, tubular and some bars.
Cold Heading - A method of forcing metal to flow cold into enlarged
sections by endwise squeezing. Typical coldheaded parts are
standard screws, bolts under 1 in. diameter and a large variety
of machine parts such as small gears with stems.
Cold Rolling - A process of forcing material through rollers to produce
bars and sheet stock.
Colorimetric - A procedure for establishing the concentration of impur-
itites in water by comparing its color to a set of known color
impurity standards.
Common Metals - Copper, nickel, chromium, zinc, tin, lead, cadmium,
iron, aluminum, or any combination thereof.
Compatible Pollutants - Those pollutants which can be adequately
treated in publicly-owned treatment works without upsetting
the treatment process.
Complexing Agent - A compound that will join with a metal to form
an ion which has a molecular structure consisting of a central
atom (the metal) bonded to other atoms by coordinate covalent
bonds.
Composite Wastewater Sample - A combination of individual samples of
water or wastewater taken at selected intervals, generally hourly
for some specified period, to minimize the effect of the varia-
bility of the individual sample. Individual samples may have
equal volume or may be proportioned to the flow at time of
sampling.
Conductance - See Electrical Conductivity.
XV-11
-------
Conductivity Surface - A surface that can transfer heat or electricity.
Conductivity Meter - An instrument which displays a quantitative
indication of conductance.
Contact Water - See Process Wastewater.
Contamination - Intrusion of undesirable elements.
Continuous Treatment - Treatment of waste streams operating without
interruption as opposed to batch treatment; sometimes referred
to as flow=through treatment.
Contractor Removal - Disposal of oils, spent solutions, or sludge
by a scavenger service.
Conversion Coating - A coating produced by chemical or electrochemical
treatment of a metallic surface that gives a superficial layer
containing a compound of the metal. For example, chromate coating
on zinc and cadmium, oxide coatings on steel.
Coolant - See Cutting Fluids.
Cooling Water - Water which is used to absorb and transport heat
generated in a process or machinery.
Copper Flash - Quick preliminary deposition of copper for making
surface acceptable for subsequent plating.
Coprecipitation of Metals - Precipitation of a metal with another
metal.
Corrosion Resistant Steels - A term often used to describe the stain-
less steels with high nickel and chromium alloy content.
Cost of Capital - Capital recovery costs minus the depreciation.
Counterboring - Removal of material to enlarge a hole for part of
its depth with a rotary, pilot guided, end cutting tool having
two or more cutting lips and usually having straight or helical
flutes for the passage of chips and the admission of a cutting
fluid.
Countercurrent Rinsing - Rinsing of parts in such a manner that the
rinse water is removed from tank to tank counter to the flow of
parts being rinsed.
Countersinking - Beveling or tapering the work material around the
periphery of a hole creating a concentric surface at an angle
less than 90 degrees with the centerline of the hole for the
purpose of chamfering holes or recessing screw and rivet heads.
XV-12
-------
Crystalline Solid - A substance with an ordered structure, such as
a crystal.
Crystallization - 1. Process used to manufacture semiconductors
in the electronics industry. 2. A means of concentrating
pollutants in wastewaters by crystallizing out pure water.
Curcumine or Carmine Method - A standard method of measuring the
concentration of boron (B) within a solution.
Cutting Fluids - Lubricants employed to ease metal and machining
operations, produce surface smoothness and extend tool life
by providing lubricity and cooling. Fluids can be emulsified
oils in water, straight mineral oils when better smoothness
and accuracy are required, or blends of both.
Cyaniding - A process of case hardening an iron-base alloy by the
simultaneous absorption of carbon and nitrogen by heating in a
cyanide salt. Cyaniding is usually followed by quenching to
produce a hard case.
Cyclone Separator - A device which removes entrained solids from gas
streams.
Dead Rinse - A rinse step in which water is not replenished or dis-
charged.
Deburring - Removal of burrs or sharp edges from parts by filing,
grinding or rolling the work in a barrel with abrasives sus-
pended in a suitable medium.
Deep Bed Filtration - The common removal of suspended solids from
wastewater streams by filtering through a relatively deep
(0.3-0.9 m) granular bed. The porous bed formed by the granular
media can be designed to remove practically all suspended
particles by physical-chemical effects.
Degassing - (Fluxing) The removal of hydrogen and other impurities
from molten primary aluminum in a casthouse holding furnace by
injecting chlorine gas (often with nitrogen and carbon).
Degradable - That which can be reduced, broken down or chemically
separated.
Demineralization - The removal from water of mineral contaminants
usually present in ionized form. The methods used include ion-
exchange techniques, flash distillation or electrolysis.
XV-13
-------
Denitrification (Biological) - The reduction of nitrates to nitrogen
gas by bacteria.
Deoxidizing - The removal of an oxide film from an alloy such as
aluminum oxide.
Depreciation - Decline in value of a capital asset caused either by use
or by obsolescence.
Descaling - The removal of scale and metallic oxides from the surface
of a metal by mechanical or chemical means. The former includes
the use of steam, scale-breakers and chipping tools, the latter
method includes pickling in acid solutions.
Desmutting - The removal of smut (matter that soils or blackens)
generally by chemical action.
Dewatering - (Sludge Processing) Removing water from sludge.
Diaminobenzidene - A chemical used in the standard method of measuring
the concentrations of selenium in a solution.
Dibasic Acid - An acid capable of donating two protons (hydrogen
ions).
Dichromate Reflux - A standard method of measuring the chemical
oxygen demand of a solution.
Die Casting - (hot chamber, vacuum, pressure) Casting are produced
by forcing molten metal under pressure into metal mold called
dies. In hot chamber machines, the pressure cylinder is sub-
merged in the molten metal resulting in a minimum of time and
metal cooling during casting. Vacuum feed machines use a
vacuum to draw a measured amount of melt from the molten bath
into the feed chamber. Pressure feed systems use a hydraulic
or pneumatic cylinder to feed molten metal to the die.
Digestion - A standard method of measuring organic nitrogen.
Dipping - Material coating by briefly immersing parts in a molten
bath, solution or suspension.
Direct Labor Costs - Salaries, wages and other direct compensations
earned by the employee.
Discharge of Pollutant(s) - 1. The addition of any pollutant to
navigable waters from any point source. 2. Any addition of any
pollutant to the waters of the continguous zone or the ocean
from any point source, other than from a vessel or other floating
craft. The term "discharge" includes either the discharge of a
single pollutant or the discharge of multiple pollutants.
XV-14
-------
Dispersed-air Flotation - Separation of low density contaminants from
water using minute air bubbles attached to individual particles
to provide or increase the buoyancy of the particle. The bubbles
are generated by introducing air through a revolving impeller or
porous media.
Dissolved-air Floatation - Separation of low density contaminants from
water using minute air bubbles attached to individual particles
to provide or increase the buoyancy of the particle. The air is
put into solution under elevated pressure and later released under
atmospheric pressure or put into solution by aeration at atmos-
pheric pressure and then released under a vacuum.
Dissolved Oxygen (DO) - The oxygen dissolved in sewage, water, or other
liquid, usually expressed in milligrams per liter or percent of
saturation. It is the test used in BOD determination.
Distillation - Vaporization of a liquid followed by condensation of
the vapor.
Distillation Refining - A metal with an impurity having a higher vapor
pressure than the base metal can be refined by heating the metal
to the point where the impurity vaporizes.
Distillation-Silver Nitrate Titration - A standard method of measuring
the concentration of cyanides in a solution.
Distillation-SPADNS - A standard method of measuring the concentration
of fluoride in a solution.
Dollar Base - A period in time in which all costs are related. Invest-
ment costs are related by the Sewage Treatment Plant Construction
Cost Index. Supply costs are related by the "Industrial Commod-
ities" Wholesale Price Index.
Drag-in - Water or solution carried into another solution by the work
and the associated handling equipment.
Dragout - The solution that adheres to the objects removed from a bath,
more precisely defined as that solution which is carried past the
edge of the tank.
Dragout Reduction - Minimization of the amount of material (bath or
solution) removed from a process tank by adherring to the part
or its transfer device.
Drainage Phase - Period in which the excess plating solution adhering
to the part or workpiece is allowed to drain off.
