U.S. DEPARTMENT OF COMMERCE
National Technical Information Service
PB-258 953
Assessment of Industrial
Hazardous Waste Practices,
Textiles Industry
Versar, Inc, Springfield, Va
Prepared for
Environmental Protection Agency, Washington, D C Office of Solid Waste
Management Programs
Jun 76
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BIBLIOGRAPHIC DATA
SHEET
1. Report No.
3. Recipient's Accession No.
PB-258 953
4. Title and Subtitle
Assessment of Industrial Hazardous Waste Practices/
Textiles Industry.
5. Report Date
June, 1976
6.
7. Author(s)
E. F. Abrams, D. K. Guinan, D. Derkiss
8« Performing Organization Rept.
No- 469
9. Performing Organization Name and Address
10. Project/Task/Work Unit No.
Versar, Inc.
6621 Electronic Drive
Springfield, Virginia
22151
11. Contract/Grant No.
EPA No. 68-01-3178
12. Sponsoring Organization Name and Address
EPA Hazardous Waste Management Division
office of Solid Waste Management Programs
Waterside Mall
401 M Street, S.W., Washington, D.C. 20460
13. Type of Report & Period
Covered ,-, < -,
Final.
April to December 197
u.
15. Supplementary Notes
EPA Project Officer - Matthew Straus
16. Abstracts This report, which covers textiles manufacturing operations, is one of a
series of several studies which examine land-destined wastes from selected industries.
The textiles industry is covered under Standard Industrial Classification (SIC) 22.
The textiles industry was studied because of the use of heavy metals such as chromium
and copper in some of the dyeing and finishing operations. These metals can be toxic
in certain concentrations and forms. The various dyes and organic chemicals used
were also considered for potential hazard. The potentially hazardous wastes destined
for land disposal include dye and chemical containers with residuals and wastewater
treatment sludges. The amount of sludges is expected to increase as effluent guide-
lines limitations are implemented.
17. Key Words and Document Analysis. 17a. Descriptors
Textiles
Wool
Knit Fabric
T-foven Fabric
Yarn and Stock
Carpet
Dye
Finish
17b. Identifiers/Open-Ended Terms
Sludges
Chromium
Cobalt
Cadmium
Copper
Lead
Disposal Technology
Disposal Cost
Nickel
Zinc
Arsenic
Organics
Landfills
17c. COSATI Field/Group
Prices subject to change
18. Availability Statement
19. Security Class (This
Report)
UNCLASSIFIED
20. Security Class (This
Page
UNCLASSIFIED
21. No. of Pages
276
22. Price
FORM NTIS-35 (REV. 3-72)
USCOMM-DC 14952-P7Z
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INDUSTRIAL HAZARDOUS WASTE PRACTICES, TEXTILES INDUSTRY
AN ASSESSMENT
This report (SW-l25o) was prepared for the
Office of Solid Waste Management Programs under
Contract No. 68-01-3178 and is reproduced
as received from the contractor.
U.S. ENVIPCNMENTAL PROTECTION AGENCY
1976
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This report has been reviewed by the Hazardous Waste Management
Division, Office of Solid Waste Management Programs, EPA, and approved
for publication. Approval does not signify that the contents necessarily
reflect the views and policies of the Environmental Protection Agency,
nor does mention of trade names or commercial products constitute endorse-
ment or recommendation for use.
ii
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TABLE OF CONTENTS
Section Page
1.0 EXECUTIVE SUMMARY .................. 1-1
1.1 Introduction .................. 1-1
1.2 Program Methodology ............... 1-2
1.3 Summary of the Study .............. 1-4
2.0 DESCRIPTION OF THE TEXTILES INDUSTRY ......... 2-1
2.1 Introduction .................. 2-1
2.2 Discussion of the Textiles Industry ...... 2-1
2.3 Industry Characterization ............ 2-8
3.0 WASTE CHARACTERIZATION
3.1 Introduction .................. 3-1
3.2 Criteria for Determination of Potentially
Hazardous Wastes ................ 3-1
3.3 Discussion of Sampling Techniques and
Analytical Methods Used ............. 3-9
3.4 Characterization of Waste Types by
Industry Categories ............... 3-10
3.5 Total Waste Quantities in the Textiles Industry
for 1974, 1977 and 1983 ............. 3-81
3.6 Rationale for Determining Waste Streams for
Technology and Cost Analysis .......... 3-81
4.0 TREATMENT AND DISPOSAL TECHNOLOGY .......... 4-1
4.1 Introduction .................. 4-1
4.2 Waste Management Practices in the Textiles
Industry .................... 4-2
4.3 Current Hazardous Waste Management Practices . . 4-4
4.4 Comparison of On-Site Vs. Off-Site Treatment
and Disposal .................. 4-10
4.5 Safeguards Employed by the Textiles Industry. . . 4-11
4.6 Hazardous Waste Management by Private
Contractors ................... 4-12
4.7 Treatment and Disposal Technologies for
Potentially Hazardous Waste Streams by
Industry Category ................ 4-12
5.0 COST ANALYSIS .................... 5-1
5.1 Introduction .................. 5-1
5.2 Techniques and Assumptions Used ......... 5-1
5.3 General Cost Basis for Treatment and
Disposal Technologies .............. 5-6
5.4 Costs for Levels I, II, and III Technologies . . 5-10
5.5 Extrapolation of Technology Costs to the
Industry Categories and the Entire Industry . . . 5-29
111
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Section
5.6 Comparison of Technology Costs with Sales
Values for the Industry Categories and the
Entire Industry 5-29
5.7 Treatment/Disposal Costs for Miscellaneous
Atypical Potentially Hazardous Textiles
Industry Wastes 5-32
6.0 REFERENCES AND ADDITIONAL SOURCES OF INFORMATION ... 6-1
7.0 AO
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LIST OF FIGURES
Figure
1-1 Estimated Quantities of Total Waste to Land
Disposal, 1974 (Dry/Vfet Weight) 1-11
1-2 Estimated Quantities of Total Potentially Hazardous
Dye and Chemical Container Wastes to Land Disposal
(Dry Weight), 1974 1-12
1-3 Estimated Quantities of Total Potentially Hazardous
Wastewater Treatment Sludge to Land Disposal,
(1974) DryAfet Weight 1-13
1-4 Typical Model of Level I Technology for Poten-
tially Hazardous Waste Streams in the Textiles
Industry 1-15
1-5 Typical Model of Level II Technology for Potentially
Hazardous Waste Streams in the Textiles Industry . . . 1-16
1-6 Typical Model of Level III Technologies for Poten-
tially Hazardous Waste Streams in the Textiles
Industry , 1-17
3-1 Category A - Typical Wool Scouring Process 3-12
3-2 Category B - Typical Wool or Wool Blend Fabric
Dyeing and Finishing Process 3-20
3-3 Category C - Typical Greige Goods Process 3-30
3-4 Category D - Typical Woven Fabric Dyeing and Finishing
Process 3-34
3-5 Category E - Typical Knit Fabric Dyeing and Finish-
ing Process 3-46
3-6 Category F - Typical Tufted Carpet Dyeing and Finish-
ing Process f , . . 3-59
3-7 Category G - Typical Yarn and Stock Dyeing and Finish-
ing Process 3-71
4-1 Typical Model of Level I Technology for Poten-
tially Hazardous Waste Streams in the Textiles
Industry 4-23
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Figure Page
if
4-2 Typical Model of Level II Technology for Poten-
tially Hazardous Waste Streams in the Textiles
Industry 4-24
4-3 Typical Model of Level III Technologies for Poten-
tially Hazardous Waste Streams in the Textiles
Industry 4-25
5-1 Regional Transportation Costs 5-9
vi
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LIST OF TABLES
Table
1-1 Summary of Land Destined Total and Potentially
Hazardous Wastes from the Textiles Industry 1-10
1-2 Summary of the Levels of Technology Determined for
the Potentially Hazardous Waste Streams in the
Textiles Industry !~18
1-3 Extrapolation of Technology Costs to the Industry
Categories and the Entire Textiles Industry 1-21
1-4 Comparison of Technology Costs with the Total Sales
by Industry Category and the Entire Textiles
Industry 1-22
2-1 Distribution of Textile Plants by Industry
Category 2-10
2-2 Distribution of Textile Plants by Size (Number
of Employees) 2-12
2-3 Distribution of Production Equipment by Age for
Plants Visited by Industry Category 2-14
2-4 Estimated Distribution of Production by Industry
Category 2-16
3-1 Category A - Wool Scouring 3-14
3-2 Category A - Estimated Quantities of Total Wastes
from Wool Scouring Operations 3-16
3-3 Category A - Quantities of Potentially Hazardous
Wastewater Treatment Sludges from Wool Scouring
Operations 3-17
3-4 Category A - Quantities of Potentially Hazardous
Wastewater Treatment Sludges from Wool Scouring
Operations 3-18
3-5 Category B - Wool Fabric Dyeing & Finishing Sludge
Analyses 3-23
3-6 Category B - Estimated Quantities of Total Wastes
from Wool Fabric Dyeing and Finishing Operations . . . 3-24
3-7 Category B - Quantities of Potentially Hazardous
Dye and Chemical Container Wastes from Wool Fabric
Dyeing and Finishing Operations, 1974, 1977, and
1983 3-25
Vll
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Table
3-8 Category B - Quantities of Potentially Hazardous
Wastewater Treatment Sludges from Wool Fabric
Dyeing and Finishing Operations, 1974 3-26
3-9 Category B - Quantities of Potentially Hazardous
Wastewater Treatment Sludges from Wool Fabric
Dyeing and Finishing Operations, 1977 3-27
3-10 Category B - Quantities of Potentially Hazardous
Wastewater Treatment Sludges from Wool Fabric
Dyeing and Finishing Operations, 1983 3-28
3-11 Category C - Estimated Quantities of Total
Wastes from Greige Goods Operations,
Dry Basis 3-32
3-12 Category D - Woven Fabric Dyeing & Finishing
Sludge Analyses 3-37
3-13 Category D - Estimated Quantities of Total
Wastes from Woven Fabric Dyeing and Finishing
Operations 3-38
3-14 Category D - Quantities of Potentially
Hazardous Dye and Chemical Container Wastes
from Woven Fabric Dyeing and Finishing
Operations, 1974 3-39
3-15 Category D - Quantities of Potentially
Hazardous Dye and Chemical Container Wastes
from Woven Fabric Dyeing and Finishing
Operations, 1.977 3-40
3-16 Category D - Quantities of Potentially
Hazardous Dye & Chemical Container Wastes
from Woven Fabric Dyeing and Finishing
Operations, 1983 3-41
3-17 Category D - Quantities of Potentially
Hazardous Wastewater Treatment Sludges from
Woven Fabric Dyeing and Finishing Operations, 1974 . . 3-42
3-18 Category D - Quantities of Potentially
Hazardous Wastewater Treatment Sludges from
Woven Fabric Dyeing and Finishing Operations, 1977 . . 3-43
3-19 Category D - Quantities of Potentially
Hazardous Wastewater Treatment Sludges from
Woven Fabric Dyeing and Finishing Operations, 1983 . . 3-44
viii
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Table Page
3-20 Category E - Knit Fabric Dyeing and Finishing
Sludge Analyses 3-49
3-21 Category E - Estimated Quantities of Total
Waste from Knit Fabric Dyeing and Finishing
Operations 3-51
3-22 Category E - Quantities of Potentially
Hazardous Dye and Chemical Container Wastes
frcm Knit Fabric Dyeing and Finishing
Operations, 1974 3-52
3-23 Category E - Quantities of Potentially
Hazardous Dye and Chemical Container Wastes
from Knit Fabric Dyeing and Finishing
Operations, 1977 3-53
3-24 Category E - Quantities of Potentially
Hazardous Dye and Chemical Container Wastes
from Knit Fabric Dyeing and Finishing
Operations, 1983 • . . . . 3-54
3-25 Category E - Knit Fabric Dyeing and Finishing
Wastewater Treatment Sludges, Current Year 3-55
3-26 Category E - Knit Fabric Dyeing and Finishing
Wastewater Treatment Sludges, 1977 3-56
3-27 Category E - Quantities of Potentially
Hazardous Wastewater Treatment'Sludges from
Knit Fabric Dyeing and Finishing Operations, 1983 . . . 3-57
3-28 Category F - Tufted Carpet Dyeing & Finishing
Sludge Analyses 3-61
3-29 Category F - Estimated Quantities of Total
Waste from Tufted Carpet Dyeing and Finishing
Operations 3-63
3-30 Category F - Quantities of Potentially
Hazardous Dye and Chemical Container Wastes
from Tufted Carpet Dyeing and Finishing
Operations, 1974 .,....<.... 3-64
3-31 Category F - Quantities of Potentially
Hazardous Dye and Chemical Container Wastes
from Tufted Carpet Dyeing and Finishing
Operations, 1977 .. i. ..... 3-65
IX
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Table
3-32 Category F - Quantities of Potentially
Hazardous Dye and Chemical Container Wastes
from Tufted Carpet Dyeing and Finishing
Operations, 1983 3-66
3-33 Category F - Tufted Carpet Dyeing and
Finishing Wastewater Treatment Sludges,
Current Year 3-67
3-34 Category F - Tufted Carpet Dyeing and
Finishing Wastewater Treatment Sludges, 1977 3-68
3-35 Category F - Quantities of Potentially
Hazardous Wastewater Treatment Sludges from
Tufted Carpet Dyeing and Finishing
Operations, 1983 3-69
3-36 Category G - Yarn & Stock Dyeing & Finishing
Sludge Analyses 3-73
3-37 Category G - Estimated Quantities of Total
Waste from Yarn and Stock Dyeing and
Finishing Operations 3-74
3-38 Category G - Quantities of Potentially
Hazardous Dye and Chemical Container Wastes
from Yarn and Stock Dyeing and Finishing
Operations, 1974 3-75
3-39 Category G - Quantities of Potentially
Hazardous Dye and Chemical Container Wastes
fron Yarn and Stock Dyeing and Finishing
Operations, 1977 3-76
3-40 Category G - Quantities of Potentially
Hazardous Dye and Chemical Container Wastes
from Yarn and Stock Dyeing and Finishing
Operations, 1983 3-77
3-41 Category G - Quantities of Potentially
Hazardous Wastewater Treatment Sludges from
Yarn and Stock Dyeing and Finishing Operations,
1974 3_78
3-42 Category G - Quantities of Potentially
Hazardous Wastewater Treatment Sludges from
Yarn and Stock Dyeing and Finishing Operations,
1977 3.79
x
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Table
3-43 Category G - Quantities of Potentially
Hazardous Wastewater Treatment Sludges from
Yarn and Stock Dyeing and Finishing Operations,
1983 3-80
3-44 Estimated Quantities of the Total Wastes
Generated by the Textiles Industry 3-82
3-45 Total Quantity of Potentially Hazardous Dye
and Chemical Container Wastes Generated by
the Textiles Industry, 1974 3-83
3-46 Total Quantity of Potentially Hazardous Dye
and Chemical Container Wastes Generated by
the Textiles Industry, 1977 3-34
3-47 Total Quantity of Potentially Hazardous Dye
and Chemical Container Wastes Generated by
the Textiles Industry, 1983 3-35
3-48 Total Quantity of Potentially Hazardous
Wastewater Treatment Sludges Generated by
the Textiles Industry, 1974 . . 3-86
3-49 Estimated Total Quantity of Potentially
Hazardous Wastewater Treatment Sludges
Generated by the Textiles Industry, 1977 3-87
3-50 Estimated Total Quantity of Potentially
Hazardous Wastewater Treatment Sludges
Generated by the Textiles Industry, 1983 3-88
4-1 Summary of Treatment/Disposal Practices
at Visited Textile Plants 4-5, 4_gf 4-7
4-2 Levels of Technology for the Dye and Chemical
Container Waste Streams 4-14, 4-15,
4-3 Levels of Technology for the Wastewater
Treatment Sludges 4-17 4-13
4-19' 4-2o'
4-4 Atypical Potentially Hazardous Textile
Industry Wastes 4-21, 4-22
5-1 Category B - Typical Plant Costs for
Treatment and Disposal, 1975 5-12
XI
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Table
5-2 Category D - Typical Plant Costs for
Treatment and Disposal, 1975 5-13
5-3 Category E - Typical Plant Costs for
Treatment and Disposal, 1975 5-14
5-4 Category F - Typical Plant Costs for
Treatment and Disposal, 1975 5-15
5-5 Category G - Typical Plant Costs for
Treatment and Disposal, 1975 5-16
5-6 Category A - Typical Plant Costs for
Treatment and Disposal, 1975 5-18
5-7 Category B - Typical Plant Costs for
Treatment and Disposal, 1975 5-20
5-8 Category D - Typical Plant Costs for
Treatment and Disposal, 1975 5-22
5-9 Category E - Typical Plant Costs for
Treatment and Disposal, 1975 5-24
5-10 Category F - Typical Plant Costs for
Treatment and Disposal, 1975 5-26
5-11 Category G - Typical Plant Costs for
Treatment and Disposal, 1975 5-28
5-12 Extrapolation of Technology Costs to
the Industry Categories and the Entire
Industry 5-30
5-13 Comparison of Technology Costs with the
Total Sales by Industry Category and the
Entire Textiles Industry 5-31
5-14 Costs for Treatment/Disposal of Miscellaneous
Atypical Potentially Hazardous Textile
Industry Wastes 5-33
Xll
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1.0 EXECUTIVE SUMMARY
1.1 Introduction
This report is the result of a study commissioned by the U.S.