XV-15
-------
Drawing - Reduction of cross section area and increasing the length
by pulling metal through conical taper dies.
Drawing Compounds - See Wire Forming Lubricants.
Drilling - Hole making with a rotary, end-cutting tool having one or
more cutting lips and one or more helical or straight flutes or
tubes for the ejection of chips and the passage of a cutting
fluid. 1. Center Drilling - Drilling a conical hole in the
end of a workpiece. 2. Core Drilling - Enlarging a hole with
a chamer-edged, multiple-flute drill. 3. Spade Drilling -
Drilling with a flat blade drill tip. 4. Step Drilling - Using
a multiple diameter drill. 5. Gun Drilling - Using special
straight flute drills with a single lip and cutting fluid at high
pressures for deep hole drilling. 6. Oil Hole or Pressurized
Coolant Drilling - Using a drill with one or more continuous
holes through its body and shank to permit the passage of a
high pressure cutting fluid which emerges at the drill point
and ejects chips.
Drip Station - Empty tank over which parts are allowed to drain
freely to decrease end dragout.
Drip Time - The period during which a part is suspended over baths
in order to allow the excessive dragout to drain off.
Drying Beds - Areas for dewatering of sludge by evaporation and
seepage.
EDTA Titration - EDTA - ethylenediamine tetraacetic acid ( or its
salts). A standard method of measuring the hardness of a
solution.
Effluent - The water and the quantities, rates, and concentrations
of chemical, physical, biological, and other constituents
which are discharged from point sources.
Effluent Limitation - Any restriction (including schedules of compli-
ance) established by a state or the federal EPA on quantites,
rates, and concentrations of chemical, physical, biological,
and other constituents which are discharged from point sources
into naviigable waters, the waters of the contiguous zone, or
the ocean.
Electrical Conductivity - The property which allows an electric current
to flow when a potential difference is applied. It is the re-
ciprocal of the resistance in ohms measured between opposite
faces of a centimeter cube of an aqueous solution at a specified
temperature. It is expressed as raicromhos per centimeter at
temperature degrees Celsius.
XV-16
-------
Electrical Discharge Machining - Metal removal by a rapid spark dis-
charge between different polarity electrodes, one the workpiece
and the other the tool separated by a gap distance of 0.0005 in.
to 0.035 in. The gap is filled with dielectric fluid and metal
particles which are melted, in part vaporized and expelled from
the gap.
Electrobrightening - A process of reversed electro-deposition which
results in anodic metal taking a high polish.
Electrochemical Machining (ECM) - A machining process whereby the part
to be machined is made the anode and a shaped cathode is maintain-
ed in close proximity to the work. Electrolyte is pumped between
the electrodes and a potential applied with the result that metal
is rapidly dissolved from the workpiece in a selective manner and
the shape produced on the workpiece complements that of the
cathode.
Electrocleaning - The process of anodic removal of surface oxides and
scale from a workpiece.
Electrode - Conducting material for passing electric current into or
out of a solution by adding electrons to or taking electrons
from ions in the solution.
Electrodialysis - A treatment process that uses electrical current and
and arrangement of permeable membranes to separate soluble minerals
from water. Often used to desalinate salt or brackish water.
Electroless Plating - Deposition of a metallic coating by a control-
led chemical reduction that is catalyzed by the metal or alloy
being deposited.
Electrolysis - The chemical decomposition by an electric current of
a substance in a dissolved or molten state.
Electrolyte - A liquid, most often a solution, that will conduct an
electric current.
Electrolytic Cell - A unit apparatus in which electrochemical react-
ions are produced by applying electrical energy or which supplies
electrical energy as a result of chemical reactions and which
includes two or more electrodes and one or more electrolytes con-
tained in a suitable vessel.
Electrolytic Decomposition - An electrochemical treatment used for the
oxidation of cyanides. The method is practical and economical
when applied to concentrated solutions such as contaminated baths,
cyanide dips, stripping solutions, and concentrated rinses.
Electrolysis is carried out at a current density of 35 amp/sq.
ft. at the anode and 70 amp/sq. ft. at the cathode. Metal is
deposited at the cathode and can be reclaimed.
XV-17
-------
Electrolytic Oxidation - A reaction by an electrolyte in which there
is an increase in valence resulting from a loss of electrons.
Electrolytic Reduction - A reaction in which there is a decrease in
valence resulting from a gain in electrons.
Electrolytic Refining - The method of producing pure metals by making
the impure metal the anode in an electrolytic cell and depositing
a pure cathode. The impurities either remain undissolved at the
anode or pass into solutions in the electrolyte.
Electrometallurgical Process - The application of electric current to
a metallurgical process either for electrolytic deposition or as
a source of heat.
Electrometric Titration - A standard method of measuring the alkalin-
ity of a solution.
Electron Beam Machining - The process of removing material from a
workpiece by a high velocity focused stream of electrons which
melt and vaporize the workpiece at the point of impingerent.
Electroplating - The production of a thin coating of one metal on a
surface by electrodeposition*
Electropolishing - Electrolytic corrosion process that increases the
percentage of specular reflectance from a metallic surface.
Embossing - Raising a design in relief against a surface.
Emulsified Oil and Grease - An oil or grease dispersed in an immis-
cible liquid usually in droplets of larger than colloidal size.
In general suspension of oil or grease within another liquid
(usually water).
Emulsifying Agent - A material that increases the stability of a
dispersion of one liquid in another.
Emulsion Breaking - Decreasing the stability of dispersion of one
liquid in another.
Emulsion Cleaning - A cleaning process using organic solvents dis-
persed in an aqueous medium with the aid of an emulsifying agent.
End-of-Pipe Treatment - The reduction and/or removal of pollutants by
treatment just prior to actual discharge.
Environmental Protection Agency - the United States Environmental
Protection Agency.
XV-18
-------
EPA - See Environmental Protection Agency.
Equalization - (Continuous Flow) - The balancing of flow or pollutant
load using a holding tank for a system that has widely varying
inflow rates.
Equilibrium Concentration - A state at which the concentration of
chemicals in a solution remain in a constant proportion to one
another.
Ester - An organic compound corresponding in structure to a salt in
inorganic chemistry. Esters are considered as derived from the
acids by the exchange of the replaceable hydrogen of the latter
for an organic alkyl radical. Esters are not ionic compounds,
but salts usually are.
Etchant - The material used in the chemical process of removing glass
fibers and epoxy between neighboring conductor layers of a PC
board for a given distance.
Etching - A process where material is removed by chemical action.
Evaporation Ponds - Liquid waste disposal areas that allow the liquid
to vaporize to cool discharge water temperatures or to thicken
sludge.
Excess Capacity Factor - A multiplier on process size to account for
shutdown for cleaning and maintenance.
Extrusion - A material that is forced through a die to form lengths
of rod, tube or special sections.
4-AAP Colorimetric - A standard method of measurement for phenols
in aqueous solutions.
Fermentation - A chemical change to break down biodegradable waste.
The change is induced by a living organism or enzyme, specific-
ally bacteria or microorganisms occurring in unicellular plants
such as yeast, molds, or fungi.
Ferrite - A solid solution in which alpha iron is present.
Ferrous - Relating to or containing iron.
Filtrate - Liquid after passing through a filter.
Filtration - Removal of solid particles from liquid or particles
from air or gas stream by means of a permeable membrane.
Types: Gravity, Pressure, Microstraining, Ultrafiltration,
Reverse Osmosis (Hyperfiltration).
XV-19
-------
Flameless Atomic Absorption - A method of measuring low concen-
tration values of certain metals in a solution.
Flame Hardened - Surface hardened by controlled torch heating
followed by quenching with water or air.
Flame Spraying - The process of applying a metallic coating to a
workpiece whereby finely powdered fragments or wire, together
with suitable fluxes, are projected through a cone of flame
onto the workpiece.
Flash Evaporation - Evaporation using steam heated tubes with feed
material under high vacuum. Feed material "flashes off" when
it enters the evaporation chamber.
Flocculation - The process of separating suspended solids from waste-
water by chemical creation of clumps or floes.
Flotation - The process of removing finely divided particles from
a liquid suspension by attaching gas bubbles to the particles,
increasing their buoyancy, and thus concentrating them at the
surface of the liquid medium.
Fluxing - (Degassing) The removal of oxides and other impurities
from molten primary aluminum in a casthouse holding furnace by
injecting chlorine gas (often with nitrogen and carbon monoxide).
Fog - A type of rinse consisting of a fine spray.
Forming Compounds (Sheet) - Tightly adhering lubricants composed of
fatty oils, fatty acids, soaps, and waxes and designed to resist
the high surface temperatures and pressures the metal would
otherwise experience in forming.
Forming Compounds (Wire) - Tightly adhering lubricants composed of
solids (white lead, talc, graphite, or molybdenum disulfide)
and solible oils for cooling and corrosion protection. Lubri-
cants typically contain sulfur, chlorine, or phsophate additives.
Free Cyanide - 1. True - the actual concentration of cyanide radical
or equivalent alkali cyanide not combined in complex ions with
metals in solutions. 2. Calculated - the concentration of
cyanide or alkali cyanide present in solution in excess of that
calculated as necessary to form a specified complex ion with a
metal or metals present in solution. 3. Analytical - the free
cyanide content of a solution as determined by a specified
analytical method.
Freezing/Crystallization - The solidification of a liquid into
aggregations of regular geometric forms (crystals) accomplished
by subtraction of heat from the liquid. This process can be used
for removal of solids, oils, greases, and heavy metals from
industrial wastewater.
XV-20
-------
Galvanizing - The deposition of zinc on the surface of steel for
corrosion protection.
Gas Carburizing - The introduction of carbon into the surface layers
of mill steel by heating in a current of gas high in carbon.
Gas Chromotagrophy - Chemical analytical instrumentation generally
used for quantitative organic analysis.
Gas Nitriding - Case hardening metal by heating and diffusing nitro-
gen gas into the surface.
Gas Phase Separation - The process of separating volatile constitu-
ents from water by the application of selective gas permeable
membranes.
Gear Forming - Process for making small gears by rolling the gear
material as it is pressed between hardened gear shaped dies.
Glass Fiber Filtration - A standard method of measuring total sus-
pended solids.
Good Housekeeping - (In-Plant Technology) Good and proper mainten-
ance minimizing spills and upsets.
GPP - Gallons per day-
Grab Sample - A single sample of wastewater taken without regard
to time or flow.
Gravimetric 103-105C - A standard method of measuring total
solids in aqueous solutions.
Gravimetric 550C - A standard method of measuring total volatile
solids in aqueous solutions.
Gravity Filtration - Settling of heavier and rising of lighter
constituents within a solution.
Gravity Flotation - The separation of water and low density contam-
inants such as oil or grease by reduction of the wastewater
flow velocity and turbulence for a sufficient time to permit
separation due to difference in specific gravity. The floated
material is removed by some skimming technique.
Gray Cast Irons - Alloys primarily of iron, carbon and silicon along
with other alloying elements in which the graphite is in flake
form. (These irons are characterized by low ductility but have
many other properties such as good castability and good damping
capacity.)
XV-21
-------
Grease - In wastewater, a group of substances including fats, waxes,
free fatty acids, calcium and magnesium soaps, mineral oils,
and certain other nonfatty materials. The type of solvent
and method used for extraction should be stated for quantifi-
cation.
Grease Skimmer - A device for removing floating grease or scum from
the surface of wastewater in a tank.
Grinding - The removal of stock from a workpiece by use of abrasive
grains held by a rigid or semi rigid binder. 1. Surface
Grinding - Producing a flat surface with a rotating grinding
wheel as the workpiece passes under the wheel. 2. Cylindrical
Grinding - Grinding the outside diameters of cylindrical work-
pieces held between centers. 3. Internal Grinding - Grinding
the inside of a rotating workpiece by use of a wheel spindle
which rotates and reciprocates through the length of depth of
the hole being ground.
Grinding Fluids - Water based, straight oil, or synthetic based
lubricants containing mineral oils, soaps, or fatty materials
lubricants serve to cool the part and maintain the abrasiveness
of the grinding wheel face.
Hammer Forging - Heating and pounding metal to shape it into the
desired form.
Hardened - Designates condition produced by various heat treatments
such as quench hardening, age hardening and precipitation
hardening.
Hardness - A characteristic of water, imparted by salts of calcium,
magnesium and iron such as bicarbonates, carbonates, sulfates,
chlorides and nitrates, that cause curdling of soap, deposition
of scale, damage in some industrial processes and sometimes
objectionable taste- It may be dtermined by a standard labora-
tory procedure or computed from the amounts of calcium and
magnesium as well as iron, aluminum, manganese, barium,
strontium, and zinc and is expressed as equivalent calcium
carbonate.
Heading - (Material forming) Upsetting wire, rod or bar stock in
dies to form parts having some of the cross-sectional area
larger than the original. Examples are bolts, rivets and
screws.
Heat Resistant Steels - Steel with high resistance to oxidation and
moderate strength at high temperatures above 500 Degrees C.
XV-2 2
-------
Heat Treatment - The modification of the physical properties of a
workpiece through the application of controlled heating and
cooling cycles. Such operations are heat treating, tempering,
carburizing, cyaniding, nitriding, annealing, normalizing,
austenizing, quenching, austempering, siliconizing, martemper-
ing, and malleabilizing are included in this definition.
Heavy Metals - Metals which can be precipitated by hydrogen sulfide
in acid solution, e.g., lead, silver, gold, mercury, bismuth,
copper, nickel, iron, chromium, zinc, cadmium, and tin.
High Energy Forming - Processes where parts are formed at a rapid
rate by using extremely high pressures. Examples: Explosive
forming, Electrohydraulic forming.
High Energy Rate Forging (HERF) - A closed die process where hot or
cold deforming is accomplished by a high velocity ram.
Robbing - Gear cutting by use of a tool resembling a worm gear in
appearance, having helically-spaced cutting teeth. In a single-
thread hob, the rows of teeth advance exactly one pitch as the
hob makes one revolution. With only one hob, it is possible to
cut interchangeable gears of a given pitch of any number of
teeth within the range of the hobbing machine.
Honing - A finishing operation using fine grit abrasive stones to
produce accurate dimensions and excellent finish.
Hot Compression Molding - (Plastic Processing) A technique of
thermoset molding in which preheated molding compound is closed
and heat and pressure (in the form of a downward moving ram)
are applied until the material has cured.
Hot Dip Coating - The process of coating a metallic workpiece with
another metal by immersion in a molten bath to provide a pro-
tective film.
Hot Rolled - A term used to describe alloys which are rolled at tem-
peratures above the recrystallization temperature. (Many alloys
are hot rolled, and machinability of such alloys may vary because
of differences in cooling conditions from lot to lot.
Hot Stamping - Engraving operation for marking plastics in which roll
leaf is stamped with heated metal dies onto the face of the
plastics. Ink compounds can also be used.
Hot Upset Forging - The diameter is locally increased i.e. to upset
the head of a bolt, the end of the barstock is heated and then
deformed by an axial blow often into a suitably shaped die.
Hydrofluoric Acid - Hydrogen fluoride in aqueous solution.
XV-23
-------
Hydrogen Embrittlement - Embrittlement of a metal or alloy caused by
absorption of hydrogen during a pickling, cleaning, or plating
process.
Hydrometallurgical Process - The treatment of ores by wet processes
such as leaching.
Hydrophilic - A surface having a strong affinity for water or being
readily wettable.
Hydrophobic - A surface which is non-wettable or not readily wettable.
Hydrostatic Pressure - The force per unit area measured in terms of
the height of a column of water under the influence of gravity.
Immersed Area - Total area wetted by the solution or plated area plus
masked area.
Immersion Plate - A metallic deposit produced by a displacement re-
action in which one metal displaces another from solution, for
example: Fe + Cu(+2) = Cu + Fe(+2)
Impact Deformation - The process of applying impact force to a work-
piece such that the workpiece is permanently deformed or shaped.
Impact deformation operations such as shot peening, peening,
forging, high energy forming, heading, or stamping.
Incineration - (Sludge Disposal) The combustion (by burning) of
organic matter in wastewater sludge after dewatering by
evaporation.