Environmental Protection Agency to assess the "Industrial Hazardous Waste
Practices—Textiles Industry," which is one of a series of industry studies
by the_Office of Solid Waste Management Programs, Hazardous Waste Manage-
ment _ Division. The studies were conducted for information purposes only and
not in response to a Congressional regulatory mandate. As such, the studies
serve to provide EPA with: (1) an initial data base concerning the current
and projected types and quantities of industrial wastes, applicable treat-
ment and disposal technologies and their associated costs; (2) a data base
for technical assistance activities; and (3) a background for guidelines
development work pursuant to Section 209 of the Solid Waste Disposal Act
as amended.
The definition of "potentially hazardous waste" in this study was
developed based upon contractor investigations and professional judgment.
This definition does not necessarily reflect EPA thinking since such a
definition, especially in a regulatory context, must be broadly applicable
to widely differing types of waste streeans. The presence of a toxic,
flammable, explosive or. reactive substance should not be the major deter-
minant of hazardousness if there are data to represent or illustrate actual
effects of wastes containing these substances in specific environments.
Thus, the reader is cautioned that the data presented in this report con-
stitute only the contractor's assessment of the hazardous waste management
problem in this industry. Further, this study has not Demonstrated that any
of the wastes from the textiles industry are hazardous. EPA reserves its
judgments pending a specific legislative mandate.
This program began on 3 April 1975 and covers the Standard Industrial
Classification (SIC) 22, the textiles industry.
The basic objectives of this study are provided in the report in four
major sections:
Industry Characterization
Characterizes the industry with regard to the number,
location, size, and production of manufacturing
establishments;
Waste Characterization
Identifies and quantifies the total wastes and potentially
hazardous wastes which are or will be generated by the
textiles industry in 1974, 1977 and 1983.
1-1
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Treatment and Disposal Technology
Describes current practices for the treatment and disposal
of potentially hazardous wastes and determines the control
technologies which might be applied to reduce potential
hazards presented by these wastes upon disposal; and
Cost Analysis
Estimates the cost for control technology implementation
and compares this cost to total sales.
The individual elements of each of these program phases are presented in
detail in their respective sections of this report.
1.2 Program Methodology
1.2.1 Data Acquisition
The data needed for this study were obtained by four different
methods. The first was by reviewing published information and data in the
technical literature, trade journals, government reports and technical
surveys which were conducted by the industry associations. These references
are cited throughout this report and are listed in Section 6.0.
The second method involved the participation of the various trade
associations by informing their member companies of the objectives of this
study and requesting their cooperation. As a result, the trade associations
supplied information to the contractor and also reviewed the progress of
the work. The American Textiles Manufacturers Institute (ATM!), the Carpet
and Rug Institute (CRI) and the Northern Textiles Association (NTA) partici-
pated in the study.
The third method of data acquisition was by personal contacts and
visits to eighty textile plants. A better and more thorough understanding
of the generation of wastes destined for land disposal from the textiles
industry was obtained through personal interviews. The following chart
summarizes the number of plants visited in each of the industry categories
and percentages of industry category production covered by the visits:
1-2
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Sunmary of Textile Plants Visited by Industry Category
Percentage of Percentage of
No. of No. of Plants Category
Industry Category Plants Visited in Category Production
A - Wool Scouring 4 24 24
B- Wool Fabric Dyeing 7 66
and Finishing
C - Greige Goods 5 0.1 2
D - Woven Fabric Dyeing 22 3 21
and Finishing
E - Knit Fabric Dyeing 20 3 17
and Finishing
F - Carpet Dyeing and 11 8 32
Finishing
G - Yarn and Stock Dyeing 11 35
and Finishing
80 1.5% 16%
Total Average Average
The fourth method of data acquisition was by the sampling and
analysis of the wastewater treatment sludges at fourteen plants. Sludges
were selected by the contractor for analysis because the composition of
this land destined waste from the textiles industry was uncertain. The
number of plants that were visited and sampled in each industry category
was based on the contractor's and ATMI's prejudged relative importance of
the category to the needs of the study. The number of plants sampled in
the various industry categories are as follows:
Industry Category No. of Plants Sampled
A-Wool Scouring 1
B-Wool Fabric Dyeing and Finishing 1
C-Greige Goods 0
D-Woven Fabric Dyeing and Finishing 5
E-Knit Fabric Dyeing and Finishing 3
F-Carpet Dyeing and Finishing 2
G-Yarn and Stock Dyeing and.Finishing 2_
Total 14
1-3
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No sampling was done in Category C - Greige Goods because this industry
category performs no dyeing and finishing operations and therefore generates
no potentially hazardous wastes destined for land disposal. Each plant
was composite sanpled once per week for 4 weeks, taking sanples from the
clarifier underflow. The sludges were analyzed for heavy metals (preserved
with nitric acid) and chlorinated organics (unpreserved). The total nuniber
of sanples analyzed was 112. Details on the sampling techniques, analytical
methods and results are presented in Appendix C.
1.2.2 Data Analysis
The major tasks involved in the data analysis were:
(a) to review the collected data for consistency, sufficiency,
and probable accuracy;
(b) to assemble the more reliable data elements into a data
base sufficient to allow meaningful projections to be
made;
(c) to utilize the data base and subsequent waste generation
factors to allow tabulation of waste quantities and other
data on a state by state, EPA Region and national basis.
The accuracy of waste quantities for all industry categories is
estimated to average about ±50 per cent. In cases where Census data or
data actually measured by plant personnel were obtained, the accuracy is
estimated to be as good as ±10 to 20 per cent. However, most plants never
weigh or otherwise quantitatively determine their land-destined wastes and
the values obtained were engineering estimates by plant personnel. Therefore,
the accuracy of some estimated values could be greater than ±50 per cent.
1.3 Summary of the Study
1.3.1 Industry Characterization
Of the more than 5,000 textile plants in the U.S., 2,007 were
identified as plants that generate potentially hazardous wastes destined
for land disposal. These plants were the ones identified that perform
dyeing and finishing operations which are the source of the potentially
hazardous wastes. The remaining plants (Greige Goods Manufacture) perform
only dry operations such as weaving and knitting and do not generate
potentially hazardous wastes.
The industry was classified into the seven categories used in the
EPA effluent limitations guidelines document (8) for this industry.
These categories and the Standard Industrial Classification (SIC) codes
included in each category are shown below:
1-4
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Category Process SIC Groups Included
A Wool Scouring 2299
B Wool Fabric Dyeing and Finishing 2231
C Greige Goods Manufacture 2211, 2221, 2231, 2241, 2251,
2252, 2253, 2254, 2257, 2258,
2259, 2281, 2282, 2283, 2284
D Woven Fabric Dyeing and Finishing 2261, 2262
E Knit Fabric Dyeing and Finishing 2251, 2252, 2253, 2254, 2257,
2258, 2259
F Carpet Dyeing and Finishing 2272
G Yarn and Stock Dyeing and Finishing 2269
Initial attempts to categorize the textiles industry by four-digit
Standard Industrial Classification (SIC) codes proved to be an inadequate
method for the purposes of this study. Reasons for this are:
a. The SIC code method of classifying the industry is obsolete. For
example, SIC 2261 is the dyeing and finishing of woven cotton broad-
cloth and SIC 2262 is the dyeing and finishing of woven man-made
fiber broadcloth. Very few plants in the industry are devoted to
either 100% cotton or 100% man-made fiber cloth. Most plants are
producing cloth with blends of fibers and there is no SIC code for
this type of plant. This is also true in SIC 2231 (woven wool
fabrics) where very few plants are producing 100% wool fabrics.
b. The SIC method of classification includes all plants in the group.
For example, SIC 225 includes all knitting plants and SIC 227
includes all carpet plants. This study is concerned only with
those plants that perform dyeing and finishing operations. These
operations are the direct or indirect source of potentially
hazardous land-destined wastes. The exception to this is Wool
Scouring which is part of SIC 2299. Sludges generated by Wool
Scouring wastewater treatment plants were found to contain heavy
metals and chlorinated organics (see Section 3 of this report).
The textile industry is heavily concentrated in the East with 91%
of the plants located in EPA Regions I, II, III and IV. Fifty per cerh are
located in Region IV alone. More than half of the plants employ between 20
and 500 workers with less than 10 per cent employing less than 20 workers.
Eleven per cent of the plants employ over 500 workers.
Almost half of the plants visited had process equipment over 20
years old, over 40 per cent had equipment ages ranging from 5 to 20 years
and less than 10 per cent were less than 5 years old.
Because of the difficulties encountered with the SIC code system
mentioned above, the industry was categorized on a process basis rather
a product basis. Over 69 per cent of the plants are engaged in either woven
or knit dyeing and finishing.
1-5
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It is estimated that the six industry categories that generate
potentially hazardous wastes for land disposal collectively produce about
5,300,000 metric tons of product per year. The total production in the
textiles industry, including Category C (Greige Goods), is estimated to be
8,300,000 metric tons per year. Therefore, about 64 per cent of the total
production in this industry generates potentially hazardous wastes. Aside
from Greige Goods Manufacture, Category D (Woven Fabric Dyeing and Finish-
ing) is the largest producer, accounting for about 34 per cent of the pro-
duction that generates potentially hazardous wastes. It is also estimated
that over 56 per cent of the 5,300,000 metric tons per year of production
occurs in EPA Region IV.
1.3.2 Waste Characterization *
The land-destined wastes from the textiles industry originate
either directly from the manufacturing processes or from the process
wastewater treatment. The various waste streams, their sources and their
quantities were determined for typical plants in each of the categories of
the textiles industry. They are as follows:
Category A - Wool Scouring
Quantity (kg of waste/
Waste Source kkg of product)
dirt and wool sorting and blending 12
dirt and vegetable matter scouring 26
fly and sweeps drying, top preparation 2
wool waste top preparation 55
wasted sludge** wastewater treatment 570 (dry) 5,700 (wet)
retained sludge*, ** wastewater treatment 780 (dry) 7,800 (wet)
Category B - Wool Fabric Dyeing and Finishing
Quantity (kg of waste/
Waste Source kkg of product)
flock carbonizing and drying 16
seams scouring 0.7
dye containers** dyeing 1.3
chemical containers** dyeing, special 1.6
finishing
fabric special finishing 1.3
flock mechanical finishing 17
fiber wastewater pretreat- 25 (dry)
ment screening 100 (wet)
wasted sludge** wastewater treatment none
retained sludge*, ** wastewater treatment 1.6 (dry) 20,000 (wet)
1-6
* The reader is cautioned that no waste products from the textiles
industry have been demonstrated to be hazardous by this study.
EPA reserves its judgments pending a specific legislative mandate.
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Category C - Greige Goods
Waste
fiber and yarn
fiber, yarn and cloth
fiber, yarn and cloth
Source
yarn preparation
knitting
weaving
Quantity (kg of waste/
kkg of product)
32
10
11
Category D - Woven Fabric Dyeing and Finishing
Waste
cloth
cloth
cloth
cloth
flock
dye containers**
chemical containers**
fiber
wasted sludge**
retained sludge*, **
Source
singe and desize
mercerize
bleach and wash
mechanical finish
mechanical finish
dye and/or print
dye and/or print,
applied finish
wastewater pretreat-
ment screening
wastewater treatment
wastewater treatment
Quantity (kg of waste/
kkg of product)
0.2
0.1
0.2
6
4
0.5
0.8
0.8 (dry)
20 (dry)
67 (dry)
2.8 (wet)
2,300 (wet)
7,300 (wet)
Category E - Knit Fabric Dyeing and Finishing
Waste
cloth
cloth
cloth
dye containers**
chemical containers**
cloth
fiber
wasted sludge**
retained sludge*, **
Source
dye and/or print
chemical finish
mechanical finish
dye and/or print
dye and/or print and
chemical finish
wash
wastewater pretreat-
ment screening
wastewater treatment
wastewater treatment
Quantity (kg of waste/
kkg of product)
2
4
3
0.9
0.9
2 (dry) 4 (wet)
0.8 (dry) 2.8 (wet)
typically none
64 (dry) 9,600 (wet)
1-7
-------
Category F - Carpet Eyeing and Finishing
Waste
yarn and sweeps
selvage
flock
dye containers**
chemical containers**
fiber
latex sludge
wasted sludge**
retained sludge*, **
Source
tufting
selvage trim
fluff and shear
dyeing and printing
dyeing and printing
wastewater pretreat-
ment screening
wastewater treatment
wastewater treatment
wastewater treatment
Quantity (kg of waste/
kkg of product)
1.0
26
4
0.13
: 0.18
1.2 (dry) 2.0 (wet)
2.3 (dry) 4.9 (wet)
typically none
5.2 (dry) 22,000 (wet)
Category G - Yarn and Stock Dyeing and Finishing
Waste
yarn
yarn
dye containers**
chemical containers**
fiber
wasted sludge**
retained sludge*, **
Source
bleaching/dyeing
beaming/quilling/
winding, etc.
dyeing
dyeing and finishing
wastewater pretreat-
ment screening
wastewater treatment
wastewater treatment
Quantity (kg of waste/
kkg of product)
0.7
5.4
0.87
2.2
9.0 (dry)
33 (wet)
typically none
2.9 (dry) 20,000 (wet)
* The retained sludge quantities are accumulations over the life of the
pond and cannot be related to production.
** Waste streams considered to be potentially hazardous.
Of the industry's current total process wastes for land disposal,
3.6 per cent by weight (dry basis) is considered to be potentially hazardous.
This potentially hazardous fraction includes dye and chemical containers
with residual dyestuff and chemicals. The remaining 96.4 per cent of land
destined wastes from the textile manufacturing processes are non-hazardous.
The non-hazardous process wastes include lint, yarn, cloth, etc.
The sludge generated by textile plant wastewater treatment systems
is also considered to be potentially hazardous. This includes both the
sludge generated and retained in the wastewater treatment system and the
excess sludge that is removed from the system for final disposal. Retained
sludge is so slowly generated by aerated biological treatment of textile
1-8
-------
wastewaters that, in many cases, there is no need for disposal. Sludge is
allowed to accumulate over a period of years (5 to 10) and is stored in the
treatment pond. Wasted sludge is excess sludge generated in textile waste-
water treatment systems which must be removed and disposed on a regular basis.
Only the Wool Scouring and Woven Fabric Dyeing and Finishing categories
typically are presently disposing of excess sludge. On a dry weight basis,
wastewater treatment sludge currently comprises about 80 per cent of the
total land destined potentially hazardous wastes and about 12 per cent of all
wastes. Table 1-1 summarizes the total wastes, the total potentially
hazardous wastes and the total hazardous constituents from the textile
industry for the years 1974, 1977 and 1983. The large increase in total (dry wt.)
quantity projected for 1983 is due mainly to the implementation of recommended
wastewater treatment technologies in the effluent limitations guidelines
document f6r this industry. (it should be noted that the wet we
quantities will decrease by 1983). we
_Figures 1-1, 1-2 and 1-3 summarize the estimated state-by-state
distribution of total wastes from the textiles industry, potentially
hazardous dye and chemical container wastes and potentially hazardous
wastewater treatment sludges, respectively. These illustrations show that
over 90 per cent of the total potentially hazardous land destined wastes
from the textile industry is generated in EPA Regions I, II, III and IV.
Eighty-seven per cent of all wastes are generated in those same regions.
The hazardous constituents in the waste streams were determined
by plant visits and by composite sampling of wastewater treatment sludge
as mentioned earlier. The hazardous constituents of the dye and chemical
container waste streams were determined to be the residual dyestuff and a
portion (estimated by the contractor to be 25 per cent by weight) of the
residual chemicals (i.e., ortho-phenyl-phenol, biphenyl, zinc salts, etc.).
The constituents identified in the wastewater treatment sludges determined
to be hazardous were heavy metals such as arsenic, barium, cadmium, chromium,
cobalt, copper, lead, mercury, nickel and zinc and chlorinated organic
compounds. The metals and chlorinated organics were determined to be e.i hher
adsorbed or included primarily in the solid phase of the sludge.
A few atypical potentially hazardous wastes were also found
throughout the industry containing chlorinated organics or flammable
solvents as the hazardous constituents. Also, one facility was found that
disposes of yarn wet with non-fixed dyes containing dyestuff as the hazard-
ous constituent. These atypical wastes could not be extrapolated to the
entire industry nor geographically distributed because, there was no way
of determining how much of the industry handled or disposed of these wastes
in the non-typical manner.
The criteria used for determining the concentration at which
textile wastes were considered potentially hazardous were the drinking
water standards for specific heavy metals and total organics. The
hazardousness of dyestuff is not as easy to delineate. There is little
information available on the toxicity of dyes to humans. However, bioassay
1-9
-------
Table 1-1. Svnnary of Land Destined Total and Potentially Hazardous Wastes
frorr. the Textiles Industry (SIC 22), kkg/yr
Total VZastes (dry/wet)
Toted Potentially
Hazardous Wastes (dry/wet)
Total
Hazardous Constituents (dry)
Industry Category
A
B
C
D
E
F
G
- Wool Scovrirsg
- Wool Fabric Dyeing
and Finishing
- Greige Goods
- Kiven Fabric
Dyeing and
Finishir.g
- Knit Fabric Dyeing
and Finishing
- Carpet Dyeiiig and
Finishir.g
- Yam and Stock
Dyeir.g and
Finishing
Total Textiles
Industry
1974
32, COO/
261,600
19,43S/
43,533
159.000/
159,000
35T616/
1,522,477
10,448/
13,239
23,539/
27,359
30,132/
71,367
310, 173/
2,098,575
1977
32,OCO/
261,600
19,438/
43,588 .
174,000/
174,000
37,7027
1,618,203
11,073/
14,065
30,06V
34,344
32,0007
75,599
336,2747
2,221,399
1983
20,900/
63,800
46,4887
150,958
207,0007
207,000
77,2247
227,070
50,0027
162,272
67,8497
116,522
64,1397
193,137
533,6027
1,120,759
1974
25,5007
255,000
8957
1,720
0
15,3007
1,500,000
1,4007
2,590
210/
1,170
- 5,0807
6,340
48,4007
1,770,000
1977
25,5007
255,000
8957
1,720
0
16,2007
1,600,000
1,49Q/
2,760
2637
1,470
5,4007
6,740
49,7007
1,870,000
1983 1974
14,3007 134
57,200
27,9007 7.6
111,600
0 0
51,4007 842
205,600
38,5007 3.4
154,000
14,6007 1.0
58,400
32,5007 36.5
130,000
179,0007 1,020
716,800
19/7 1983 Hazardous Constituents
134 76 heavy metals*,
chlorinated organics**
7.6 2,040 heavy metals,
dyestuff***
and chenicals***
0 0 none
892 2,980 heavy netals,
chlorinated organics,
dyestuff & chemicals
3.7 2,020 heavy metals,
chlorinated organics,
dyestuff & chemicals
1.3 817 heavy metals,
chlorinated organics,
dyestuff & chsricals
38.7 1,430 heavy netals,
chlorinated crganics,
dyestuff & chendcals
1,080 9,360 see above
ir-cl'jcas arsenic, barium, cadrdun, chrccriizn, cobalt, copper, iron, lead, manganese, mercury, nickel and zinc
»* ir-divisual chlorinated organic ccrpounds were not identified in the laboratory, only total quantities
*** see Section 3.2 cf this report for explanation of types of dyestuff and chemicals
-------
Figure 1-1. ESTIMATED QUANTITIES OF TOTAL WASTE TO LAND DISPOSAL 1974
(DRY/WET WEIGHT)
KEY:
XX/XXX Dry/Wet Weights of
Total Waste in KKG
REGION TOTALS:
I - 38,328/353,689
II - 52.618/244,330
III - 28,193/70,915
IV - 151,090/1,215.954
V - 11.763/85,172
VI - 12,573/102,587
VII - 1,598/6.157
VIII - 800/1,880
IX - 10.590/13.814
X - 2,450/3,680
MAINE
2,307/14,266
NEW
HAMPSHIRE
2,121/13,079
MASSACHUSETTS
20,541/232,155
RHODE ISLAND
5,770+/17,234+
CONNECTICUT
3.281+/38.674+
NEW JERSEY
24,988/154,060
DELAWARE
179/3^62
MARYLAND, 609/8,969
NORTH CAROLINA
58.776/340,621
SOUTH CAROLINA
23,899+/464^08+
+ Waste quantities from Wool Scouring Operations not included. See Table 3-2.
-------
Figure 1-2. ESTIMATED QUANTITIES OF TOTAL POTENTIALLY HAZARDOUS DYE
AND CHEMICAL CONTAINER WASTES TO LAND DISPOSAL (DRY WEIGHT), 1974
V
i--
to
KEY:
XX Total Potentially Hazardou?
Waste Stream in KKG
(XX) Total Hazardous Constitue
in KKG
REGION TOTALS:
I -1550(19)
II -1610(18)
III - 830(6)
IV -5100(70)
V - 410(6)
VI - 120(2)
VII _ SO (OS}
VIII- 10(0.1)
IX - 170(1)
X - 60 (0.4)
Total
U.S. 9910 (123)
MAINE
NEW
HAMPSHIRE
140(1.4)
MASS. 650 (10)
RHODE IS. 430 (3.4)
CONN. 180(2.4)
NEW JERSEY 780 (10)
DELAWARE 5 (0.17)
MARY LAND 15 (0.43)
NORTH
CAROLINA
SOUTH
CAROLINA
-------
Figure 1-3. ESTIMATED QUANTITIES OF TOTAL POTENTIALLY HAZARDOUS WASTEWATER
TREATMENT SLUDGE TO LAND DISPOSAL. (1974) DRY/WET WEIGHT
M
OJ
KEY"
Dry/Wet Weights of
XX/XXX Potentially Ha:
Sludge in KKG
(XX) Dry Weight of Total
Hazardous Constituents
in KKG
REGION TOTALS:
I - 12.400/311,000(158)
II - 1540/180,000(91)
III - 3300+/66,000+(37+)
IV - 12,700+/1.000,000+(510+)
V - 600/70,000 (36)
VI 5940/95,000 (49)
VII - 35/4100(2)
VIII - 7/840 «1)
IX - 14/1600 (<1)
X - 1000+710,000+(5+)
Total
US. - 38,400/1,760,000(900)
MAINE
84/9900(5)
NEW
HAMPSHIRE
78/9200(4)
MASSACHUSETTS
8600/214,000(110)
RHODE ISLAND
65+/8000-H3.8+)
L- CONNECTICUT
290+/34,100+(16.7+)
NEW JERSEY
1100/130,000(65)
DELAWARE 29/3400(1.7)
MARYLAND 72/8400(4)
NORTH CAROLINA
2400/271,OOO( 143)
SOUTH CAROLINA
380O+/441,000+(226+)
110/13,OOO(5.6)
-------
studies sponsored by the American Eye Manufacturers Institute (ADMI) have
shown that some dyes do exhibit appreciable toxicities to fish and algae.
Other studies concerning the effects of dyes on aerobic and anaerobic
systems showed that dyes are refractory to conventional aerobic biological
treatment systems. However, there were indications of dye degradation
under anaerobic conditions and this raises the problem of the fate of dyes
in a landfill subject to anaerobic processes. There is no information
available on the nature, toxicity or carcinogenicity of any metabolites
resulting from dye degradation. It is possible that dyes may degrade into
carcinogenic synthesis intermediates. This presents the problem of leaching
of toxicants or carcinogens from landfill sludges into potential drinking
water supplies. Thus,all dye-containing waste streams were determined to
be potentially hazardous. This includes adsorbed dyes in wastewater treat-
ment sludges as well as residual dyestuff discarded with containers.
The drinking water standard for specific heavy metals and total
organics was also applied to residual chemicals in discarded containers as
well as any chemicals adsorbed onto the sludges.
The criteria for determining the hazardousness for the atypical
wastes includes the drinking water standards for total organics as well as
the criteria cited above for dye-containing waste streams. The criteria
applied for flammable solvents was the Department of Transportation flash-
point standard of 38° C. (25). Details of the criteria for categorizing
wastes as potentially hazardous are presented in Section 3.2.
1.3.3 Treatment and Disposal Technology
Three levels of treatment and disposal technology for potentially
hazardous wastes were determined for the industry. These levels are briefly
defined as follows and are illustrated for the textiles industry in
Figures 1-4, 1-5 and 1-6.
Level I - broad average of current practice
Level II - current best practice from an
environmental standpoint
Level III - technology necessary to provide
adequate health and environmental
protection
Table 1-2 summarizes the levels of technology determined for the
various potentially hazardous waste streams in the textiles industry. Most
of the industry in all categories disposes of the potentially hazardous dye
and chemical containers, with residual dyestuff and chemicals,in municipal
or county general purpose landfills taking no extraordinary environmental
precautions. Several plants wash and clean the residual dyestuff and
chemicals from the containers prior to disposal and send the small amount of
wash water to wastewater treatment. This waste control practice converts a
1-14
-------
Figure 1-4. TYPICAL MODEL OF LEVEL I TECHNOLOGY FOR
' POTENTIALLY HAZARDOUS WASTE STREAMS IN
THE TEXTILES INDUSTRY
TEXTILE
PLANT
1
DYE AND
CHEMICAL
CONTAINERS
WITH
RESIDUAL DYES
AND CHEMICALS
/COMPACTION
i (SOME
V PLANTS)
GENERAL
•PURPOSE
LANDFILL
RAW WASTE WATER
E W
L
PRIMARY
SCREENING
PRIMARY
SETTLING BASIN
(WOOL SCOURING
ONLY)
AERATED
BIOLOGICAL
TREATMENT
BASIN
CHLORIN
ATION
(SOME
PLANTS)
UNDERFLOW
WASTED
SLUDGE.
-fl»> LANDFILL
OR LANDSPREAD
PLANT EFFLUENT
1-15
-------
Figure
1-5- TYPICAL MODEL OF LEVEL II TECHNOLOGY FOR POTENTIALLY
HAZARDOUS WASTE STREAMS IN THE TEXTILES INDUSTRY
DYE AND CHEMICAL
CONTAINERS WITH
RESIDUAL DYES
AND CHEMICALS
WASHING
AND
CLEANING
CLEAN
CONTAINERS
TO LANDFILL
(NO LONGER
POTENTIALLY
HAZARDOUS)
RESIDUAL DYES
AND CHEMICALS
CONCRETE-LINED
PRIMARY
SETTLING BASIN
(WOOL SCOURING
ONLY)
REMOVED WATER
AERATED
BIOLOGICAL
TREATMENT
BASIN
CHLORIIM-
ATION
(SOME
PLANTS)
PLANT EFFLUENT
1-16
-------
Figure 1-6. TYPICAL MODEL OF LEVEL III TECHNOLOGIES FOR POTENTIALLY
HAZARDOUS WASTE STREAMS IN THE TEXTILES INDUSTRY
TEXTILE
PLANT
DYE AND CHEMICAL
CONTAINERS
WITH RESIDUAL
DYES AND
CHEMICALS
RAW WASTE WATER
WASHING
AND
CLEANING
CLEAN
CONTAINERS
TO LANDFILL
JNOLONGER
POTENTIALLY
HAZARDOUS)
RESIDUAL
DYES AND
CHEMICALS
PRIMARY
SCREENING
LINED PRIMARY
SETTLING BASIN
(WOOL SCOURING
ONLY)
LINED AERATED
BIOLOGICAL
TREATMENT
BASIN
CHLORIN-
ATIOIM
(SOME
PLANTS)
1.2 - ALTERNATE TECHNOLOGIES
PLANT EFFLUENT
1-17
-------
Table 1-2. Sunrnary of the Levels of Technology Determined for the Potentially Hazardous
Waste Streams in the Textiles Industry
Potentially Hazardous
Waste Stream
Dye and Chemical
containers
Wastewater treatment
sludge
Atypical Hastes:
Solvent recovery
sludges
Lint wet with non-
fixed dye
Level I
Prevalent Technology
General purpose landfilled
(categories A,B,D,E,F and G)
(1) Retention of sludge in
unlined aeration ponds
(categories A,B,D,E,F
and G)
(2) Disposal of excess sludge
in general purpose land-
fills, dumps and/or land-
spreading on farm land
(categories A and D)*
Drummed and general purpose
landfilled (categories B,D),
or stored on-site (category
G)
General purpose landfilled
(category F)
Level II
Best Available Technology
Wash containers prior to gerv-
eral purpose landfilling
(categories D,E and G)
(1) Retention of sludge in
lined aeration ponds
(categories A and E)
(2) Disposal of dewatered ex-
cess sludge in an approved
landfill (category E)
Incineration or recovery by
waste disposal contractor
(category E)
Same as Level I
Level III
Adequate Health and
Environmental Protection
Same as Level II
(1) Same as Level II
(2) Same as Level II
Sane as Level II
Future environmentally adequate
treatnent/disposal technologies
include washing, approved
landfilling or incineration
* Categories B, E, F and G typically were found not to have excess sludge for disposal
-------
potentially hazardous waste into a non-hazardous waste and only slightly
increases the raw waterborne waste load.
The major potentially hazardous waste generated by the textile
industry was determined to be wastewater treatment sludges. Of course,
sludges are generated by only those plants having their own wastewater
treatment facilities. It is estimated that 488 plants of the 2,007
identified (24 per cent) which generate potentially hazardous waste have
wastewater treatment facilities. (10). ATMI estimates that these 488 plants
comprise 65 per cent of the total production of the 2,007 plants. The
remaining 1,519 plants use municipal sewage treatment (10) which transfers
the problem of potentially hazardous sludge disposal and its associated
costs to the municipalities. About 7 per cent of the plants visited con-
tributed 50 to 95 per cent of the total wastewater load to the municipal
sewage treatment system. Several of the municipal treatment facilities
were constructed with plant funds and turned over to the municipality for
operation and maintenance.
Ninety-six per cent of the 488 plants with treatment systems are
generating sludge in unlined aeration basins which have potential for
percolation to underlying strata. Four per cent were found to have concrete
lined aeration or settling basins. The lined ponds were found to be most
prevalent in Category A, Wool Scouring, where 67 per cent of the plants
use them. Category E, Knit Fabric Dyeing and Finishing, was the only
other industry category found to be using lined ponds to the extent of
12 per cent of the plants in the category.
The necessity to dispose of excess sludge was found to be typical
in only two industry categories, Wool Scouring and Woven Fabric Dyeing and
Finishing. All plants in the Wool Scouring category find it necessary to
dispose of sludge. About 40 per cent of the plants (56 per cent of the
category production) engaged in Woven Fabric Dyeing and Finishing find it
necessary to dispose of excess sludge. Most facilities in the other indus-
try categories are generating sludge at a low enough rate to preclude the
need to dispose of any excess.
Based on the plants visited, all plants that have dye and
chemical container wastes dispose of them off-site. The ratio of on-site
to off-site sludge disposal is about one to one, also based upon the plants
surveyed. The typical disposal methods used are land dumping, land spread-
ing and landfilling with no special environmental protection precautions
being taken. In one instance, a plant employee hauled excess sludge to his
farm and spread the sludge as fertilizer. Only one plant was found that
disposed of dewatered sludge in a state approved landfill with leachate
and runoff controls. See Section 4.2.6 for the definition of an approved
landfill.
1.3.4 Cost Analysis
The estimated total annual costs of potentially hazardous waste
treatment/disposal technologies for the entire industry at the three levels
1-19
-------
of technology are $4,700,000, $6,500,000 and $11,700,000, respectively,
as shewn in Table 1-3. The total industry technology cost rates in terms
of dollars per metric ton of product are $0.88, $1.23 and $2.21, respectively.
The rates in terms of dollars per metric ton of waste (wet/dry) are $2.40/
$97, $3.35/$134 and $6.03/$242, respectively. The difference between what
the industry is presently spending and what is required for adequate health
and environmental protection is approximately $7,000,000. This amounts to
$1.32 per metric ton of total production.
The technology costs as a per cent of the total sales for the
various industry categories are less than 1 per cent at all three tech-
nology levels as shown in Table 1-4. The weighted average values for the
entire industry at the three levels of technology are 0.07 per cent, 0.1 per
cent and 0.18 per cent, respectively. For less than 0.2 per cent of the
sales value, the industry as a whole can provide treatment and disposal
technology for potentially hazardous land-destined wastes that will give
adequate health and environmental protection. From industry category to
category, this value ranges from a high of 0.9 per cent of sales value
for wool scouring to none for greige goods. A somewhat wider spread of
cost ijtipacts from manufacturer to xnanufacturer can be expected because of
local situations, but these specific impacts have not been determined.
1-20
-------
Table 1-3. Extrapolation of Technology Costs to the Industry
Categories and the Entire Textiles Industry
Annual Production
Annual Costs, 1975 Dollars *
Industry Category
A - Wool Scouring
B - Wool Fabric
Dyeing and
Finishing
C - Greige Goods
D - Woven Fabric
Dyeing and
Finishing
E - Knit Fabric
Dyeing and
Finishing
F - Carpet Dyeing and
Finishing
G - Yarn and Stock
Dyeing and Finish-
ing
Total Industry
Total Industry Rate
$/kkg of product
$/kkg of potentially
hazardous waste (dry
$/kkg of potentially
hazardous waste (wet
Thousand Metric Tons
69
309
3,000
1,801
771
679
1,660
5,289**
weight)
weight)
Level I
850,000
13,600
No potentially
3,700,000
21,600
3,400
76,000
4,664,600
$0.88
$97
$2.40
Level II
988,000
13,600
hazardous wastes
3,800,000
1,*600,000
3,400
83,000
6,488,000
$1.23
$134
$3.35
Level III
1,910,000
-no technology costs
5,740,000
1,600,000
400,000
1,300,00.0
11,704,000
$2.21
$242
$6.03
* To convert costs to Decanter 1973 dollars, multiply by 0.82
** Does not include Category C - Greige Goods
-------
Table 1-4. Comparison of Technology Costs with the Total Sales by
Industry Category and the Entire Textiles Industry
Sales Value * Technology Costs as Per Cent of Sales Value
ro
to
Industry Category
A - Wool Scouring
B - Wool Fabric Dyeing
and Finishing
C - Greige Goods
D - Woven Fabric Dyeing
and Finishing
E - Knit Fabric Dyeing
and Finishing
F - Carpet Dyeing and
Finishing
G - Yarn and Stock Dyeing
and Finishing
Weighted Average for
Entire Industry
$Akg
3,000
1,650
No potentially
1,280
1,840
1,850
450
1,218
Level I
0.4
0.003
hazardous wastes
0.16
0.0015
0.0003
0.01
0.07
Level II
0.5
0.003
- no technology costs
0.16
0.11
0.0003
0.01
0.1
Level III
0.9
0.15
0.25
0.11
0.032
0.17
0.18
* 1975 Dollars
-------
2.0 DESCRIPTION OF THE TEXTILES INDUSTRY
2.1 Introduction*
The textiles industry produced approximately $35 billion worth of
fabrics (as measured by plant shipments) for various uses in 1974. The
major uses of textile fabrics are for apparel (38 per cent); hone furnish-
ings (31 per cent); other consumer products, such as piece goods for home
sewing, medical, surgical and sanitary products (11 per cent); and industrial
products, such as transportation fabrics, hose and belting, filtration and
protective fabrics (17 per cent). Exports account for the remaining 3 per
cent.