Incompatible Pollutants - Those pollutants which would cause harm to,
adversely affect the performance of, or be inadequately treated
in publicly-owned treatment works.
Independent Operation - Job shop or contract shop in which electro-
plating is done on workpieces owned by the customer.
Indirect Labor Costs - Labor-related costs paid by the employer
other than salaries, wages and other direct compensation such as
social security and insurance.
Induction Hardened - Surface or through hardened using induction
heating followed by quenching with water or air.
Industrial User - Any industry that introduces pollutants into public
sewer systems and whose wastes are treated by a publicly-owned
treatment facility.
Industrial Wastes - The liquid wastes from industrial processes, as
distinct from domestic or sanitary wastes.
XV-2 4
-------
Inhibition - The slowing down or stoppage of chemical or biological
reactions by certain compounds or ions.
In-Process Control Technology - The regulation and the conservation
of chemicals and the reduction of water usage throughout the
operations as opposed to end-of-pipe treatment.
Inspection - A checking or testing of something against standards or
specification.
Intake Water - Gross water minus reuse water.
Integrated Chemical Treatment - A waste treatment method in which a
chemical rinse tank is inserted in the plating line between the
process tank and the water rinse tank. The chemical rinse
solution is continuously circulated through the tank and removes
the dragout while reacting chemicals with it.
Integrated Circuit (1C) - 1. A combination of interconnected circuit
elements inseparably associated on or within a continuous sub-
strate. 2. Any electronic device in which both active and
passive elements are contained in a single package. Methods of
making an integrated circuit are by masking process, screening
and chemical deposition.
Intraforming - A method of forming by means of squeezing.
Investment Costs - The capital expenditures required to bring the
treatment or control technology into operation.
Ion Exchange - A reversible chemical reaction between a solid (ion
exchanger) and a fluid (usually a water solution) by means of
which ions may be interchanged from one substance to another.
The superficial physical structure of the solid is not
affected.
Ion Exchange Resins - Synthetic resins containing active groups
(usually sulfonic, carboxylic, phenol, or substituted amino
groups) that give the resin the property of combining with
or exchanging ions between the resin and a solution.
Ion-Flotation Technique - Treatment for electroplating rinse waters
(containing chromium and cyanide) in which ions are separated
from solutions by flotation.
Iridite Dip Process - Dipping process for zinc or zinc-coated objects
that deposits protective film that is a chromium gel, chromium
oxide, or hydrated chromium oxide.
Isolation - Segregation of a waste for separate treatment and/or
disposal.
XV-25
-------
Kiln - (Rotary) A large cylindrical mechanized type of furnace.
Kinematic Viscosity - The viscosity of a fluid divided by its density.
The C.G.So unit is the stoke (cm2/sec).
Knurling - Impressing a design into a metallic surface, usually by
means of small, hard rollers that carry the corresponding design
on their surfaces,
Lagoon - A man-made pond or lake for holding wastewater for the removal
of suspended solids. Lagoons are also used as retention ponds,
after chemical clarification to polish the effluent and to safe-
guard against upsets in the clarifier; for stabilization of
organic matter by biological oxidation; for storage of sludge;
and for cooling of water.
Laminate - 1. A composite metal, wood or plastic usually in the form
of sheet or bar, composed of two or more layers so bonded that
the composite forms a structural member. 2. To form a product
of two or more bonded layers.
Landfill - Disposal of inert, insoluble waste solids by dumping at an
approved site and covering with earth.
Lapping - An abrading process to improve surface quality by reducing
roughness, waviness and defects to produce accurate as well as
smooth surfaces.
Laser Beam Machining - Use of a highly focused mono-frequency colli-
mated beam of light to melt or sublime material at the point of
impingement on a workpiece.
Leach Field - A area of ground to which wastewater is discharged.
Not considered an acceptable treatment method for industrial
wastes.
Leaching - Dissolving out by the action of a percolating liquid,
such as water, seeping through a landfill.
Ligands - The molecules attached to the central atom by coordinate
covalent bonds.
Liquid/Liquid Extraction - A process of extracting or removing contam-
inant(s) from a liquid by mixing contaminated liquid with another
liquid which is immiscible and which has a higher affinity for
the contaminating substance(s) .
Liquid Nitriding - Process of case hardening a metal in a molten
cyanide bath.
XV-26
-------
Liquid Phase Refining - A metal with an impurity possessing a lower
melting point is refined by heating the metal to the point of
melting of the low temperature metal. It is separated by sweat-
ing out.
Machining - The 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, drill-
ing, boring, tapping, planing, broaching, sawing and filing, and
chamfering are included in this definition.
Maintenance - The upkeep of property or equipment.
Malleablizing - Process of annealing brittle white cast iron in such
a way that the combined carbon is wholly or partly transformed
to graphitic or temper carbon nodules in a ferritic or pearlitic
microstructure, thus providing a ductile and machinable material.
Manual Plating - Plating in which the workpieces are conveyed manually
through successive cleaning and plating tanks.
Maraged - Describes a series of heat treatments used to treat high
strength steels of complex composition (maraging steels) by
aging of martensite.
Martensite - An acicular or needlelike microstructure that is formed
in quenched steels. (It is very hard and brittle in the quenched
form and, therefore, is usually tempered before being placed into
service. The harder forms of tempered martensite have poorer
machinability-)
Martempering - Quenching an austentized ferrous alloy in a medium at a
temperature in the upper part of the martensite range, or slight-
ly above that range, and holding it in the medium until the
temperature throughout the alloy is substantially uniform.
The alloy is then allowed to cool in air through the martensite
range.
Masking - The application of a substance to a surface for the pre-
vention of plating to said area.
Material Modification - (In-Plant Technology) Altering the substance
from which a part is made.
Mechanical Agitation - The agitation of a liquid medium through the
use of mechanical equipment such as impellers or paddles.
Mechanical Finish - Final operations on a product performed by a
machine or tool. See: Polishing, Buffing, Barrel Finishing,
Shot Peening, Power Brush Finishing.
XV-2 7
-------
Mechanical Plating - Providing a coating wherein fine metal powders
are peened onto the part by tumbling or other means.
Membrane - A thin sheet of synthetic polymer through the apertures
of which small molecules can pass, while larger ones are re-
tained.
Membrane Filtration - Filtration at pressures ranging from 50 to 100
psig with the use of membranes or thin films. The membranes
have accurately controlled pore sites and typically low flux
rates.
Metal Ion - An atom or radical that has lost or gained one or more
electrons and has thus acquired an electric charge. Positively
charged ions are cations, and those having a negative charge
are anions. An ion often has entirely differnt properties from
the element (atom) from which it was formed.
Metal Oxidation Refining - A refining technique that removes impuri-
ties from the base metal because the impurity oxidizes more
readily than the base. The metal is heated and oxygen supplied.
The impurity upon oxidizing separates by gravity or volatilizes.
Metal Paste Production - Manufacture of metal pastes for use as pig-
ments by mixing metal powders with mineral spirits, fatty acids
and solvents. Grinding and filtration are steps in the process.
Metal Powder Production - Production of metal particles for such uses
as pigments either by milling and grinding of scrap or by atomi-
zation of molten metal.
Metal Spraying - Coating metal objects by spraying molten metal upon
the surface with gas pressure.
Microstraining - A process for removing solids from water, which con-
sists of passing the water stream through a microscreen with
the solids being retained on the screen.
Milling - Using a rotary tool with one or more teeth which engage the
workpiece and remove material as the workpiece moves past the
rotating cutter. 1. Face Milling - Milling a surface perpendi-
cular cutting edges remove the bulk of the material while the
face cutting edges provide the finish of the surface being
generated. 2. End Milling - Milling accomplished with a tool
having cutting edges on its cylindrical sufaces as well as on
its end. In end milling - peripheral, the peripheral cutting
edges on the cylindrical surface are used; while in end milling-
slotting, both end and peripheral cutting edges remove metal.
3. Slide and Slot Milling - Milling of the side or slot of a
workpiece using a peripheral cutter. 4. Slab Milling - Milling
of a surface parallel to the axis of a helical, multiple-toothed
cutter mounted on an arbor. 5. Straddle Milling - Peripheral
milling a workpiece on both sides at once using two cutters
spaced as required.