The markets for apparel and home furnishings are very much influenced
by general economic conditions. In particular the apparel market is closely
related to the level of disposable income. In recent years apparel expendi-
tures have averaged approximately 6.5 per cent of disposable income. The
home furnishings market is influenced in addition by new family formations
and the consequent demand for new housing.
The market for other consumer products is basically influenced by
population growth, but under adverse economic conditions will make temporary
gains at the expense of the apparel and hone furnishing markets.
The specialized markets for industrial fabrics have shown good
growth in recent years. Further growth in these markets will depend largely
on the development of new products.
Textile exports rose sharply in 1973 and 1974, because of rising
world demand and assisted by the lower prices of American textiles in the
world market, as a result of dollar devaluation. However, by early 1975,
exports were running below those of a year earlier. This reversal was due
to generally softening of demand in the world markets and to the intensifi-
cation of price competition.
2.2 Discussion of the Textiles Industry **
2.2.1 Products of the Industry
Textile fabrics are produced by the weaving or knitting of fibers.
At some point in the manufacturing process the fiber, yarn, or fabric is
bleached, finished and dyed or printed as dictated by the needs of the
finished product.
The major products of the textile industry are:
* All data in Section^ 2.1 were obtained from Reference 1
** All data in Section 2.2 were obtained from Reference 1
2-1
-------
(a) Apparel. This segment of the market represents 38 per cent of
the textiles produced in this country. Apparel usage is closely tied to the
growth in disposable personal income. During the 1960's, expenditures for
apparel production was approximately 93 per cent of the growth in disposable
income for the decade. For the 1970-74 period, growth in apparel usage was
about 40 per cent compared to a disposable income increase of 41.5 per cent.
These unusually high percentage gains, however, were the result in part to
the rapid inflation in 1973 and 1974. Spending for apparel should continue
to grow, although possibly at a lower rate, with most of the growth coming
from a greater representation of the 20 to 39-year-old segment of the U.S.
population (which encompasses the biggest spenders for apparel), and from
upgrading of living standards by lower income, groups.
(b) Home Furnishings. Home furnishings account for 31 per cent of
the textile industry.
The major textile products for home furnishings are draperies,
furniture fabrics and upholstery, sheets, bedding material, blankets, carpets
and rugs.
This market segment approximately doubled'during the 1960's By
the end of the decade, consumer expenditures at the retaillevel .exceeded
$37 billion, and in 1974 rose to nearly $59 billion. Noteworthy is that as
a percentag^ of total consumer expenditures, these outlays also shew a steady
increase from 5.8 per cent in 1960 to 6.4 per cent in 1969 and then to 6.7
per cent in 1974.
Demand for home furnishings arises primarily fron_new family
formations (which dictate initial purchases), from changes in residence and
from wearing out or style obsolescence of existing furnishings. The declin-
ing birthrate and the trend to smaller sized homes tend to slow down the
growth rate.
(c) Other Consumer Products. Other consumer products are piece
goods for home sewing, craft and handwork yarns, medical, surgical and
sanitary products and toy fabrics. These products account for 11 per cent
of textiles production. Steady growth in these areas is to be expected.
(d) Industrial Products. Industrial fabrics make up 17 per cent
of the .textile output in the U.S., and growth has been experienced in a
number of these specialized markets, such as transportation fabrics,'hose
and belting, filtration, coated and protective fabrics, industrial sewing
thread and glass-fiber fabrics for reinforced plastics. The potential 'for
further growth is good and can be greatly augmented by development of new
products.
2-2
-------
2.2.2 Raw Material and Fabric Usage in the Industry
Fiber is the basic raw material in the manufacture of textile
products, Approximately 70 per cent of the fibers used in U.S. mills in
1974 were man-made with the use of cotton diminishing drastically to
approximately 29 per cent in 1974. Wool is of small significance, account-
ing for less than 1 per cent usage in 1974.
Woven fabrics form the largest segment of the textile industry,
however, woven goods production has been dropping steadily since 1965.
The 1974 production is only 80 per cent of 1965's peak production. The
decline has come totally in cotton woven goods, with the 1974 production
being approximately half of that of 1965. Woven fabrics of man-made
fibers actually increased about 50 per cent during this period, but the
increase was not sufficient to offset overall the decline in woven cotton
goods production.
The knitting segment has been growing in importance. Knit cloth
shipments nearly doubled between 1966 and 1973. A major portion of this
growth was due to the introduction and popularization of double-knit fabrics.
In 1967, it was estimated that there were 4,600 double-knit machines in use.
By 1971, there were 16,000 and in 1973, there were 23,275, resulting in
overexpansion and subsequent withdrawal and mothballing.
Another segment of the textiles industry that expanded substan-
tially was carpets and rugs. From 1966 to 1973, shipments in this segment
increased by almost 120 per cent. In 1974 there was a slight drop-off.
More recently some mills abandoned such operations, suggesting again
overexpansion and overcapacity.
Man-made fibers, especially the newer ones, have excellent
uniformity and are available in a growing variety of types. They offer a
higher degree of processing efficiency. In addition, there is a much
smaller inventory risk, as compared with natural fibers. The wide and
erratic price fluctuations of cotton and wool sometimes make carrying
inventories almost a wild speculation.
Man-made fibers are further classified into non-cellulosic and
cellulosic. The non-cellulosic fibers have attained a position of
dominance, accounting for about 85 per cent of the production of man-made
fibers. These non-cellulosic fibers, sometimes called chemical fibers,
are essentially extruded filaments of compounds such as polyester, nylon,
polyethylene, polypropylene, acrylics and glass. Of these, polyester is
in greatest demand, and accounts for about 42 per cent of the non-cellulosic
fibers produced. Nylon ranks next in importance and accounts for 31 per
cent of production. Glass fiber is the major inorganic chemical fiber
used in textiles, accounting for 9 1/2 per cent of production; its use is
rising sharply, both in irxtustrial applications in home furnishings, where
its fire retardant properties have helped in opening additional markets.
2-3
-------
Other man-made fibers are derived fron cellulose. Examples are
rayon (regenerated cellulose), acetate (cellulose acetate), and triacetate
(cellulose triacetate). This class of fibers constitutes only 15 per cent
of the man-made fibers or about 11 per cent of the total fibers used in
the U.S. Cellulosic fibers use has been adversely affected by the shift in
popularity to the non-cellulosic fibers. Since 1970, both use and production
capacity have decreased markedly.
Cotton has been of diminishing importance as a textile raw
material. It comprised 88 per cent of the fiber used in textiles in the 1920'
By 1960 it was 64%, and by 1974 it had dropped to a new low of 29 per cent.
In 1975, its use is expected to decrease even more. Price and consumption
support plans of the Federal Government may have contributed to pricing
cotton out of the market in its competition with synthetic fibers.
2.2.3 Current Economic Structure
Since 1970, a considerable shift of assets has taken place in the
textiles industry. Plants which gave low returns on investments or offered
poor prospects for growth were closed, while new capital investments were
made in areas promising better growth prospects and therefore possibly
better returns on investment.
Ihe return on investment in the textiles industry has always
compared unfavorably with investments in other industries, generally being
approximately one-third less than the average for all^manufacturing com-
panies. Under adverse economic conditions the comparison is even worse;
for instance, in 1970 the ratio of returns dropped to only 55 per cent.
Capital expenditures increased from $560 million in 1970 to
$840 million in 1974, but the increase was superficial rather than real,
because inflation was responsible for most of the money spent. Furthermore,
the expenditure was for substitution of newer and more efficient equipment,
so that there were few actual physical additions in production units.
The reduced pace of earnings since 1974 have prompted efforts
to improve the financial structure in the industry. Tighter controls
to reduce inventories and receivables, cuts in dividends to stockholders
and downward revisions of capital expenditures have been instituted.
Capital expenditures were expected to decline to $700 million in 1975,
partly because of the overexpansion of the last few years. Further re-
duction in capital expenditures is likely in the future, with a growing
portion of the capital expenditures to be earmarked, for equipment or
programs to comply with new Government health and environmental legislation.
Raising the funds for capital expenditures will present the
industry with a dilemma. Raising money by equity financing (selling
stock to the public) is unpalatable, as the stocks, of most textile com-
panies are selling at substantial discounts from book value. Growing
2-4
-------
companies may finance their capital needs by increasing long-term
borrowing, but the prevailing high interest rates make this method
expensive and ultimately result in lower earnings. The smaller and more
marginal companies may well find the problem very difficult to surmount.
The situation may become somewhat alleviated if demand for
textiles resurges in the later months of 1975 as the economy improves as
is expected and prices become firmer as inventory levels are worked down.
If the economy continues to improve into 1976, stimulating a further
increase in demand, then the efficiencies instituted in the last 2 years
will result in a substantial improvement to the financial situation of
the industry.
Profit margins,* as in the case of return on investment, are
significantly lower in the textiles industry than for industry at large,
averaging 10.8 per cent for the last 10 years. This figure is about
30 per cent less than the 15.5 per cent for industry at large.
In the textiles industry, material costs represent almost 60 per
cent of the value of the product, and exert the greatest influence on
profit margins. By far, the greatest portion of the material costs is
accounted for by the fibers used. These wide swings in fiber prices have
caused not only changes in cost, but also in inventory evaluations. It is
the uncertainty of prices of the natural fibers that has accentuated the
shift to the use of man-made fibers. The cost of chemicals and dyes has
also increased sharply in recent years.
Labor is the second largest cost factor. Labor costs, however,
vary widely with the nature of the products made, the production methods
used, and also with the extent of automation and integration. According
to the 1972 Census data, overall labor costs for the textiles industry
were 21.6 per cent of the value of goods produced. However, the break-
down showed that labor costs were 27 per cent for cotton mills, 26 per
cent for man-made fiber weaving mills and 17 per cent for knit fabric
mills. One year later, in 1973, the labor costs of six leading integrated
textile companies were reported to be about 30 per cent of sales.
Wage rates in the textiles industry are about 28.5 per cent lower
than wage rates for all manufacturing companies. Nevertheless, the
general rise in wage rates has caused labor costs to double in the last
15 years. To counter the uptrend, steps have been taken to modernize
equipment, to eliminate less productive plants, and to put greater empha-
sis on higher priced products in the product mix.
Furthermore, management has turned to greater utilization of
electronic data processing to supply useful and up-to-date information
for decision making. The use of such specialized management techniques
has permitted much better procurement control, production scheduling,
* Profit margin is defined as operating income before deducting depreciation
and Federal taxes, divided by sales.
2-5
-------
sales-to-inventory turnover ratio and improvement in warehousing and
distribution costs.
Inventory control has historically been a major weakness in
the textiles industry. The industry tended to overbuild inventories both
in raw materials and finished products during periods of prosperity,
gearing production to equipment capability rather than to actual orders
or demand. The subsequent decrease in business activity would render such
high inventory levels expensive to maintain because of finance charges.
The problem was further aggravated by the drop in the value of raw
materials and finished products during such slack periods. Often in the
past, the companies had to cut back on their inventories of finished pro-
ducts at prices below cost. The use of electronic data processing appears
to have improved inventory control considerably. Management has also put
increased emphasis on consumer market studies and consumer testing of new
lines.
2.2.4 Future Trends and Developments
Since 1970, the textiles industry has made substantial additions
to its production capacity. Indeed this expanded capacity was heavily
taxed in 1973, when mill operating rates rose to 90 per cent of capacity.
The subsequent economic downturn of 1974-75 found the industry with a huge
inventory and idled about one-third of production capacity. At this time,
there appears to be sufficient capacity to meet market needs for several
years to cone.
During the recent expansion, quite aside from the growth in
numbers of production units (cotton-weaving was the only sector showing
a decline), there was a decided effort to replace older equipment with
modem and more productive machines and to direct capital outlays into
newer marketing areas such as for the production of double-knits and
stretch-woven fabrics.
Over the next three years, no further increase in production units
is expected. Capital expenditures were projected to be about $700 million
for 1975, and $850 million for 1976. However, the American Textile Manu-
facturers Institute projected that for 1975-77, annual outlays of about
$659 million would be required for equipment and programs to comply with
Government health and environmental legislation. If this projection is
even approximately accurate, very little funds will be left for plant
modernization.
Raising the funds for capital expenditures will be somewhat of
a problem for the industry. Equity financing by selling common stock is
not advantageous because most textile stocks are selling at substantial
discounts from book value. Long-term debt financing will saddle the indus-
try with high interest charges. The smaller or marginal companies may
find the problem especially difficult to surmount.
2-6
-------
Raw material supplies should be more than adequate to meet
expected needs and no shortages are expected. Production capacity of
polyester, both in the U.S. and worldwide, is 25 per cent greater than
usage even during the peak period in 1973, and even if there were no
further increase, this capacity would be sufficient to meet demand for the
next two years. Late in 1974, demand was so slack that prices weakened
and only half the polyester producing capacity was utilized. Some upward
revision in demand took place in 1975, but supplies are still excessive
and will probably remain so for the next two years.
Nylon production capacity similarly has outstripped production
needs, and nylon is now also in excess supply.
Cotton is declining in importance as a textile fiber and^sharp
drops in its use are expected. Nevertheless, production will continue to
be excessive, and carryover stocks are increasing both in the U.S. and
worldwide. Thus, supplies are more than adequate to meet expected needs.
The textile industry, therefore, can expect price stability in its major
raw materials for the next two years.
Labor cost, the industry's second largest cost factor, is expected
to continue its uptrend. Since wage rates are lower than those prevalent
in industry at large, wages are expected to move closer to^ the higher ^.
average rates. Additional upward pressure is to be expected if domestic
or worldwide inflation persists.
Management, for its part, has adopted more sophisticated techniques
to improve its performance. It has made greater use of electronic data
processing to control procurement, production and inventory. It has also
changed from its former practice pf gearing production to equipment
capacity, and now attempts'to match production to the demands of the
marketplace. Increased emphasis has been placed on consumer market studies
and consumer testing of new lines as guides to production planning and to
development of new markets. The benefits of these measures will become
more evident with improvement in market conditions.
The economy was expected to and did begin recovery in the second
half of 1975 and continue to improve into 1976. Demand for textile
products should keep pace with the recovery as more disposable income
becomes available. The higher level of business'activity coupled with
the recent cost-cutting measures and stable raw material prices should
enhance the profitability of the textile companies.
The export markets may offer another area of improvement.
For many years, world prices were considerably lower than domestic prices.
Recently, exports have risen sharply as domestic prices have moved closer
to world prices. The devaluation of the dollar, the rapid advances in
labor costs abroad, the greater efficiency of domestic plants, and the
2-7
-------
development of newer products by U.S. companies have all contributed
to the export surge. These same reasons and the reduction in delivery
lead time will also make domestic products more competitive with imported
textiles.
2.3 Industry Characterization
Industry characterization is concerned with the categorization
of the industry by products manufactured, processes used, or any other
viable method to determine the distribution of the number of plants in
each industry category, the distribution of plants by size (number of
employees), the distribution of plants by age of processing equipment,
the distribution by manufacturing processes and the distribution of pro-
duction in each industry category.
This task was accomplished by utilizing various sources of data
as well as information obtained from trade associations and plant visits.
The major efforts in this phase were directed toward collecting information
on the distribution of the number of plants and the distribution of pro-
duction of the plants in the industry categories that generate potentially
hazardous wastes destined for land disposal ;jince this information was
required to accomplish the other three phases of the study (Phase II -
Waste Characterization, Phase III - Treatment/Disposal Technology, and
Phase IV - Cost Analysis).
2.3.1 Rationale for Industry Categorization
Initial attempts to categorize the textiles industry by four-
digit Standard Industrial Classification (SIC) codes proved to be an
inadequate method for the purposes of this study. Reasons for this are:
a. The SIC code method of classifying the industry is obsolete.
For example, SIC 2261 is the dyeing and finishing of woven
cotton broadcloth and SIC 2262 is the dyeing and finishing of
woven man-made fiber broadcloth. Very few plants in the industry
are devoted to either 100 per cent cotton of 100 per cent man-
made fiber cloth. Most plants are producing cloth with blends
of fibers and there is no SIC code for this type of plant.
This is also true in SIC 2231 (woven wool fabrics) where very
few plants are producing 100 per cent wool fabrics.
b. The SIC code method of classification includes all plants in the
group. For example, SIC 225 includes all knitting plants and
SIC 227 includes all carpet plants. This study is concerned only
with those plants that perform dyeing and finishing operations.
These operations are the direct or indirect source of potentially
hazardous land-destined wastes. The exception to this is Wool
Scouring which is part of SIC 2299. Sludges generated by Wool
Scouring wastewater treatment plants were found to contain
heavy metals and chlorinated organics (see Section 3 of this report).
2-8
-------
The SIC code mathod of categorizing the textiles industry was
also found inadequate by another EPA contractor (Arthur D. Little, Inc.)
during their development of the effluent limitations guidelines for the
textiles industry. Versar and the American Textile Manufacturers Insti-
tute (ATMI) agreed that the best method for categorizing the industry for
this study was by process and not by product. Therefore, the method used
by Versar is the same as was ultimately used in the effluent limitations
guidelines document and is as follows:
Category Process SIC Groups Included
A Wool Scouring 2299
B Wool Fabric Dyeing and 2231
Finishing
C Greige Goods 2211, 2221, 2231, 2241, 2251,
2252, 2253, 2254, 2257, 2258,
2259, 2281, 2282, 2283, 2284
D Woven Fabric Dyeing and 2261, 2262
Finishing
E Knit Fabric Dyeing and 2251, 2252, 2253, 2255, 2257,
Finishing 2258, 2259
F Carpet Dyeing and Finishing 2272
G Yarn and Stock Dyeing and 2269
Finishing
2.a.2 Distribution of Plants by Number of Establishments
Table 2-1 shows the distribution of textile plants by industry
category. The wet processing plants (plants that perform dyeing and/or
finishing operations) listed are the ones which generate potentially
hazardous wastes for land disposal. The 3,359 greige goods plants,
Category C, do not generate potentially hazardous waste.
A total of 2,007 establishments that perform dyeing and/or
finishing operations was identified. The breakdown of this part and
the entire industry on an EPA Regional basis is as follows:
2-9
-------
Table 2-1. Distribution of Textile Plants by Industry Category
Industry Category
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I . Connecticut
III Delaware
tv Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississipoi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Hampshire
II New Jersey
VI New Mexico
II New York
IV North Carolina
VIII .North Dakota
V Ohio
Vl Oklahoma
X Oregon
III Pennsylvania
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
V^ Texas
VIII Utah
i Vermont
III Virginia
X Washington
III West Virainia
V Wisconsin
VIII Wyoming
TOTAL
Region I
II
III
IV
V
VI
VII
VIII
IX
X
A
1
t
5
1
1
2
2
4
1
17
8
2
2
4
1
B
1
4
5
1
9
16
2
1
6
11
10
9
1
4
10
6
4
1
3
1
2
3
1
1
12
43
21
13
19
5
3
1
1
1
5
C
47
11
128
4
31
3
91
266
1
46
1
4
3
8
8
7
1
80
19
17
19
6
7
10
294
2
AS4
71S
39
13
14
334
44
\JI
93
23
4
7
45
14
4
11
,359
179
978
397
,419.
143
57
20
9
128
29
D
20
1
19
2
18
2
7
41
8
3
1
. 3
5
5
52
2
1
2
9
5
79
RR
104
II
2
43
35
49
IV
4
2
17
1
651
117
l
-------
Entire Industry
EPA Region
I
II
III
IV
V
VI
VII
VIII
IX
X
No. Of
Plants
437
1,345
603
2,417
214
87
35
13
177
38
5,366
Percentage
of Total
8.1
25.1
11.2
45.1
4.0
1.6
0.7
0.2
3.3
0.7
Plants Performing Dyeing
and Finishing Operations
No. of Percentage
Plants of Total
100
258
367
206
998
71
30
15
4
49
9_
2,007
13.0
18.0
10.0
50.0
3.
1.
0.7
0.2
2.4
0.4
100
.8
.5
As shown in this breakdown, ninety-one per cent of the plants
that generate potentially hazardous wastes are located in EPA Regions I,
II, III and IV with fifty per cent located in Region IV alone. Also, the
textiles industry as a whole is heavily concentrated in the eastern part of
the U.S.
The 2,007 plants of concern to this study are approximately
37 per cent of the total nunfoer of textile operations in the U.S. (10).
The remaining 63 per cent are dry operations and do not generate potentially
hazardous land-destined wastes.
2.3.3 Distribution of Plants by Size (Nuirber of Employees)
Table 2-2 shews the distribution of the textile plants with
respect to their size (nuntoer of employees) (4), (5), (6), (7). Data for
the plants listed in the "unknown" column were not available.
The distribution of the plants in the various size ranges is
as follows:
Size Range
(No. of Employees)
1-4
5-9
10-19
20-49
50-99
100-249
250-499
500-999
1,000-2,499
over 2,500
unknown
Totals
Number of
Plants in Range
103
144
242
653
614
991
602
377
159
37
1,444
5,366
Percentage of
Total Plants
1.9
2.7
4.5
12.2
11.4
18.5
11.2
.0
.0
7.
3.
0.7
26.9
100
2-11
-------
Toble 2-2. Distribution of Textile Plants by Size (Number of Employees)
Number of Employees
IX Arizona
VI Arkansas
VIII Colorado
I Connecticut
III Delaware
IX Hawaii
X Idaho
? Indiana
7TI — Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michioan
V Minnesota
VII. Missouri
VII Nebraska
IX Nevada
I New Hampshire
II New Jersey 1
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Pennsylvania
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Uta T
i Vermont
I'll Virqir.ia
X Washington ~~
III West Virginia
V Wisconsin
71 1 1 Wyoming
TOTAL
Region I
II
III
IV
VI
VII
VIII
IX
X
*No data could be found
Unknown*
41
\7
\\s "••
2 .....
•j
5
6
.6.
269
11
2
m
77
,_ 112 ...
39
3
26
. 4
1,444
108
376
166
56
21
3
concerning t
1-4 .
3__
13
2
11..
~TfT
3_
103 _
8
49
9
31
. „ 3-
•>e size
S-9
2
2
<) )
~?r^
•M-.
6
29
3
144
7
41
31
13
2
_L2_
of the
0-19
2
6
4~~
2
c
-IT
60
.. 47
6_
3
26
3
?42
11
. 91
26
83
6
18
e plant
20-49 i
3
6
3
~43 '
13
2
2
21
6
4
2
_ 94 .
"U2""1
129
3
54
28
TT-
7
3
5
5_
653
57
1 256
-~M~
207
2
(numbe
0-99
33
6
56
10
2
...25 ..
3
69
~~35
139
3
12
66
13
18
6
4
""6T4~
52
159
"26f
3_
36
1 ^
r of emp
100-249
13. '
— R
T5
7
7
4
3
9
--^9—
1
7
6
BO I
-nf—
r 234
9
_J6
92
25
39
23
9
8
18
4
~991
91
~221
TT9
'430 '
~72
— 33
~^-
25
loyees).
250-499
10
2
25
22 _
'3
6
27
4
~To
_J2fl
~m —
168
~T3 '
39
~T9
39
2o
~T2
2
"~555
75
85
"~33
324 '
59
4
H
15
500-999
13
•
4
. 49. -
3
2
4~~
7
_. 2
i
20 '
138
. 6 ...
\l
5
48
5
2
6
5
377
21
42
27
7-S9..._
17
7
1000-2499
6
" n ~
i ~
3
4
.
22
45
22
io
15
12 ~
V59
7
22
93 , .
3
>2500
^
7.
2
3
3 ..
. 2
37
24
4
4
Total
97
14
5
.108 ..
479
2
66
-fK
-fr-
184
— 25 —
45_2
893
•^4o
60
19
21
487
1?1
287 ,
-4f-
12
. S'
s
73
1,366
437
"1,345
603
> 417
214
177
2-12
-------
Of the plants with known sizes, the facilities which employ
between 100-249 workers are the most numerous. Plants having size ranges
of 20-49, 50-99 and 250-499 are the next largest with respect to the
number of employees and are about equal in magnitude. Together these
four groups contain over 53 per cent of the plants. It is probable that
many of the plants in the "unknown" column would also fall into these
four size groups.
2.3.4 Distribution of Plants by Age
Table 2-3 shows the distribution of production equipment by age
for the plants visited by industry category. Process equipment age data
was not available in the literature and the extrapolation of the data in
Table 2-3 to the entire industry would be meaningless. However, process
equipment age was not considered to be a determining factor in the genera-
tion of potentially hazardous waste destined for land disposal.
The following data summarizes the ages of the process equipment
at the plants visited in each category:
(No.) and Percentage of Plants in Age Range
Category less than 5 years 5-20 years more than 20 years
A - Wool Scouring (2) 50 (2) 50
B - Wool Fabric Dyeing
and Finishing (1) 14 (6) 86
C - Greige Goods (1) 20 (3) 60 (1) 20
D - Woven Fabric Dyeing
and Finishing (10) 45 (12) 55
E - Knit Fabric Dyeing
and Finishing (4) 20 (10) 50 (6) 30
F - Carpet Dyeing and (1) 9 (8) 73 (2) 18
Finishing
G - Yarn and Stock Dyeing (1) 9 (1) 9 (9) 82
and Finishing
Totals (7) (35) (38)
Of the plants visited, 47.5 per cent had process equipment with
ages over 20 years, 43.8 per cent with ages from 5-20 years and 8.7 per
cent with ages less than 5 years. These percentages would most likely
be representative of the industry as a whole.
2.3.5 Distribution of Plants by Process
Because the industry was categorized on a process oriented basis
rather than a product oriented basis, Table 2-1, distribution of the
number of establishments by industry category, also shows the distribution
of the plants by process. The following summarizes the process distribution:
2-13
-------
Table 2-3. Distribution of Production Equipment by Age for Plants Visited by Industry Category
X Alaska
VI A r K a ns a s
VlTl~Colornr.6
Y Connecticut
Hi. Dulawarc
IFE™
X Idaho
pn — 15^3
VII Kansas
TV Kentucky
'* Maine ""
ill Maryland
V Minnesota, .
IV MiEsisr.ipoi
VII Missouri
vT—iSKSTEa- 1
II New Jersey
V"l Now Mexico
Tl New York
IV north Carolina
VIII North Dakota
71 Oklahoma
III Pennsylvania
I Khode Islnn3
IV South C.irollm
VIII South Dakota
IV Tennessee
VI Texas
Vlll vfJn
I Vermont
III Virninia
f Wis cor.ci n
VIII WyoS.-cj
TOTAL
Reaion I
II
i7i ~
IV
VIII
IX
X
1
A-W
in
2
1
~T
2
»IS
)
3
T~
1
t
cou
~T
:
4
i
i
B
1
- Wo
Dl
2
T~
olF
IF
3
T
T~
ibric
T
T
T
C-Greig
1 2
T"
__l_
• Goods
3 T
._£_
D-Wo
[
1 2
^
~T
| a
K
1
9
ven 1
)&F
3
~T
2
~r
_3_
_1_
2
?
i
9
abric
T
^
4
J-O.
_3.
E-Knit
D
1 2
. -4-
. L*
J^
. n.a_
Fabric' | F-Cor
S.F 1
3 T 1 1 2
I ^
LJ_
_^L
~~T
I lal
r
20
1
2
\t\
T
m
1 8
_L ^__
TT"
pel DiF jl G-Ya
I Stock
} 3 jT [' ( 2
_L-ji_ X_l_
-LIl_jj_L_JL._i
!
IL
2 9 j L_f
1*1
rn and
D * F Total
fl-,1- J3iLtsL-___
1 —
3mz3Ezn::
-3 — - •
4 — .
2 -•
1
i_i n -•
^
4=^=t
. 55— —-f
i — (.
I 1_ 12 J
<— H '
~-la- — — 4LHZT
j- — -j
Key: 1 - l«u than 5 yean
2-5-20 yean
3 - more than 20 yoori
T - Totol
2-14
-------
Process No. of Plants Percentage of Total
Wool Scouring 17 0.3
Wool Fabric Dyeing and
Finishing 112 2.1
Greige Goods 3,359 62.6
Woven Fabric Dyeing and
Finishing 651 12.1
Knit Fabric Dyeing and
Finishing 738 13.8
Carpet Dyeing and Finishing 144 2.7
Yarn and Stock Dyeing and
Finishing 345 6.4
Ibtals 5,366 100
As shown in the above breakdown, over 62 per cent of the plants are
engaged in greige goods manufacture which generates no potentially
hazardous wastes. Of the remaining plants that perform dyeing and/or
finishing operations, over 69 per cent are in the woven fabric and knit
fabric dyeing and finishing categories.
2.3.6 Distribution of Plants by Production
Table 2-4 shows the estimated distribution of production by
industry category. The methodology used to distribute the production on a
state-by-state basis for the industry categories is as follows:
Category A - Wool Scouring
The total estimated annual production in this category, 69,000 kkg/
year, was obtained by multiplying the average production rate of the four
plants visited by the number of plants identified. Some of the state-by-
state data was withheld because of the small number of plants in this
category and the possibility of revealing proprietary production rate
information.
Category B - Wool Fabric Dyeing and Finishing
The total estimated annual production in this category, 309,000 kkg/
year, was obtained by multiplying the average production rate of the seven
plants visited by the number of plants identified. The state-by-state
distribution was obtained the same way.
Category C - Greige Goods
The total estimated annual production in this category is
3,000,000 kkg/year. This figure is based on information supplied by the
ATMI. Production data distribution was estimated using 1972 Census of
Manufactures data, Dun Market Indicator data and contractor judgment.
2-15
-------
Table 2-4. Estimated Distribution of Production by Industry Category
Industry Category - Production Thousand Metric Tons/Year
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michiaan
V Minnesota
IV Mississiooi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Hair.nshire
II New Jersey
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Pennsylvania
I Rhode Island
IV South Ceiroiina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
Vermont
III Virginia
k Washington
III West Virginia
V Wisconsin
VIII Kvominct
TOTAL
Region I
II
III
IV
V
VI
VII
VIII
IX
X
A
*
20
*
*
*
*
15
*
69
20+
20
IS
B
3
11
14
3
25
44
5
3
16
30
28
25
3
11
28
16
11
3
8
3
5
8
3
3
309
117
58
36
53
14
R
3
3
3 '
14
C
46
127
4
22
2
90
263
45
1
4
3
8
8
5
8
57
19
17
19
6
7
7
210
2
489
710
39
13
14
330
3?
175
90
23
4
5
44
14
4
11
3,000
128
699
388
.401
14?
"57
20
9
127 .
29
D
84
2
2
1
40
4
15
170
45
6
2
6
12
10
166
4
2
4
3
11
154
60
334
25
4
9
9
530
20
41
4
20
2
.801
242
214
43
.163
R4
47
5
1
2
E
30
1
5
10
36
4
2
6
3
1
1
15
1
5
4
5
70
310
4
1
1
65
9
60
38
4
1
21
1
6
771
36
10
88
494
70
R
2
11
2
F
9
9
81
4
409
4
9
9
4
4
13
27
4
9
22
27
18
9
4
4
679
9
17
26
503
19
27
4
81
G
38
38
29
197
38
10
10
91
5
10
24
135
178
409
19
5
5
154
i?n
87
38
10
10
1.660
274
313
164
779
79
5
10
38
5
Total State
I 207
22
262
5
107+
6
119 '
1,089 "
2
132 ~
21
9
5
39
11
53
19
402
33
32
27
19
1
7
-63
573
2
838
1,815
94
32
31 +
608+
1RA+
890+
207
TOO '
11
15
107+
17
5
32
8.289
826+
1.411
745+
4.393+
.144
167
40
17
262
50+
* Data withheld because of its proprietary nature.
Key: A -Wool Scouring
D -Wool Fabric D & F
C - Greige Goods
D-Woven Fabric D & F
E - Knit Fabric D & F
2-16
F - Carpet D & F
G - Yarn and Stock D & F
-------
Category D - Woven Fabric Dyeing and Finishing
The total estimated annual production of 1,801,000 kkg/year was
obtained from the 1972 Census of Manufactures. Values for some of the
major producing states such as North Carolina, South Carolina, Georgia,
Massachusetts, etc., were also obtained from Census data, however, for
those states not included in the Census report, the production, after sub-
tracting the known state productions from the total, was divided by the
number of plants remaining to obtain an average production per plant.
This value was then used to determine the production for those states not
identified in the Census report.
Category E - Knit Fabric Dyeing and Finishing
Estimating the total annual production of dyed and finished knits
from the Census data is extremely difficult if not impossible because of
the way the information is reported. For example, hosiery is reported in
thousand dozen pairs. The estimate of the total annual production, 771,000 kkg/
year, is based on figures supplied by the ATM! and the assumption that the
ratio of dyed and finished goods to greige goods is the same for knits as
it is for wovens. The state-by-state distribution was based on contractor
estimates made by using the data obtained from the visited plants and
judgment as to whether the state totals were consistent with the gathered
information and the number of plants identified in the state.
Category F - Carpet Dyeing and Finishing
The total estimated annual production for this category, 679,000 kkg/
year, was obtained as follows:
877 x 106 x 144 x 4.5 x 0.91 = 679,000 kkg
381g 2000
where: 877 x 10 = square yards of carpet/year from 1972 Census of
Manufactures
144 = number of carpet plants that dye and finish
381 = total number of carpet plants
4.5 = pounds per square yard of finished carpet (average value)
2000 = pounds per ton
0.91 = metric tons per ton
The state-by-state distribution was accomplished by attributing
12 per cent of the total production to California (an estimate obtained
during a visit to a California carpet plant) and allocating the remainder
on an average production per plant basis. This method is felt to be
reasonably accurate because the production for the state of Georgia amounts
to about 60 per cent of the total, as claimed by the Carpet and Rug
Institute (CRI).
2-17
-------
Category G - Yarn and Stock Dyeing and Finishing
Census data could not .be used in this category because the Census
report does not include data for captive products. Many integrated plants
that dye and finish their own yarn and stock do not appear in the Census
data. Therefore, the total annual production of 1,660,000 kkg/year was
obtained by usihg a selected average of the 11 plants visited and multi-
plying by the total nurrber of plants identified. The state-by-state distri-
bution was done the sane way.
In sunmary, a total of 8,289,000 kkg/year is produced by the
textiles industry. Those categories that generate potentially hazardous
land-destined wastes produce 5,289,000 kkg/year. The percentages of the
total for each industry category are:
Annual Production Percentage of
Industry Category Rate (kkg/year) Total Production
A - Wool Scouring 69,000 0.8
B - Wbol Fabric Dyeing and 309,000 3.7
Finishing
C - Greige Goods 3,000,000 36.2
D - Woven Fabric Dyeing and 1,801,000 21.8
Finishing
E - Knit Fabric Dyeing and 771,000 9.3
Finishing
F - Carpet Dyeing and Finishing 679,000 8.2
G - Yarn and Stock Dyeing and 1,660,000 20.0
Finishing
Totals 8,289,000 100
Of the categories that generate potentially hazardous wastes,
Woven Fabric Dyeing and Finishing and Yarn and Stock Dyeing and Finishing
are the largest with respect to annual production and conbined, amount
to 41.8 per cent of the total production.