XV-28
-------
Molecule - Chemical units composed of one or more atoms.
Monitoring - The measurement, sometimes continuous, of water quality.
Multi-Effect Evaporator - A series of evaporations and condensations
with the individual units set up in series and the latent heat of
vaporization from one unit used to supply energy for the next.
Multiple Operation Machinery - Two or more tools are used to perform
simultaneous or consecutive operations.
Multiple Subcategory Plant - A plant discharging process wastewater
from more than one manufacturing process subcategory.
National Pollutant Discharge Elimination System (NPDES) - The federal
mechanism for regulating point source discharge by means of
permits.
Navigable Waters - All navigable waters of the United States; tribu-
taries of navigable waters of the United States; interstate
waters,intrastate lakes, rivers and streams which are utilized
for recreational or other purposes.
Neutralization - Chemical addition of either acid or base to a solu-
tion such as the pH is adjusted to 7.
New Source - Any building, structure, facility, or installation from
which there is or may be the discharge of pollutants, the con-
struction of which is commenced after the publication of proposed
regulations prescribing a standard of performance under Section
306 of the Act which will be applicable to such source if such
standard is thereafter promulgated in accordance with Section
306 of the Act.
Nitriding - A heat treating method in which nitrogen is diffused into
the surface of iron-base alloys. (This is done by heating the
metal at a temperature of about 950 degrees F in contact with
ammonia gas or other suitable nitrogenous materials. The surface,
because of formation of nitrides becomes much harder than the
interior. Depth of the nitrided surface is a function of the
length of time of exposure and can vary from .0005" to .032"
thick. Hardness is generally in the 65 to 70 Re range, and,
therefore, these structures are almost always ground.)
Nitriding Steels - Steels which are selected because they form good
case hardened structures in the nitriding process. ( In these
steels, elements such as aluminum and chromium are important
for producing a good case.)
Nitrification (Biological) - The oxidation of nitrogenous matter into
nitrates by bacteria.
XV-29
-------
Noble Metals - Metals below hydrogen in the electromotive force series;
includes antimony, copper, rhodium, silver, gold, bismuth.
Noncontact Cooling Water - Water used for cooling which does not come
into direct contact with any raw material, intermediate product,
waste product, or finished product.
Nonferrous - No iron content.
Non-Water Quality Environmental Impact - The ecological impact as a
result of solid, air, or thermal pollution due to the appli-
cation of various wastewater technologies to achieve the effluent
guidelines limitations. Associated with the non-water quality
aspect is the energy impact of wastewater treatment.
Normalizing - Heat treatment of iron-base alloys above the critical
temperature, followed by cooling in still air. (This is often
done to refine or homogenize the grain structure of castings,
forgings and wrought steel products.)
Notching - Cutting out various shapes from the edge or side of a
sheet, strip, blank or part.
NPDES - See National Pollutant Discharge Elimination System.
Oil Cooker - Open-topped vessel contining a heat source and typically
maintained at 68°C (180°F) for the purpose of driving off excess
water from waste oil.
Operation and Maintenance Costs - The cost of running the wastewater
treatment equipment. This includes labor costs, material and
supply costs, and energy and power costs.
Organic Compound - Any substance that contains the element carbon,
with the exception of carbon dioxide and various carbonates.
ORP Recorders - Oxidation-reduction potential recorders.
Oxidants - Those substances which aid in the formation of oxides.
Oxidizable Cyanide - Cyanide amenable to oxidation.
Oxidizing - Combining the material concerned with oxygen.
Paint Stripping - The term "paint stripping" shall mean the process
of removing an organic coating from a workpiece or painting
fixture. The removal of such coatings using processes such
as caustic, acid, solvent and molten salt stripping are included.
XV-30
-------
Parameter - A characteristic element of constant factor.
Passivation - The changing of the chemically active surface of a
metal to a much less reactive state by means of an acid dip.
Patina - A blue green oxidation of copper.
Pearlite - A microstituent found in iron-base alloys consisting of
a lamellar (Patelike) composite of ferrite and iron carbide.
(This structure results from the decomposition of austenite
and is very common in cast irons and annealed steels.)
Peening - Mechanical working of metal by hammer blows or shot im-
pingement.
p_H - A unit for measuring hydrogen ion concentrations. A pH of 7
indicates a "neutral" water or solution. A pH lower than 7,
a solution is acidic. At pH higher than 1, a solution is
alkaline.
pH Buffer - A substance used to stabilize the acidity or alkalinity
in a solution.
Phenols - A group of aromatic compounds having the hydroxyl group
directly attached to the benzene ring. Phenols can be a con-
taminant in a waste stream from a manufacturing process.
Phosphate Coating - Process of forming a conversion coating on iron
or steel by immersing in a hot solution of manganese, iron or
zinc phosphate. Often used on a metal part prior to painting
or porcelainizing.
Phosphate - Salts or esters of phosphoric acid.
Phosphatizing - Process of forming rust-resistant coating on iron
or steel by immersing in a hot solution of acid manganese,
iron or zinc phosphates.
Photoresists - Thin coatings produced from organic solutions
which when exposed to light of the proper wave length are
chemically changed in their solubility to certain solvents
(developers). This substance is placed over a surface which
is to be protected during processing such as in the etching
of printer circuit boards.
Photosensitive Coating - A chemical layer that is receptive to
the action of radiant energy.
XV-31
-------
Pickling - The immersion of all or part of a workpiece in a
corrosive media such as acid to remove scale and related
surface coatings.
Planing - Producing flat surfaces by linear reciprocal motion of
the work and the table to which it is attached relative to
a stationary single-point cutting tool.
Plant Effluent or Discharge After Treatment - The wastewater
discharged from the industrial plant. In this definition,
any waste treatment device (pond, trickling filter, etc.)
is considered part of the industrial plant.
Plasma Arc Machining - The term "plasma arc machining" shall mean
the process of material removal or shaping of a workpiece
by a high velocity jet of high temperature ionized gas.
Plated Area - Surface upon which an adherent layer of metal is
deposited.
Plating - Forming an adherent layer of metal upon an object.
Point Source - Any discernible, confined, and discrete conveyance
including, but not limited to, any pipe, ditch, channel,
tunnel, conduit, well, discrete fissure, container, rolling
stock, concentrated animal feeding operation, or vessel or
other floating craft from which pollutants are or may be
discharged.
Point Source Category - See Category.
Polishing - The process of removing stock from a workpiece by the
action of loose or loosely held abrasive grains carried to
the workpiece by a flexible support. Usually, the amount of
stock removed in a polishing operation is only incidental to
achieving a desired surface finish or appearance.
Polishing Compounds - Fluid or grease stick lubricants composed
of animal tallows, fatty acids, and waxes. Selection depends
on surface finish desired.
Pollutant - Dredged spoil, solid waste, incinerator residue, sewage,
garbage, sewage sludge, munitions, chemical wastes, biological
materials, radioactive materials, heat, wrecked or discarded
equipment, rock, sand, cellar dirt and industrial, municipal
and agricultural waste discharged into water. It does not
mean (1) sewage from vessels or (2) water, gas, or other mat-
erial which is injected into a well to facilitate production
of oil or gas, or water derived in association with oil or
gas production and disposed of in a well, if the well, used
either to facilitate production or for disposal purposes, is
XV-32
-------
approved by authority of the State in which the well is
located, and if such State determines that such injection
or disposal will not result in degradation of ground or
surface water resources.
Pollutant Parameters - Those constituents of wastewater deter-
minded to be detrimental and, therefore, requiring control.
Pollution - The man-made or man-induced alternation of the
chemical, physical, biological, and radiological integrity
of water.
Polychlorinated Biphenyl (PCB) - A family of chlorinated biphenyls
with unique thermal properties and chemical inertness which
have a wide variety of uses as plasticizers, flame retardants
and insulating fluids. They represent a persistent contam-
inant in waste streams and receiving waters.
Polyelectrolyte - A high polymer substance, either natural or
synthetic, containing ionic constituents; they may be either
cationic or anionic.
Post Curring - Treatment after changing the physical properties
of a material by chemical reaction.
Pouring - (Casting and Molding) Transferring molten metal from
a furnace or a ladle to a mold.
Power Brush Finishing - This is accomplished (wet or dry) using a
wire or nonmetallic-fiber-filled brush used for deburring,
edge blending and surface finishing of metals.
Precious Metals - Gold, silver, iridium, palladium, platinum,
rhodium, ruthenium, indium, osmium, or combination thereof.
Precipitate - The discrete particles of material rejected from a
liquid solution.
Precipitation Hardening Metals - Certain metal compositions which
respond to precipitation hardening or aging treatment.
Pressure Deformation - The process of applying force, (other than
impact force), to permanently deform or shape a workpiece.
Pressure deformation operations may include operations such
as rolling, drawing, bending, embossing, coining, swaging,
sizing, extruding, squeezing, spinning, seaming, piercing,
necking, reducing, forming, crimping, coiling, twisting,
winding, flaring or weaving.
Pressure Filtration - The process of solid/liquid phase separation
effected by passing the more permeable liquid phase through a
mesh which is impenetrable to the solid phase.
XV-33
-------
Pretreatment - Treatment of wastewaters from sources before intro-
duction into municipal treatment works.
Primary Settling - The first treatment for the removal of settle-
able solids from wastewater which is passed through a treat-
ment works.
Primary Treatment - The first stage in wastewater treatment in
which floating or settleable solids are mechanically removed
by screening and sedimentation.
Printed Circuit Boards - A circuit in which the interconnecting
wires have been replaced by conductive strips printed, etched,
etc., onto an insulating board. Methods of fabrication in-
clude etched circuit, electroplating, and stamping.
Printing - A process whereby a design or pattern in ink or types
of pigments are impressed onto the surface of a part.
Process Modification - (In-Plant Technology) Reduction of water
pollution by basic changes in a manufacturing process.
Process Wastewater - Any water which, during manufacturing or
processing, comes into direct contact with or results from
the production or use of any raw material, intermediate
product, finished product, byproduct, or waste product.
Process Water - Water prior to its direct contact use in a process
or operation. (This water may be any combination of raw water,
service water, or either process wastewater or treatment facil-
ity effluent to be recycled or reused).
Punching - A method of cold extruding, cold heading, hot forging or
stamping in a machine whereby the mating die sections control
the shape or contour of the part.
Pyrolysis - (Sludge Removal) Decomposition of materials by the
application of heat in any oxygen-deficient atmosphere.
Pyrazolone-Colorimetric - A standard method of measuring cyanides
in aqueous solutions.
Quantity GPP - Gallons per day.
Quenching - Rapid cooling of alloys by immersion in water, oil, or
gases after heating.
Racking - The placement of parts on an apparatus.for the purpose
of plating.
Rack Plating - Electroplating of workpieces on racks.
KV-34
-------
Radiography - A nondestructive method of internal examination
in which metal or other objects are exposed to a beam of
x-ray or gamma radiation. Differences in thickness, density
or absorption, caused by internal discontinuities, are
apparent in the shadow image either on a fluorescent screen
or on photographic film placed behind the object.
Raw Water - Plant intake water prior to any treatment or use.
Reaming - An operation in which a previously formed hole is sized
and contoured accurately by using a rotary cutting tool (reamer)
with one or more cutting elements (teeth). The principal sup-
port for the reamer during the cutting action is obtained from
the workpiece. 1. Form Reaming - Reaming to a contour shape.
2. Taper Reaming - Using a special reamer for taper pins. 3.
Hand Reaming - Using a long lead reamer which permits reaming
by hand. 4. Pressure Coolant Reaming (or Gun Reaming) -
Using a multiple-lip, end cutting tool through which coolant is
forced at high pressure to flush chips ahead of the tool or
back through the flutes for finishing of deep holes.
Receiving Waters - Rivers, lakes, oceans, or other water courses
that receive treated or untreated wastewaters.
Recirculating Spray - A spray rinse in which the drainage is pumped
up to the spray and is continually recirculated.
Recycled Water - Process wastewater or treatment facility effluent
which is recirculated to the same process.
Recycle Lagoon - A pond that collects treated wastewater, most of
which is recycled as process water.
Reduction - A reaction in which there is a decrease in valence
resulting from a gain in electrons.
Redox - A term used to abbreviate a reduction-oxidation reaction.
Residual Chlorine - The amount of chlorine left in the treated
water that is available to oxidize contaminants.
Reverse Osmosis - The application of pressure to the surface of
solution through a semipermeable membrane that is too dense
to permit passage of the solute, leaving behind the dissolved
solids (concentrate).
Reused Water - Process wastewater or treatment facility effluent
which is further used in a different manufacturing process.
Ring Rolling - A metals process in which a doughnut shaped piece of
stock is flattened to the desired ring shape by rolling between
variably spaced rollers. This process produces a seamless ring.
XV-35
-------
Rinse - Water for removal of dragout by dipping, spraying,
fogging, etc.
Riveting - Joining of two or more members of a structure by means
of metal rivets, the undeaded end being upset after the rivet
is in place.
Routing - Cutting out and contouring edges of various shapes in a
relatively thin material using a small diameter rotating
cutter which is operated at fairly high speeds.
Running Rinse - A rinse tank in which water continually flows in
and out.
Rust Prevention Compounds - Coatings used to protect iron and steel
surfaces, against corrosive environment during fabrication,
storage, or use.
Salt - 1. The compound formed when the hydrogen of an acid is
replaced by a metal or its equivalent (e.g., an NH4 radical).
Example: HC1 + NaOH = NaCl + H20
This is typical of the general rule that the reaction of an
acid and a base yields a salt and water. Most salts ionize
in water solution. 2. Common salt, sodium chloride, occurs
widely in nature, both as deposits left by ancient seas and
in the ocean, where its average concentration is about 3%.
Salt Bath Descaling - Removing the layer of oxides formed on some
metals at elevated temperatures in a salt solution. See:
Reducing, Oxidizing, Electrolytic.
Sand Bed Drying - The process of reducing the water content in a wet
substance by transferring that substance to the surface of a
sand bed and allowing the processes of drainage through the
sand and evaporation to effect the required water separation.
Sand Blasting - The process of removing stock including surface
films, from a workpiece by the use of abrasive grains
pneumatically impinged against the workpiece.
Sand Filtration - A process of filtering wastewater through sand.
The wastewater is trickled over the bed of sand where air and
bacteria decompose the wastes. The clean water flows out
through drains in the bottom of the bed. The sludge accumulat-
ing at the surface must be removed from the bed periodically.
Sanitary Water - The supply of water used for sewage transport and
the continuation of such effluents to disposal.
Sanitary Sewer - Pipes and conveyances for sewage transport.
Save Rinse - See Dead Rinse-
XV-3 6
-------
Sawing - Using a toothed blade or disc to sever parts or cut
contours. 1. Circular Sawing - Using a circular saw fed
into the work by motion of either the workpiece or the
blade. 2. Power Band Sawing - Using a long, multiple-
tooth continuous band resulting in a uniform cutting
action as the workpiece is fed into the saw. Power Hack
Sawing - Sawing in which a reciprocating saw blade is fed
into the workpiece.
Scale - Oxide and metallic residues.
Screening - Selectively applying a resist material to a surface
to be plated.
Secondary Settling - Effluent from some prior treatment process
flows for the purpose of removing settleable solids.
Secondary Treatment - The second step in most sanitary waste
treatment plants in which bacteria consume the organic
portions of the waste. This removal is accomplished by trick-
ling filters, an activated sludge unit, or other processes.
Sedimentation - The process of subsidence and deposition of suspended
matter carried by water, wastewater, or other liquids by
gravity. It is usually accomplished by reducing the velocity
of the liquid below the point at which it can transport the
suspended material. Also called settling.
Sensitization - The process in which a substance other than the
catalyst is present to facilitate the start of a catalytic
reaction.
Sequestering Agent - An agent (usually a chemical compound) that
"sequesters" or holds a substance in suspension.
Series Rinse - A series of tanks which can be individually heated
or level controlled.
Service Water - Raw water which has been treated preparatory to
its use in a process or operation; i.e., makeup water.