2-18
-------
The EPA Regional distribution of the total production is:
EPA Region kkg/year in Region Percentage of Total Production
I 826,000 + 9.9 +
II 1,411,000 17.0
III 745,000 + 9.0 +
IV 4,393,000 + 53.0 +
V 344,000 4.2
VI 167,000 2.0
VII 40,000 0.5
VIII 17,000 0.2
IX 262,000 3.2
X 50,000 + . 0.6 +
More than 53 per cent of the total production in the industry occurs in EPA
Region IV alone. Approximately 90 per cent of all production occurs in
EPA Regions I, II, III and IV.
2-19
-------
3.0 WASTE CHARACTERIZATION *
3.1 Introduction
In this section, the processes, the wastes resulting from each
process, and the quantity of total and potentially hazardous waste generated
are described for each segment of the industry. Discussions of the criteria
enployed for the determination of potentially hazardous wastes and a
general description of the waste sampling techniques and analytical methods
used are also included. Finally, a rationale for the selection of waste
streams for technology and cost analysis is presented as the final sub-
division of the waste characterization section.
The flow diagrams accompanying the process and waste streams
descriptions are presented in the following format:
Raw materials are on the left and products are on the right.
Waste products, both solid and liquid, are projected downward.
All diagrams are based on 1,000 units of mass of the principal product.
For clarity, several operations have, in some cases, been corbined in one
block. The diagrams reflect our technical judgment of typical or usual
operations in the given industrial category, rather than those associated
with a specific, identifiable plant. Production rates and other data for
the assumed typical plant are given in the text accompanying each diagram.
Descriptions of individual processing steps were kept as brief and as
general as possible. The glossary (Appendix A) of this report addresses
specific operations and serves as an excellent supplement to the reader who
would like more detailed information on any given operation. Dyeing and
printing operations are extensively described in the glossary.
3.2 Criteria for Determination of Potentially Hazardous Wastes
"Hazardous wastes" are defined as any wastes or combination of wastes
which pose a substantial present or potential hazard to human health or
living organisms because such wastes are: lethal, nondegradable, or persistent
in nature; may be biologically magnified; or may otherwise cause or tend to
cause detrimental cumulative effects (11).
Hazardous wastes include materials which are:
a. toxic or poisonous (producing injury or illness through
ingestion, inhalation or absorption through any skin surface);
b. corrosive (destructive to living tissue);
c. irritants (induce local inflammatory reaction in living
tissue);
3-1
* The reader is cautioned1 that no waste products from the textiles
industry have been demonstrated to be hazardous by this study.
EPA reserves its judgments pending a specific legislative mandate.
-------
d. strong sensitizers (cause hypersensitivity an living tissue
through an allergic or photo-dynamic process);
e. flammable;
f. explosive (generate pressure through decomposition, heat or
other means) ;
g. infectious (represent a potential source of the transmission
of diseases to human domestic animals or wildlife) ;
h. radioactive;
i. carcinogenic (causes malignant tumors);
j. mutagenic (causes heritable genetic changes);
k. teratogenic (causes non-heritable genetic changes).
These wastes can take the form of solids, sludges, liquids or gases (12,13).
The criteria used to determine the hazardousness of heavy metals
and total organics present in textile wastes are the U.S. Public Health
Service 1962 drinking water standards. The limit for total organics is
0.7 mg/liter and contractor analytical results showed much greater amounts
(as much as 500 mg/liter) in sampled sludges. The heavy metals of most
concern in the textile industry include arsenic, cadmium, chromium, cobalt,
copper, lead, mercury and zinc. The specific limits in drinking water
range from 0.001 mg/liter for mercury to 5 mg/liter for zinc. The other
limits are detailed in the table below.
Metal T.itnit Source
As 0.05 mg/liter 1962 Mandatory drinking water standards,
U.S. Public Health Service
Ba 1.0 mg/liter 1962 Mandatory drinking water standards,
U.S. Public Health Service
Cd 0.01 mg/liter 1962 Mandatory drinking water standards,
U.S. Public Health Service
Cr 0.05 mg/liter 1962 Mandatory drinking water standards,
U.S. Public Health Service
Co 0.2 mg/liter Criteria for agricultural waters (irrigation)
Cu 1.0 mg/liter 1962 Recarmended drinking water standards,
U.S. Public Health Service
Fe 0.3 mg/liter 1962 Reccranended drinking water standards,
U.S. Public Health Service
Pb 0.05 mg/liter 1962 Mandatory drinking water standards,
U.S. Public Health Service
Mn 0.05 mg/liter 1962 Recommended drinking water standards,
U.S. Public Health Service
3-2
-------
Metal Limit Source
Hg 0.001 rag/liter Tentative suggested limits of certain trace
elements not included in drinking water
standards, U.S. Public Health Service
Ni 0.5 mg/liter Criteria for agricultural waters (irrigation)
Se 0.01 mg/liter 1962 Mandatory drinking water standards,
U.S. Public Health Service
Zn 5 mg/liter 1962 Recottnended drinking water standards,
U.S. Public Health Service
The drinking water standards were chosen as> the criteria for deter-
mining the hazardousness of textile wastes since the landfill is a canton
disposal site for these wastes and resultant leachate may contaminate an
aquifer, the ground water, or surface water, and ultimately reach a drink-
ing water supply.
The problem of hazardousness of dyestuffs is of major concern in
the textiles industry.
. i '. •
Dyestuffs are complex organic compounds refractory (non-bio-
degradable) to conventional aerobic treatment systems. Some dyestuffs con-
tain heavy metals, such;as chromium, copper and zinc. Only about 50 per
cent by weight of commercial dye is dyestuff. -The remainder is usually a
non-hazardous filler (such as sugar) and surfactant. The consumer has
actively demanded brighter colors as well as better lightfastness and wash-
fastness in fabrics. This has resulted in the various types of resistant
dyes in the textiles industry today.
The major dye types used on different fibers and the amount of
total dye use this represents is given below. (8)
Per Cent
of Total
Dye Types Fiber Used On Dye Use
Vat dyes cotton, rayon, polyester/cotton 26%
Direct dyes cotton, rayon, polyester/cotton,
nylon/cotton ' 17%
Disperse dyes acrylic, acetate, polyester, polyester/
cotton, nylon 15%
Acid dyes wool, nylon 10%
Sulfur dyes cotton, rayon, polyester/cotton - 10%
Basic (cationic) dyes , acrylic, polyester, polyester/cotton,
nylon 6%
Azoic dyes i cotton, rayon 3%
Fiber reactive dyes cottpn . 1%
Fluorescent dyes cotton, wool, rayon, polyester/cotton 1%
3-3
-------
Per Cent
of Total
Dye Types Fiber Used On Dye Use
Mordant dyes wool 1%
Aniline black dyes cotton )
Developed dyes cotton, rayon )
Dye blends polyester/cotton ) Totals
Indigo dyes cotton, nylon/cotton ) approximately 10%
Natural dyes cotton )
Oxidation base dyes cotton )
100%
As consumer demands shift toward greater use of synthetic fibers,
percentages should shift toward greater use of disperse, direct and basic
dyes. However, as more information becomes available on the nature of the
environmental hazards posed by various dye types, it is possible that these
percentages will shift to vat dyes and perhaps of necessity to new dye
types not yet developed.
Although pollution resulting from dye process effluents is highly
visible, the toxicity of dye wastes has largely been ignored until recently.
The American Dye Manufacturers Institute (ADMIX beginning in 1971, sponsored
several studies to evaluate the toxicity of a broad spectrum of dyes on
fish and algae; to evaluate dye.biodegradability and effect on aerobic and
anaerobic processes; and to evaluate dye and non-dye sources of heavy metals
in textile effluents.
Dyes derive their color from electron transitions between various
orbitals. All organic compounds absorb light energy, but in an unsaturated
system, the electrons are more mobile and resonance will cause absorption
of the lower energy light in the visible range. Certain groups of atoms are
associated with color and are called chromophores: C-C, C-O, C-S, C-N, N-N,
N-O, and NO*. However, colored molecules (chromogens) are not dyes unless
they contain auxochrcmes such as NH2, NH(CH3)/ N(CH3)2/ and OH, which enable
the molecule to dissociate electrolytically for binding with a substrate.
Auxochromes may or may not alter the color of a dye.
One of the problems encountered in trying to assess the toxicity
of dyes is that toxicity analogies between known structures and dyes fall
short. A simple change in the location of an auxochrome, chrcmophore or
other substituent may alter the toxicity of a dye drastically. Also, many
dyes are heterocyclic compounds and exhibit chelating action. Therefore,
toxicity could result either by the removal of metals essential to the
environment or by synergistic action to increase the toxic effects of metals
normally present.
3-4
-------
The observations from the ADMI sponsored fish bioassay study of
46 dyes include the following: (16)
- none of the direct or vat dyes were toxic and most disperse
dyes were not toxic.
- mordant black 11 and acid black 52, similar in structure, had
similar *TL50 values (6 and 7 mg/liter, respectively).
- triphenylmethane dyes were the most toxic with the triamino-
phenylmethane, basic violet 1, toxic at lower concentration
than was the diaminophenylmethane, basic green 4.
- in diaminoanthraquinone dyes the degree of toxicity appeared
to be directly related to the amount of substitution.
- pH may affect toxicity by influencing the degree of ionization
of the dye and the degree of ionization of its site of action
on a test organism.
Of the 46 dyes studied, 13 had *TL50 values less than 50 mg/liter,
with 10 of these dyes at less than 10 mg/liter. From a dye class standpoint,
the basic dyes appear to be the most toxic due to their cationic nature.
Cationics such as malachite green have long been known for their therapeutic
fungicidal effects and bacteriostatic and amebicidic activity. (16, p. 11)
direct and vat dyes were in all cases found to be non-hazardous.
However, th^ disperse and acid dyes had a few exceptions:
Dye Name TL50
disperse blue 3 1 mg/liter
disperse blue 7 52 mg/liter
acid black 52 7 mg/liter
acid yellow 38 23 mg/liter
acid blue 113 4 mg/liter
acid green 25 1 mg/liter
acid blue 25 6.2 mg/liter
acid yellow 151 29 mg/liter
A similar bioassay study of algae was undertaken (17) on the 46 dyes
previously studied along with 10 additional basic dyes since these showed
the most toxic effects in the fish bioassays. Hie results showed a strong
correlation with the effects on fish. The basic (cationic) dyes inhibited
algal growth by more than 80 per cent at 1 mg/liter. Mordant black 11 and
disperse blue 7 also showed these results.
*TLso values are concentration values of the dyes in the experimental water
environment at which 50 per cent of the fish survived.
3-5
-------
A study of the effect of biological treatment on nine dyes shown
to be toxic to fish (18) concluded that lone of the dyes seriously interfered
with the reduction of BOD. Some of the dyes did inhibit nitrification
(oxidation of anttonia to nitrate) and this could reduce the effectiveness
of a biological treatment system. While the dyes tested did not seriously
interfere with conventional biological treatment, this treatment was not
adequate for removal of color or toxicity due to the presence of dyes.
Other ADMI sponsored studies included investigation of the effect
of dyes on both aerobic (19) and anaerobic systems (15). In an aerobic
system, 17 of the 46 dyes tested were inhibitory; however, some of these
dyes became non-inhibitory after microbial acclimation. In the anaerobic
process studies, two of the dyes (both anthraquinones) caused complete
process failure by inhibiting methane fermentation. Two other dyes had
initial inhibitory effects which were overcome by acclamation. The dyes
also showed varying amounts of deoolorization possibly due to physical
adsorpHon onto the sludge, reduction reactions, microbial activity or
various combinations of all three.
Thus while data on human toxicity is not available, the various
studies sponsored by the ADMI on fish and algal toxicity do indicate that
the basic^cationic) dyes and sane acid and disperse dyes do warrant the>
label "potentially hazardous." Various thesis studies done at the Georgia
Institute of Technology also serve to show the refractory nature of such
dye types as anthraquinone disperse dyes (20), vinyl sulfone reactive dyes
(21), and azo disperse dyes (22) in waste treatment systems. The conclusion
to be drawn from these various sources are that dyes are essentially non-
biodegradable given the aeration and retention tijne in a conventional waste
treatment facility. There is no indication fron these studies of how these
dyes might react in a landfill. In fact, they may be subject to anaerobic
degradation. This gives rise to another problem concerning the nature of
dye metabolites which may arise from dye degradation.
In the ADMI sponsored study of anaerobic processes (15), it was
found that many of the dyes appeared to have been decolored or altered (in
visible spectra) during the anaerobic digestion process. Only 4 of the 46
dyes tested showed no signs of decolonization. The extent of degradation
was not studied, but the various possible mechanisms of decolonization were
discussed. A sanitary landfill is subject to anaerobic digestion and, there-
fore, the possibility of degradation of dyes present in landfilled sludges
exists. Industry contacts indicated that a number of dyes such as acid
blue 113, acid red 85, and direct blue 2 have carcinogenic intermediates.
Acid b]ue 113 requires the use of alpha naphthylamine as a synthesis inter-
mediate, and acid red 85 and direct blue 2 are both benzidene-based colors.
While studies (15) indicate possible anaerobic digestion of dyes in land-
filled textile sludges, they provide no knowledge of the nature of any
metabolites resulting from the dye degradation. It is obvious that much
work is needed to confirm anaerobic digestion of dyes and to characterize
resultant dye metabolites for toxicity and/or carcinogenicity. However,
3-6
-------
until such studies are initiated and completed, the contractor believes the
question of dye degradation under anaerobic landfill conditions and resultant
metabolites indicates the necessity of labeling dye-containing waste streams
"potentially hazardous."
A large variety of chemically complex dyes are used in mills
where textile products are dyed. On an industry-wide basis, it is a
virtually insurmountable task to trace the uses and fates of those dyes
shewn by the ADMI studies to be toxic. To further illustrate the complexity
of the problem and the lack of data, only 56 of the more than 1,000 dyes
commercially available were tested. It is more than likely that many more
dyes could also prove toxic if additional bioassay studies were done.
However, since 30 per cent of the dyes tested proved to have appreciable
toxicities to fish and/or algae, and since knowledge on human toxicity is
almost totally lacking in this area, it is felt that dye-containing waste
streams are potentially hazardous.
In summary, basic (cationic) dyes, sore acid dyes, and some disperse
dyes have been shown to be toxic to fish and algae in bioassay studies, and
therefore, are considered potentially hazardous. The remaining dye types
are refractory organics which may degrade in an anaerobic atmosphere such
as a landfill and leach out possible carcinogenic metabolites. For these
reasons, all dye-containing waste streams are to be considered potentially
hazardous.
Heavy metals are recognized as potential toxicants, depending on
their concentration and chemical form in the environment. Metals which are
most likely to be present in textile wastes and which have been cited as
cause for concern (23) include:
Range of Metal Dye Type with Highest
Metal Concentrations, ppm Metal Content
Arsenic <1 to 1.4 fiber reactive
Cadmium <1 all types
Chromium 3 to 83 vat
Cobalt <1 to 3.2 acid
Copper 33 to 110 vat
Lead 6 to 52 fiber reactive
Mercury 0.5 to 1 vat
Zinc 3 to 32 basic
These metals are contained in premetallized dyes (3-4 per cent metal content)
and some basic dyes requiring preparation as a double salt of zinc (3 per
cent metal content), dichromates used to oxidize and fix certain dyes;
chromium compounds used in topchroming; various metal salts such as
Zn(N03)2 used as catalysts for the application of wash-and-wear, durable
press and water repellent finishes; heavy metal compounds used to improve
3-7
-------
washfastness or lightfastness in certain fabrics; metals used in flame
retardant finishes; and metals entering a mill on fabrics and fibers also
from application of pesticides or other chemicals.
In all cases where limits have been recommended for amounts of
heavy metals in drinking water, these limits are used to define a substance
as hazardous. The 1962 mandatory and recommended drinking water standard
limits of the U.S. Public Health Service were chosen because of the possibi-
lity of leachate from textile sludges in a landfill contaminating an aquifer
or groundwater and ultimately reaching a drinking water supply. In the case
of Co and Ni, no drinking water standards have been recommended. The limits
used for Co and Ni were found in the Criteria for Agricultural Waters
(Irrigation). The Hg limit selected is one of the tentative limits suggested
by the U.S. Public Health Service for certain trace elements not included
in the drinking water standards.
The other hazardous components of textile wastes includes some of
the many chemicals used in dyeing and finishing operations, such as acids,
alkalies, bleaches, adhesives and polymers, cross-linking agents, carbonizing
agents (wool), conditioners, catalysts, detergents, dye carriers, chemical
finishes (including flame retardants) and solvents. See Appendix D for a
partial listing of the chemicals most used in the textile industry. The
chemicals most likely to be potentially hazardous are the dye carriers,
solvents, and chemical finishes. Dye carriers are organic compounds such
as biphenyl, orthophenylphenol, butyl benzoate, methyl salicylate, trichloro-
benzene, perchloroethylene, and other chlorinated aromatics, which accelerate
the absorption of dyes by the fibers in a dye bath. A study (24) of the
biodegradability of some dye carriers in activated sludge waste treatment
systems shewed the carriers used roost heavily in the textiles industry
today to be resistant to conventional waste treatment systems. Therefore,
these dye carriers could be expected to persist in the environment. Also
certain of the carriers such as biphenyl, toluene, naphthalene were con-
sidered toxic to the biota of the aeration basin in which they were tested
for degradation.