Settleable Solids - That matter in wastewater which will not stay
in suspension during a preselected settling period, such as one
hour, but either settles to the bottom or floats to the top.
Settling Ponds - A large shallow body of water into which indus-
trial wastewaters are discharged. Suspended solids settle
from the wastewaters due to the large retention time of water
in the pond.
XV-3 7
-------
Shaping - Using single point tools fixed to a ram reciprocated in
a linear motion past the work. 1. Form Shaping - Shaping
with a tool ground to provide a specified shape. 2. Contour
Shaping - Shaping of an irregular surface, usually with the
aid of a tracing mechanism. 3. Internal Shaping - Shaping
of internal forms such as keyways and guides.
Shaving - 1. As a finishing operation, the accurate removal of a
thin layer by drawing a cutter in straight line motion across
the work surfaces. 2. Trimming parts like stampings, forgings
and tubes to remove uneven sheared edges or to improve accuracy,
Shearing - The process of severing or cutting of a workpiece by
forcing a sharp edge or opposed sharp edges into the workpiece
by forcing a sharp edge or opposed sharp edges into the work-
piece stressing the material to the point of sheer failure and
separation.
Shipping - Transporting.
Shot Peening - Dry abrasive cleaning of metal surfaces by impacting
the surfaces with high velocity steel shot.
Shredding - (Cutting or Stock Removal) Material cut, torn or broken
up into small parts.
SIC - Standard Industrial Classification - Defines industries in
accordance with the composition and structure of the economy
and covers the entire field of economic activity.
Silica - (Si02^ Dioxide of silicon which occurs in crystalline form
as quartz, cristohalite, tridymite. Used in its pure form for
high-grade refractories and high temperature insulators and in
impure form (i.e. sand) in silica bricks.
Siliconiz ing - Diffusing silicon into solid metal, usually steel,
at an elevated temperature for the purposes of case hardening
thereby providing a corrosion and wear-resistant surface.
Sintering - The process of forming a mechanical part from a
powdered metal by bonding under pressure and heat but below
the melting point of the basis metal.
Sizing 1. Secondary forming or squeezing operations, required
to square up, set down, flatten or otherwise correct surfaces,
to produce specified dimensions and tolerances. See restriking.
2. Some burnishing, broaching, drawing and shaving operations
are also called sizing. 3. A finishing operation for correct-
ing ovality in tubing. 4. Powder metal. Final pressing of
a sintered compact.
XV-38
-------
Skimming - The process of removing floating solid or liquid wastes
from a wastewater stream by means of a special tank and skim-
ming mechanism prior to treatment of the water.
Slaking - The process of reacting lime with water to yield a
hydrated product.
Sludge - Residue produced in a waste treatment process.
Sludge Dewatering - The removal of water from sludge by introducing
the water sludge slurry into a centrifuge. The sludge is
driven outward with the water remaining near the center. The
water is withdrawn and the dewatered sludge is usually land-
filled.
Slurry - A watery suspension of solid materials.
Snagging - Heavy stock removal of superfluous material from a work
piece by using a portable or swing grinder mounted with a
coarse grain abrasive wheel.
Soldering - 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).
Solids - (Plant Waste) Residue material that has been completely
dewatered.
Solute - A dissolved substance.
Solution - Homogeneous mixture of two or more components such as a
liquid or a solid in a liquid.
Solution Treated - (Metallurgical) A process by which it is
possible to dissolve micro-constituents by taking certain
alloys to an elevated temperature and then keeping them in
solution after quenching. (Often a solution treatment is
followed by a precipitation or aging treatment to improve
the mechanical properties. Most high temperature alloys which
are solution treated and aged machine better in the solution
treated state just before they are aged.)
Solvent - A liquid used to dissolve materials. In dilute solutions
the component present in large excess is called the solvent
and the dissolved substance is called the solute.
Solvent Cleaning - Removal of oxides, soils, oils, fats, waxes,
greases, etc. by solvents.
XV-3 9
-------
Solvent Degreasing - The removal of oils and grease from a
workpiece using organic solvents or solvent vapors.
Specific Conductance - The property of a solution which allows
an electric current to flow when a potential difference is
applied.
Spectrophotometry - A method of analyzing a wastewater sample by
means of the spectra emitted by its constituents under
exposure to light.
Spray Rinse - A process which utilizes the expulsion of water
through a nozzle as a means of rinsing.
Spinning - Shaping of seamless hollow cylindrical sheet metal parts
by the combined forces of rotation and pressure.
Spotfacing - Using a rotary, hole piloted end facing tool to produce
a flat surface normal to the axis of rotation of the tool on or
slightly below the workpiece surface.
Sputtering - The process of covering a metallic or non-metallic
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.
Squeezing - The process of reducing the size of a piece of heated
material so that it is smaller but more compressed than it
was before.
Stainless Steels - Steels which have good or excellent corrosion
resistance. (One of the common grades contains 18% chromium
and 8% nickel. There are three broad classes of stainless
steels - ferritic, austenitic, and martensitic. These various
classes are produced through the use of various alloying
elements in differing quantities.
Staking - Fastening two parts together permanently by recessing
one part within the other and then causing plastic flow at
the joint.
Stamping - A general term covering almost all press operations.
It includes blanking, shearing, hot or cold forming, drawing,
bending and coining.
Stamping Compounds - See Forming Compounds (Sheet).
Standard of Performance - Any restrictions established by the Admin-
istrator pursuant to Section 306 of the Act on quantities,
rates and concentrations of chemical, physical, biological,
and other constituents which are or may be discharged from
new sources into navigable waters, the waters of the contiguous
zone or the ocean.
XV-40
-------
Stannous Salt - Tin based compound used in the acceleration process.
Usually stannous chloride.
Utill Rinse - See Dead Rinse.
Storm Water Lake - Reservoir for storage of storm water runoff
collected from plant site; also, auxiliary source of process
water.
Stress Relieved - The heat treatment used to relieve the internal
stresses induced by forming or heat treating operations.
(It consists of heating a part uniformly, followed by cooling
slow enough so as not to reintroduce stresses. To obtain low
stress levels in steels and cast irons, temperatures as high
as 1250 degrees F may be required.)
Strike - A thin coating of metal (usually less than 0.0001 inch in
thickness) to be followed by other coatings.
Stripping - The removal of coatings from metal.
Subcategory or Subpart - A segment of a point source for which
specific effluent limitations have been established.
Submerged Tube Evaporation - Evaporation of feed material using
horizontal steam-heat tubes submerged in solution. Vapors
are driven off and condensed while concentrated solution is
bled off.
Subtractive Circuitry - Circuitry produced by the selective etching
of a previously deposited copper layer.
Substrates - Thin coatings ( as of hardened gelatin) which act as a
support to facilitate the adhesion of a sensitive emulsion.
Surface Tension - A measure of the force opposing the spread of
a thin film of liquid.
Surface Waters - Any visible stream or body of water.
Surfactants - Surface active chemicals which tend to lower the
surface tension between liquids, such as between acid and
water.
Surge - A sudden rise to an excessive value, such as flow, pressure,
temperature.
Swaging - Forming a taper or a reduction on metal products such as
rod and tubing by forging, squeezing or hammering.
Tank - A receptacle for holding transporting or storing liquids.
XV-41
-------
Tapping - Producing internal threads with a cylindrical cutting
tool having two or more peripheral cutting elements shaped
to cut threads of the desired size and form. By a combination
of rotary and axial motion, the leading end of the tap cuts
the thread while the tap is supported mainly by the thread it
produces.
Tempering - Reheating a quench-hardened or normalized ferrous alloy
to a temperature below the transformation range then cooling
at any rate desired.
Testing - The application of thermal, electrical, or mechanical
energy to determine the suitability or functionality of a
part, assembly or complete unit.
Thermal Cutting - The term "thermal cutting" shall mean the process
of cutting, slotting or piercing a workpiece using an
oxy-acetylene oxygen lance or electric arc cutting tool.
Thermal Infusion - The process of applying a fused zinc, cadmium or
other metal coating to a ferrous workpiece by imbueing the
surface of the workpiece with metal powder or dust in the
presence of heat.
Thickener - A device or system wherein the solid contents of slurries
or suspensions are increased by gravity settling and mechanical
separation of the phases, or by flotation and mechanical separ-
ation of the phases.