The remainder of the chemicals used in the textiles industry
(estimated to be 75 per cent by weight) are non-hazardous materials such
as common salt and sodium sulfate. This estimate was based on information
from industry contacts.
The criteria for considering textile processing chemicals
hazardous includes the drinking water limits for the various heavy metals
contained in seme of the salts and the limit for total organics (0.7 mg/
liter) in drinking water. The criteria applied for determining the
hazardousness of flammable solvents and still bottom wastes is the
Department of Transportation's Flashpoint Standard of 38 C (100 F) (25).
We consider these to be potentially hazardous if the solvent constituent
has a flashpoint below the DOT standard.
3-8
-------
Seme of the solvents used include:
Solvents Flashpoints, C (F)
Acetone - 9 (15)
Methanol 18 (65)
Naphtha - 7 to 43 (20 to 110)
Trichloroethane none
Dioxane 18 (65)
Butyl Carbitol 115 (240)
Butyl Cellosolve 74 (165)
3.3 Discussion of Sampling Techniques and Analytical Methods Used
Sampling of a representative nurrber of dyeing and finishing mills
in each subcategory, except C, Greige Goods, was carried out during this
program. The plants chosen were those deemed representative of a certain
subcategory in terms of processing and fiber types used.
Four-hour composite sludge samples from textile mill wastewater
treatment facilities were collected from the clarifier underflow returning
to the aeration pond. Two separate sets of samples were taken, one for
heavy metal analyses and one for chlorinated organic analyses. Sampling
was repeated at each plant once a week for four consecutive weeks.
Samples earmarked for heavy metal analysis were put in plastic
bottles and acidified with nitric acid to a pH of 2. The samples for
organics analysis were not acidified and were handled carefully to avoid
contamination.
The textile sludges had solids contents of 2 per cent or less
and therefore, the atomic absorption method for determining total trace
metals was used. The solids content of the textile sludges was determined
by total evaporation of a volume of unpreserved sample and drying to a
constant weight. Details of this and other analytical methods used can
be found in Appendix C.
For atomic absorption analysis, the sludge samples were digested
using heat and acid addition, the residue redissolved in acid and sample
volume adjusted with distilled water. The samples were then filtered to
remove insoluble materials, and aspirated directly into the flame source.
The absorbence was recorded and the corresponding metal concentration
determined.
Alternate methods were used to determine mercury and arsenic
concentrations. Mercury concentration was measured by the flameless
atomic absorption method using a quartz lamp as the radiation source to
vaporize the mercury. Arsenic was determined either by atomic absorption
or by the silver diethyldithiocarbamate method (see Appendix C).
3-9
-------
Trace amounts of itetals in the suspended solids portion of the
non-acidified sludge samples were measured by centrifuging a sample,
drying and digesting the solids and then using the atomic absorption method
as mentioned above.
The suspended solids in the sludge samples were determined by
filtering, drying and weighing a known volume of the sample.
The chlorinated organics were determined from the non-acidified
sludge samples by gas chronatography. The samples were prepared by
adjusting the pH to 6.5-7.5, extracting with methylene chloride in hexane,
concentrating the extract on an evaporating hot water bath and injecting
the extract into the gas chromatograph. The concentration of chlorinated
organics was then calculated.
3.4 Characterization of Waste Types by Industry Categories
The method used to extrapolate waste quantities to the entire
industry category is the same in all categories that generate potentially
hazardous wastes. Therefore, to avoid repetition in each category's dis-
cussion of waste quantities, the extrapolation method used is given below.
Waste quantities were keyed to the production rates. The waste
generation factors (kg of waste/metric ton of product) identified in
£«**
sludge.
Through discussions with industry representations, the contractor
has estimated that only 25 per cent of the chemicals used in dyeing and
finishing operations should be considered,potentially hazardous. This
figure was used in the estimation of hazardous constituents in the chemical
container waste streams.
Retained sludge quantities were established using the following
equation:
V x SS x SRP = DSR
P
Where:
V = Average ratio of wastewater aeration basin volume* to
~TT production of the direct discharge plant*
SS = Per cent suspended solids** divided by 100
SRP = State or regional production attributed to direct discharge
plants
3-10
-------
DSR = Total amount of dry solids retained in any given state
or region
* Data acquired by plant visits
** Data acquired by laboratory analysis
Once the dry retained sludge quantities were identified, the
total heavy metal and total chlorinated organics concentrations were multi-
plied by the sludge quantities to determine state or EPA regional distri-
butions of these hazardous constituents. Wet retained sludge quantities
were calculated from the dry amounts using per cent suspended solids
measurements determined by laboratory sludge analysis.
Dyestuff quantities in the sludge were estimated by the contractor
to be approximately 5 per cent of the dry weight of the sludge.
Descriptions of typical processes employed and wastes generated
by each category of the textiles industry are given below. The reader
should be aware that while data in the state-by-state distribution of the
tables are esqpressed in two significant figures, they are displayed in this
manner simply to have the columns total properly. Data in the "Total" and
"Region Total" sections may be expressed in three or more digits. It should
not be construed that these totals have a higher degree of accuracy than
the "state" entries.
3.4.1 Category A - Wool Scouring
The four plants yisited in this category are located in EPA regions
I, III and IV. Annual production of the visited plants range from 1,400
metric tons to 5,700 metric tons. A typical plant with wastewater treatment
facilities produces 5,600 metric tons/year of product. The number of
employees at the four plants range from 85 to 270 and average 180. Plant
ages range from 15 to 75 years, and average 33 years. Operations normally
run 2 or 3 shifts per day, 5 days per week, 52 weeks per year.
3.4.1.1 Process Description
A mass-balanced flow diagram of the typical wool scouring pro-
cess is shown in Figure 3-1. Grease wool, received in bales (each bale
usually contains the fleece of 2 or 3 sheep) is first sorted and blended
with other wool according to the grade of the wool and its ultimate
use. The wool is then fed to the scouring train, which consists of several
bowls (open tanks) through which the scouring liquor flows countercurrent
to the wool flow. Detergent is not added until after the wool passes
through the first bowl. Grease-laden water from the first bowl is sent to
a grease recovery system. Mechanical separation (heating, settling,
centrifuging, recirculating) is the most widely used system in the
United States for grease recovery; however, acid cracking is an alternative
method of grease recovery. Approximately 3 to 3 1/2 per cent of the
3-11
-------
Figure 3-1. CATEGORY A - TYPICAL WOOL SCOURING PROCESS
GREASE
WOOL
2,000
SORT AND
BLEND
I
SCOUR AND
DESUINT
I
DIRT AND
VEG.
MATTE
26
N)
RECOVERED
GREASE
FOR LANOLIN
PROCESSING
75
WASH
GREASE
RECOVERY
DRY
TOP
PREPARATION
i
I
WOOL
TOP
1.000
I
SALEABLE
WOOL WASTE
260
RETAINED SLUDGE*
SEE NOTE
WASTEWATER
TREATMENT
V
o
- PROCESS WASTE TO LAND
- WATER POLLUTION ABATEMENT WASTE TO LAND
• - POTENTIALLY HAZARDOUS WASTE STREAM TO LAND
** - SEE TABLE 3-1 FOR SPECIFIC METALS
NOTE: AN AVERAGE OF 780 KG (DRY), 7,800 KG (WET) SLUDGE IS
RETAINED CONTAINING 4.1 KG TOTAL HEAVY METALS,**
AND T.OxlO"3 TOTAL CHLORINATED ORGANICS (NOT
INCLUDED IN MASS BALANCE).
WASTED
SLUDGE*
570 DRY
5700 WET
LIQUID
EFFLUENT
POTENTIALLY HAZARDOUS
CONSTITUENTS:
TOTAL HEAVY METALS** 3.0
TOTAL CHLORINATED ORGAMCS 730x10-°
-------
weight of the grease wool is recoverable and is usually sold to processors
who further refine it into lanolin. The scouring operation removes the
natural impurities (grease, suint, some vegetable natter, etc.) from the
wool. Ihe wool is then washed to remove any traces of the scouring
chemicals, and dried. Clean wool may be sold at this point, however, at all
the plants visited, it was further processed into top. Top preparation
is a series of operations usually consisting of carding, gilling, combing,
and final gilling.
3.4.1.2 Waste Stream Descriptions *
Product (wool top) weight is approximately 50 per cent of the
raw material (grease wool) weight. This figure may range from about
35 per cent to 55 per cent depending on the grade of wool, its origin, and
other variables, but usually averages near 50 per cent for the typical
plant and product mix. As a result, this category's total waste (including
saleable waste and grease) weighs approximately as much as the product. This
category's typical plant land-destined waste streams are surrmarized as follows:
Quantity (kg of waste/
Waste Source kkg of product)
dirt and wool sorting and blending 12
dirt and vegetable scouring 26
matter
fly and sweeps drying, top preparation 2
wool waste top preparation 55
wasted sludge wastewater treatment 570 (dry) 5,700 (wet)
retained sludge * wastewater treatment 780 kg (dry)
7,800 kg (wet)
* The retained sludge quantity is an accumulation over the life of
the pond.
3.4.1.2.1 Potentially Hazardous or Non-Hazardous Constituents
There are no potentially hazardous constituents in the land-
destined wool, dirt, vegetable matter, fly, and sweeps wastes identified
in Figure 3-1. Additionally, there are no dye or chemical container
wastes (and their potentially hazardous residuals) due to the simplicity of
the process, purchase of detergent in bulk, and no dyeing operations.
However, potentially hazardous constituents were found in samples of this
industry's wastewater treatment sludge. These potentially hazardous
constituents are heavy metals and chlorinated organics.
3.4.1.2.2 Sampling Results
Table 3-1 shows the results of analyses performed on composite
sludge samples taken weekly over a period of four weeks. In every instance
where drinking water limits are established, metals or organics concen-
trations exceed these limits. Solids content of this sludge was the
highest of all categories of the industry. Iron accounted for over 90 per
cent by weight of the heavy metals content. Analysis performed for total
3-13
* The reader is cautioned that no waste products from the textiles
industry have been demonstrated to be hazardous by this study
EPA reserves its judgments pending a specific legislative mandate
-------
Parameter
Table 3-1
Category A - Wool Scouring
Sludge Analyses
(mgAg of dry sludge)
Drinking Water
Limit* (ppm)
Average
(1)
Arsenic
Barium
Cadmium
Chromium
Cobalt
Copper
Iron
Lead
Manganese
Mercury
Molybdenum
Nickel
Aluminum
Magnesium
Potassium
Sodium
Strontium
Total Chlorinated
Organ ics
Suspended Sol ids (%)
Total Solids (%)
0.05
1.0
0.01
(0.05
**
1.0
0.3
0.05
0.05
0'.002
**•
**
5.0
**
60.0
**
**
**
0.7
**
**
59
.2
19
4.2
18
4,820
28
205
0.01
<2
12.5 .
106
4,860
5,560
9,240
675
21.6
1.28
9.8
10.1
(1) Average of 4 measurements from one plant
(2) Less than values were considered to be at the maximum in computing the totals
* U.S. Public Health Service. Drinking Water Standards. 1962.
** No drinking water standards have been set for these metals.
3-14
-------
chlorinated organics showed 99.1 per cent by weight of the total content
(1.28 ppm) was in the solid phase of the sludge, with the remainder in the
liquid phase. Detailed sampling results may be found in Appendix C of
this report.
An average of 780 kg (dry) or 7,800 kg (wet) of sludge is retained
in the typical plant's wastewater treatment system, containing 4.1 kg of
total heavy metals, and 1.0 x 10-3 kg of chlorinated organics. The typical
plant disposes of 570 kg (dry) or 5,700 kg (wet) of sludge for every metric
ton of wool top produced. This wasted sludge contains 3 kg of total heavy
metals and 7.3 x 10- kg of total chlorinated organics.
3.4.1.3 Waste Quantities for 1974, 1977, and 1983
Table 3-2 identifies total wastes for this category in 1974, 1977
and 1983. Waste generation shows no change of status in 1977 and 1983
because production is considered stabilized at the current level for these
years.
Sludge quantities and its potentially hazardous constituents
amounts appear in Table 3-3 for 1974 and 1977. Because there is little
or no change anticipated in textile wastewater treatment in 1977, it was
considered to relate sludge quantities to production for that year. However,
it is anticipated that 1983 regulations will bring about a change in methods
of treatment. Table 3-4 lists the quantities of wastewater treatment sludge
expected in 1983. The best estimate of the effects of 1983 legislation was
found in the report prepared for the National Commission on Water Quality
entitled "Textile Industry Technology and Costs of Wastewater Control" (10).
The figures for sludge generation in 1983 were based on the projected
figures from this report. It was not possible to differentiate the amounts
of retained and disposed of sludge for 1983 so the estimated values for
this year reflect the total amount.
Region I is the primary center for this industry, with 40 to
50 per cent of production and wastes. Some state-by-state data has been
withheld due to the proprietary nature of production figures, on which
waste generation is based.
3.4.2 Category B - Wool Fabric Dyeing and Finishing
The seven facilities visited in this category are located in
Massachusetts, Maine, New Hampshire, and Georgia. Annual production of
these plants range from 450 metric tons to 9,000 metric tons. The typical
plant with wastewatier treatment facilities produces 5,200 metric tons
annually. None of the seven plants produces 100 per cent wool cloth as a
sole product. The following data summarizes various aspects of these plants:
3-15
-------
Table 3-2. Category A - Estimated Quantities of Total Wastes
from Wool Scouring Operations (KKG/VR)
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California N
VIII Colorado
I • Connecticut
III De lav/are
IV Florida
IV Georgia
IX Hawaii
X Idaho
•V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michiaan
V Minnesota .
IV Mississippi
VII Missouri __
VIII Montana
Vll Nebraska ._
IX Nevada
I New Hampshire
II New Jersev
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
' X Oregon
III Pennsvlvania
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
i Vermont
III Virginia
X Washington
III West Virainia
V Wisconsin
VIII Wvoming
TOTAL
Region I
II
III, IV and
V
VI
VII
VIII
IX
1
Dry
9.300
*
*
*
7rOOO
32fOO(L
13,500
11,600
7rOOG
974
Wet
75.900
*
*
57.400
7A1r600
109,800
94,000
57r400
19
Dry
9.300
7.000
32/00
13,500
11,600
7.000
77
Wet
75.90Q ,
*
57.400
261JOO
109.800
94/00
57.400
V
Dry
6.100
4.500
20.900
8.800
7,600
4.500
?83
Wet
lff.700
13,800
63.8QQ ,
26,800
23,200
13.800
* Production data was withheld due to its proprietary nature; thus waste
quantities are not provided.
3-16
-------
Table 3-3.
Category A - Quantities of Potentially Hazardous Wastewater Treatment Sludges
from Wool Scouring Operations, 1974 and 1977.
IV Alabama
X Alaska
IX Arizona
VI A i; Kansas
TX CaTil'ornio
VIII Colorado
1 Connecticut
III Delaware
Y\7 Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massac msetts
V1 Michiqan
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I NPW I!amrjshiro
II Hew Jersey
VI Now Mexico
II Mew York
IV north Carolina
VIII North "Da iota
V Ohio
Ifl Oklahoma
X Oregon
III Pennsylvania
I Rhode Island
TV South Carolina
VIII South Dakota
I\ Tennessee
VI Texas
VIII Utah
I Vermont
III Virginia
55 WnsTiiriqton
III West Virginia
VIII Wyoming
Region I
III. IV and
X
VI
VII
V1I1
' IX
RETAINED SLUDGES1 (KKG)
oral
Dry
2
*
i
3
o
i
Total
Wet
19~
*
14
27
23
U~"
Total
Heovy Metals
*
0.005
0.016
0.009
0.005
otol Chlor-
nated Organics
(x 10"6)
TZ
*
1.3
7?
3.8
2.4
1.3
Total
hazardous
Constituents
6761
•
0.005
0 03
0.016
0.009
0.005
WASTED SLUDGES"
otal
Dry
7,400
.,5.60(
10,700
1 9,200
" 5,600
Total
Wet
•
74.000
56rCXX
107,000
82,000
56.000
otal
eavy
Metals
~~3T~
29
134
56
49
29
Total
Chlorinated
Qrgonics
53091
"
0 0329
0.014
0.0117
0.0072
Total
Hazardous
Constituents
29
T34
56
49
2V
— .«-. . ,_
•Production data withheld because of its proprietary nature; thus waste quantities are not provided.
1 Retained sludge is so slowly gcnerolod by aerated biological trealmc-nt of textile wostewaters that, in many cases, there is no need
for disposal. Sludge is allowed to accumulate over a period of years and is stored in trie treatment pond.
'Wasted sludge is excess sludge generated in textile mill wastewoter treatment systems which must be removed and disposed of on a
regular basis.
3-17
-------
Table 3-4. Category A - Quantifies of Potentially Hazardous Wastewater Treatment
Sludges from Wool Scouring Operations,** 1983 (KK<5/YR)
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I Now Hampshire
II New Jersey
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Pennsvlvania
•I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III Virginia
X Washington
Total Potentially
Hazardous Waste
Dry
(x 103)
f
*
4.2
*
*
3.1
it •
III Nest Virginia i
V Wisconsin
VIII Wyoming t
TOTAL
Region I
II
III. IV and
X
V
VI
VII
VIII
IX
14.3
$
5.2
3.1
.
Wet
(x 103)
*
16.8
»
it
*
12.4
*
57.2
24
20.8
12.4
*
Total
Heavy Metal
(x icn
*
0.022
A
*
*
..