Thickening - (Sludge Dewatering) Thickening or concentration is the
process of removing water from sludge after the initial separ-
ation of the sludge from wastewater. The basic objective of
thickening is to reduce the volume of liquid sludge to be
handled in subsequent sludge disposal processes.
Threading - Producing external threads on a cylindrical surface.
1. Die Threading - A process for cutting external threads
on cylindrical or tapered surfaces by the use of solid or
self-operning dies. 2. Single-Point Threading - Turing
threads on a lathe. 3. Thread Grinding - See definition
under grinding. 4. Thread Milling - A method of cutting
screw threads with a milling cutter.
Threshold Toxicity - Limit upon which a substance becomes toxic or
poisonous to a particular organism.
Through Hole Plating - The plating of the inner surfaces of holes in
a PC board.
Titration 1. A method of measuring acidity of alkalinity. 2. The
determination of a constituent in a known volume of solution by
the measured addition of a solution of known strength for complet-
ion of the reaction as signaled by observation of an end point.
XV-42
-------
Total Chromium - The sum of chromium in all valences.
Total Cyanide - The total content of cyanide expressed as the
radical CN- or alkali cyanide whether present as simple or
complex ions. The sum of both the combined and free cyanide
content of a plating solution. In analytical terminology,
total cyanide is the sum of cyanide amenable to oxidation
by chlorine and that which is not according to standard
analytical methods.
Total Dissolved Solids (TDS) - The total amount of dissolved solid
materials present in an aqueous solution.
Total Metal - Sum of the metal content in both soluble and insoluble
form.
Total Organic Carbon (TOC) - TOC is a measure of the amount of
carbon in a sample originating from organic matter only. The
test is run by burning the sample and measuring the CC^2
produced.
Total Solids - The sum of dissolved and undissolved constituents
in water or wastewater, usually stated in milligrams per liter.
Total Suspended Solids (TSS) - Solids found in wastewater or in the
stream, which in most cases can be removed by filtration. The
origin of suspended matter may be man-made or of natural
sources, such as silt from erosion.
Total Volatile Solids - Volatile residue present in wastewater.
Tool Steels - Steels used to make cutting tools and dies. (Many of
these steels have considerable quantities of alloying elements
such as chromium, carbon, tungsten, molybdenum and other
elements. These form hard carbides which provide good wearing
qualities but at the same time decrease machinability. Tool
steels in the trade are classified for the most part by their
applications, such as hot work die, cold work die, high speed,
shock resisting, mold and special purpose steels.)
Toxic Pollutants - A pollutant or combination of pollutants including
disease causing agents, which after discharge and upon exposure,
ingestion, inhalation or assimilation into any organism either
directly or indirectly cause death, disease, cancer, genetic
mutations, physiological malfunctions (including malfunctions
in such organisms and their offspring.
Treatment Facility Effluent - Treated process wastewater.
Trepanning - Cutting with a boring tool so designed as to leave
an unmachined core when the operation is completed.
XV-4 3
-------
Trickling Filters - A filter consisting of an artificial bed of
coarse material, such as broken stone, clinkers, slate, salts, or
brush over which an effluent is distributed and applied in drops,
films, or spray from troughs, drippers, moving distributors, or
fixed nozzles and through which it trickles to the underdrains
giving opportunity for the formation of zoological slimes which
clarify and oxidize the effluent.
Tumbling - See Barrel Finishing.
Tubidimeter - An instrument for measurement of turbidity in which
a standard suspension is usually used for reference.
Turbidity - 1. A condition in water or wastewater caused by the
presence of suspended matter resulting in the scattering and
absorption of light rays. 2. A measure of fine suspended
matter in liquids. 3. An analytical quantity usually report-
ed in arbitrary turbidity units determined by measurements of
light diffraction.
Turning - Generating cylindrical forms by removing metal with a
single-point cutting tool moving parallel to the axis of
rotation of the work. 1. Single-Point Turning - Using a
tool with one cutting edge. 2. Face Turning - Turning a
surface perpendicular to the axis of the workpiece. 3.
Form Turning - Using a tool with a special shape. 4.
Turning Cutoff - Severing the workpiece with a special
lathe tool. 5. Box Tool Turning - Turning the end of
workpiece with one or more cutters mounted in a boxlike
frame, primarily for finish cuts.
Ultrafiltration - A process using semipermeable polymeric membranes
to separate molecular or colloidal materials dissolved or
suspended in a liquid phase when the liquid is under pressure.
Ultrasonic Agitation - The agitation of a liquid medium through
the use of ultrasonic waves.
Ultrasonic Cleaning - Immersion cleaning aided by ultrasonic waves
which cause microagitation.
Ultrasonic Machining - Material removal by means of an ultrasonic-
vibrating tool usually working in an abrasive slurry in close
contact with a workpiece or having diamond or carbide cutting
particles on its end.
Unit Operation - A single, discrete process as part of an overall
sequence, e.g., precipitation, settling and filtration.
Vacuum Deposition - Condensation of thin metal coatings on the cool
surface of work in a vacuum.
XV-4 4
-------
Vacuum Evaporization - A method of coating articles by melting
and vaporizing the coating material on an electrically
heated conductor in a chamber from which air has been
exhausted. The process is only used to produce a decor-
ative effect. Gold, silver, copper and aluminum have been
used.
Vacuum Filtration - A sludge dewatering process in which sludge
passes over a drum with a filter medium, and a vacuum is
applied to the inside of the drum compartments. As the
drum rotates, sludge accumulates on the filter surface,
and the vacuum removes water.
Vacuum Metalizing - The process of coating a workpiece with
metal by flash heating metal vapor in a high-vacuum
chamber containing the workpiece. The vapor condenses on
all exposed surfaces.
Vapor Blasting - A method of roughing plastic surfaces in prepar-
ation foe plating.
Vapor Degreasing - Removal of soil and grease by a boiling liquid
solvent, the vapor being considerably heavier than air. At
least one constituent of the soil must be soluble in the
solvent.
Vapor Plating - Deposition of a metal or compound upon a heated
surface by reduction or decomposition of a volatile compound
at a temperature below the melting points of either the
deposit or the basis material.
Viscosity - The resistance offered by a real fluid to a shear
stress.
Volatile Substances - Material that is readily vaporizable at a
relatively low temperature.
Volumetric Method - A standard method of measuring settleable
solids in an aqueous solution.
Waste Discharged - The amount (usually expressed as weight) of
some residual substance which is suspended or dissolved
in the plant effluent.
Wastewater Constituents - Those materials which are carried by
or dissolved in a water stream for disposal.
XV-4 5
-------
Wastewater - Any water that has been released from the purpose
for which it was intended to be used.
Water Balance - An accounting of all water entering and leaving
a unit process or operation in either a liquid or vapor
form or via raw material, intermediate product, finished
product, by-product, waste product, or via process leass,
so that the difference in flow between all entering and
leaving streams is zero. The water balance should clearly
identify and indicate the magnitude of each water flow and
distinguish between process wastewater and non-contact cool-
ing water.
Water Recirculation or Recycling - The volume of water already
used for some purpose in the plant which is returned with or
without treatment to be used again in the same or another
process.
Water Use - The total volume of water applied to various uses in
the plant. It is the sum of water recirculation and water
withdrawal.
Water Withdrawal or Intake - The volume of fresh water removed
from a surface or underground water source by plant facil-
ities or obtained from some source external to the plant.
Welding - 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 interface.
Wet Air Oxidation - (Sludge Disposal) The process of oxidizing
sludge in the liquid phase without mechanical dewatering.
High-pressure high-temperature air is brought into contact
with the waste material in a pressurized reactor. Oxidation
occurs at 300 to 500 degrees F and from several hundred to
3,000 psig.
Wholesale Price Index - A measure of the fluctuation of the
wholesale price of goods and services with time. The base
period to which all wholesale prices are related is 1967
(index = 100).
Withdrawal Phase - Period for the withdrawal of a part of
workpiece from an immersion tank.
"Vorkpiece - The item to be processed.
"ought - Condition of a material which has been worked mechani-
cally as in forging, rolling, drawing, et.
XV-4 6
-------