0.017
*
0.0762
0.032
0.0272
0.017
Total Chlor-
inated Organics
(x 10"3)
*
5.3
i *
*
*
T ^
4.0
*
18.3
7.7 '
' 6.6
4.0
i
—
Total
Hazardous
Constituents
(x 103!
'
*
—
•
0.052
•
*
.
*
*
*
0-017
•• --
*
—
0.07^?
._ 0.032
0.0272
0.017
— . __
•Reduction data withheld because of its proprietary nature; thus waste quantities are not provided.
3-18
-------
Range Average
100% wool cloth output* 0-50% 26%
100% synthetic cloth output* 0-35% 10%
wool blend cloth output* 35-95% 64%
number of employees 160-1700 610
production equipment age 1-40 years 33 years
plant age 20-134 years 64 years
* Figures are percentages of total cloth output
Plants normally operate 2 to 3 shifts per day, 5 to 6 days per week, 50 weeks
per year.
3.4.2.1 Process Description
A mass-balanced flow diagram of the typical wool fabric dyeing
and finishing process is shown in Figure 3-2. The individual operations
are addressed below.
Carbonizing. Not all woolen fabrics are carbonized. Of the seven
plants visited, only two carbonized fabric. In this operation,
pure wool fabric is usually treated with sulfuric acid and heat to
eliminate any vegetable matter and impurities left in the fabric.
The char from the impurities can then be dusted from the fabric
when it is dry.
Fulling. Woolen fabrics are subjected to heat, mechanical action,
and chemicals which etch the surface of the woolen fibers in an
aqueous bath, causing the cloth to mat and shrink and thus become
denser. Worsteds usually do not require this process step because
they are made of longer fibers which are more tightly woven than
the softer, less dimensionally stable woolen fabrics.
Scour. In order to prepare the fabric for dyeing, it is scoured to
remove excess chemicals, processing oils, and sizing.
Bleach and rinse. When white cloth is desired or light pastel shades
are to be dyed, the cloth may be bleached and then rinsed to remove
excess bleaching chemicals.
Dye. Cloth may be beam dyed or piece dyed. Slightly more dye - an
. estimated 3 per cent of the weight of the cloth as opposed to the
usual 2 per cent - may be used in dyeing due to the generally
darker shades and deeper dyeing of woolens and worsteds. If the
cloth was woven from pre-dyed yarn, or if the cloth was bleached
and is to remain white, this operation would be bypassed.
3-19
-------
Figure 3-2. CATEGORY B - TYPICAL WOOL OR WOOL BLEND FABRIC DYEING AND
FINISHING PROCESS
DYE CONTAINERS 1 3
DYE (50% DYESTUFF) 30
CHEMICAL CONTAINERS 1.6
GREIGE
FABRIC
1.046
V
NJ
O
FINISHED
WOOL OR
WOOL BLEND
FABRIC
1,000
LW
WASTES KEY:
LW
- PROCESS WASTE TO LAND
O
WATER POLLUTION
ABATEMENT WASTE TO
LAND
- POTENTIALLY HAZARDOUS
WASTE STREAM TO LAND
- SEE TABLE 3* FOR SPECIFIC
METALS
LKV - LIQUID WASTE
POTENTIALLY
HAZARDOUS
CONSTITUENTS:
RESIDUAL
DYESTUFF -
0.0065
RETAINED SLUDGE*
SEE NOTE
POTENTIALLY
HAZARDOUS
CONSTITUENTS:
RESIDUAL
CHEMICALS-0.018
PRETREATMENT
SCREEN
WASTEWATER
TREATMENT
LIQUID
EFFLUENT
NOTE: AN AVERAGE OF 1.6 KG (DRY), 20 000 KG (WET)
SLUDGE IS RETAINED CONTAINING 34x10'3KG
TOTAL HEAVY METALS,'* 108x10-9 KG TOTAL
CHLORINATED ORGANICS AND 0.08 KG DYESTUFF
(NOT INCLUDED IN MASS BALANCE)
-------
Special finish. In this operation, chemical finishes such as anti-
soils, anti-statics, water-repellents or mothproofs may be applied.
Currently, very little mothproofing is done. (Some government
contracts require mothproofing, but mothproofing in this industry
is an unconmon occurrence).
Mechanical finish. Decatizing (treating with hot water or steam),
napping or brushing, shearing and pressing are carman mechanical
finishing operations performed on the fabric to remove wrinkles,
improve the hand of the cloth, or alter its surface characteristics.
Ihe cloth may pass through any one or usually several of these
operations.
3.4.2.2 Waste Stream Description *
This category's typical plant land-destined waste streams are:
Quantity (kg of waste/
Waste Source kkg of product)
flock carbonizing and drying 16
seams scouring 0.7
dye containers dyeing 1.3
chemical containers dyeing-,, special finishing 1.6
fabric special finishing 1-3
flock mechanical finishing 17
fiber wastewater pretreatment 25 (dry)
screening , 100 (wet)
wasted sludge wastewater treatment none
retained sludge* wastewater treatment 1.6 kg (dry)
20,000 kg (wet)
* The retained sludge quantity is an accumulation over the life of
the pond.
3.4.2.2.1 Potentially Hazardous or Non-Hazardous Constituents
The flock, seams, fabric, and fiber wastes identified in
Figure 3-2 are considered non-hazardous. The dye and chemical container
waste streams are considered potentially hazardous because they contain
hazardous residuals such as dyestuff and zinc compounds. The potentially
hazardous portions of the dye container and chemical container waste streams
are 0.0065 kg/kkg of product and 0.018 kg/kkg of product, respectively.
Sludges retained in the wastewater treatment system (typically, no sludges
are disposed of by this industry category) contain potentially hazardous
heavy metals and dyestuff.
3.4.2.2.2 Sampling Results
Table 3-5 lists the results of analyses performed on composite
sludge samples taken weekly over a period of four weeks at one plant. In
3-21
* The reader is cautioned that no waste products from the textiles
industry have been demonstrated to be hazardous by this study.
EPA reserves its judgments pending a specific legislative mandate.
-------
every instance where drinking water limits have been set, metals concen-
trations exceed these limits. Solids content of this sludge was the low-
est of all categories of the industry. Total heavy metals concentration
(20,900 mg/kg of dry sludge) in this category's sludge was the highest of
all categories, with iron and manganese together accounting for just
slightly more than 90 per cent by weight of the total heavy metals content,
while chromium accounted for less than 2 per cent of the total heavy
metals content. This is due, in part, to this category's continuing
effort to reduce usage of chrome dyes, (and hence chromium in plant effluent)
which were once important in wool fabric dyeing. Total chlorinated organics
analysis was not performed on the solid phase of the sludge in this category.
There was not enough solids content in the samples to analyze. Detailed
sampling results appear in Appendix C.
An average of 1.6 kg (dry) or 20,000 kg (wet) of sludge is re-
tained in the typical direct discharge plant's wastewater treatment system,
containing 34 x 10-3 kg of total heavy metals, 1.8 x 10-7 kg of total
chlorinated organics, and 0.08 kg of dyestuff. The amounts of chlorinated
organics found in the liquid phase of the sludge is below the drinking
water standard of 0.7 ppm.
3.4.2.3 Waste Quantities for 1974, 1977 and 1983
Table 3-6 identifies total wastes for this category in 1974,
1977 and 1983. Total waste generation shows no change of status in 1977
and 1983 because production is considered stabilized at the current level
for these years.
Table 3-7 lists dye and chemical container and potentially
hazardous container residuals wastes for 1974, 1977 and 1983. These wastes
also show no change because of stabilized future production.
Sludge quantities and its potentially hazardous constituents
amounts appear in Tables 3-8, 3-9 and 3-10 for 1974, 1977 and 1983,
respectively. Because there is little or no change anticipated in textile
wastewater treatment in 1977, it was considered valid to relate sludge
quantities to production for that year. However, it is anticipated that
1983 regulations will bring about a change in methods of treatment. The
best estimate of the effects of 1983 legislation was found in the report
prepared for the National Commission on Water Quality entitled "Textile
Industry Technology and Costs of Wastewater Control" (10). The figures for
sludge generation in 1983 were based on the projected figures from this
report. It was not possible to differentiate the amounts of retained and
disposed of sludge for 1983 so the estimated values for this year reflect
the total amount.
3.4.3 Category C - Greige Goods
The estimate has been reported (8) that 80 per cent of the 600
to 700 greige woven goods mills are located in Alabama, Georgia, North
Carolina, South Carolina, and Virginia. The five greige mills visited
were located in Alabama, Georgia, North Carolina, and South Carolina.
3-22
-------
Table 3-5
Category B - Wool Fabric
Dyeing & Finishing
Sludge Analyses
(mg/kg of dry sludge)
Parameter •
Arsenic
Barium
Cadmium
Chromium
Cobalt
Copper
Iron
Lead
Manganese
Mercury
Molybdenum
Nickel
Zinc
Drinking Water
Limit* (ppm)
0.05
1.0
0.01
0.05
**
1.0
0.3
0.05
• 0.05
0.002
**
**
5.0
(1)
Average
<17<2)
<170
<17
267
<67
117
1100
<170
8,000
<1.7
<333
<33
1,130
Total Heavy Metals . 11,423
Aluminum ** 11,500
Magnesium 60.0 12,000
Potassium ** 14,000
Sodium ** 137,000
Strontium ™ 1ZP.
Total Chlorinated
Organ ics 0.7 0.11
Suspended Sol ids (%) ** 0.008
Total Solids (%) *2 0.06
(1) Average of 4 measurements from one plant
(2) Less than values were considered to be at the maximum in computing the totals
* U.S. Public Health Service. Drinking Water Standards. 1962
** No drinking water standards have been set for these metals
3-23
-------
Table 3-6. Category B - Estimated Quantities of Total Wastes
from Wool Fabric Dyeing and Finishing Operations
(KKGAR)
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Marvland
I Massachusetts
V Michiqan
V Minnesota
IV Mississinpi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Hamoshire
II New Jersey
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
' X Orecon
III Pennsylvania
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III virainia
X Washington
III West Virninia
V Wisconsin
VIII Kvorriing
TOTAL
Region I
II
III
IV
V
VI
VII
VIII
IX
X
1974
Dry
189
692
880
189
1,572
2,727
315
189
1,007
7,887
1.781
1,572
189
692
1.781
1,607
692
189
503
189
315
503
189
189
19.438
7,320
3,668
2,284
3.333
882
503
189
189
189 '
881
Wet
416
1,560
1,975
416
3.535
6,137
708
416
2,287
4,163 /
3.952
3,535
416
1,560
3,952
2^287
1.560
416
1.143
416
708
1,143
416
416
3.533
6,514
8,115
5.095
7,486
1,956
Ir143
416
416
416
1,976
1977
Dry
189
692
880
T89~
1.572
2,727
315
189
1,007
7,887
1,781
1,572
189
692
1,781
1,607
692
189
503
189
315
503
189
189
19,438
7,320
3,668
2,284
3r333
882
503
189
189
189
881
Wet
417
1,512
1,977
?T7
3.539
6,147
709
417
2,289
4,168
3,956
3,539
417
1,562
3,956
2,289
1,562
417
1,144
417
709
1,144
417
417
43,588
16,535
8,124
5,100
7,495
1,960
1.144 -
417
417
417
1,979
1983
Dry
459
1,672
2,080
439
3,87?
6,727
775
459
2,407
4,587
4.281
3,872
459
1,672
4,?f)1
2,407
962
459
1,223
459
775
1,223
459
459
46,488
17,860
8,868
5,504
7,373
2,152
1.223
459
459
459
2,131
Wet
1,489
5,452
6,740
1,489 '
12.672
22,027
2.535
.489
7,847
14,887
13,881
12,672
1,489
5,452
13.881
7,847
2.612
1,489
4,003
1.489
2,535
4,003
^489
'ITS? —
50,958
58,380
~28,7£8
17,884
^23,513 "~
7,002
4.003
1,489
1,489
1,489
6,941 '
3-24
-------
Table 3-7 . Category B - Quantities of Potentially Hazardous Dye and Chemical Container Wastes from Wool Fabric Dyeing
and Finishing Operations, 1974, 1977, and 1983 (KKG/YR.) Dry Weight*
IV Al.:.m<1
X AJar.ha
YX Arizona
VI ArKuiiF.aji_|
jX CaTii or n i a
VIII Colo~c-clo
'J Connecticut
VT"T nolav-'ctrc;
TV" Florida
jV Georgia
v Idaho
V illirio_is
<3 "TndiTTria
VII aow;;
VTT Kansas
f\T Kentucky
VT Louisiana
Y~ Maine
tTl Maryls.r.d.
"f Macsacr.ucetts _|
V MIC Die-ail
v MTnr.eRota
5V Mlr.sissippi
vii Missouri
VIII Montana
VII RoUrssKa
IX Kevaoa
T Nov.- <:.-.r.pshirc
il New .jersey
VI New Koxico
II New ^oiK
IV Worth Carolina
VIII Noroh Dakota
V Ohio
^r" Oklahoma
5f drenon
TlT Pcnnsvivania
I Khode island
TV south Carolina
VIII Poutli DaKota
IV Tennessee
VT ToXilS
VTTT Utah
I Vorwcnt
jTT Virginia
X ' Hashin<'ton
III v.'ost Viroinia
if wjr.oons.in
VTII Wvoniriii
TOTAL
H"ii2? -1
J 11
Ill
~ jv
V
" ' VI
— — Vii"
• v:cii
.i.\
• ~" x
Dye Container
3^
14
To
3"9
32
57
6J
3.9
21
39
36
32
3.9
14
3$
21
14
3.9
10
"3>
6.5
10
3.9
3.9
398.2
151.5
75
46
67.9
18.2
10
3,9
3.9
3-9
17.9
Hazardous
Residual
Dye«tuff
0.020
0.072
— tnraj
0.16
0.29
0.032
0.020
0.10
0.20
0.18
0.16
0.020"
0.072
0.18
0.10
0.072
0.020
0.052
5.025
0.032
0.052
0.050
0.020
2.005
0.754
_.0,38
0.232
0.343
0.092
0.052
O.D20... ,
0.020
0.020
0.092
Chemical
Container
13
18
ii
^-g
40
70
8
4.8
26
48
45
40
4.8
13
45
26
18
4.8
13
4.8
8
13
4.R
4.8
496.4
188
93
5§
84.8
22.4
13
49
4.8
4.8
22.8
Hazardous
Residual
Chemicals*
0.054
0.020
-25
0 054
0.45
0.79
0.090
0.054
0.29
OJ54
0.50
flAS
0.054
0.20
0.50
0.29
0.20
0.054
0-.14
0.054
0.090
0.14
o ns4
0.054
5.372
1.93
1.04
0.64
0.954
0.252
0.14
9 OS')
0.054
0.054
0.254
Total Potentially
Hazardous Waste
8.774
32.092
W.J*H
8.7/4
72.61
123.08
14 f,??
8.774
47.39
87.74
81.68
72.61
8.774
32.272
81.68
47.39
32.272
8.774
23.192
8.774
14.622
23.192
8.774
8.774
• 901.977
342.184
169.42
104.872
153.997
40.944
93.195
8.774
8.774
8.774
41.046
Total Hazardous
rnmfitiipnl-.
0.074
0.092
0 341
0.074
0.61
i.oa
n.17?
0.074
.0.39
0.74
0.68
0.61
0.074
0.272
0.68
0.39
0.272
0.074
0.192
0.074
0.122
0.192
0.074
0.074
7.377
2.684
1.42
0.872
1.297
0.344
0 199
0.074
0.074
0.074
0.346
• Dry Weight oWet Weight
3-25
-------
Toble 3- 8. Category B - Quantities of Potentially Hazardous Wostewater Treatment Sludges
Wool Fabric Dyeing and Finishing Operations, 1974 (! no need for disposal. Slddgo is allowed to accumulate over a period of
years and is stored in the treatment pond. Wasted sludge is excess sludge generated in textile mi.ll
wastewater treatment systems which must be removed and disposed of on a regular basis.
3-26
-------
Table 3-9. Category B - Quantities of Potentially Hazardous Wastewater Treatment Sludges
from Wool Fabric Dyeina and Finishina Ooerations, 1977 (KKG)
IV Alabama
X '"Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
'IV Florida
IV Georqia
IX Hawaii
X "'Idaho
V Illinois
V Indiana
Vll Iov;a™
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V MJrinosota
IV Missisrioci
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Hampshire
II New Jersey
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Pennsy.lve.nia
I Rhode Inland
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VII I "Utah
I Vermont
III Virginia
X Washington
III West Virginia
V Wisconsin
VIII Wvorainct
TOTAL
Region I
II
III
IV
V
VI.
V.I i
VIII
IX
X
RETAINED SLUDGES*
(NO WASTED Miinr,FM
Tota Pot. Haz. Waste
Total Dry
(x 10-3)'
0.64
2.3
3.0
0.64 ' "
5.3
9.3
1.1
0.64
3.4
6.4
5.9
S..T
O.A4
2.3
5.9
3.4
2.3
P. 64
1.7
0.64
, - •-! -
.7
0.64
0.64
«5,52....
24,8
12.3 ,
7. A
. 11,24...
3,02
.7
„., 0.64....
0.64
P,6A.-_
_ 2..9J _
otal Wet
8.1
30
37
8.1
67
120
U
8.1
42
81
75
A7
8.1
otal
leavy Metals
(f. 1CT6)
13
49
62
13
110
190
??
13
71
130 -
120
110
13
30 I 49
75
42
30
8.1
120
7T
49
13
21 > 36
8.1
14
13
22
21 36
8.1 13
8.1 13
J130.8 1351
i
315 513
156 j 250
9A _.. : 156
142.1 234
38.3 61
21 36
8.1 ' 13
JJ 13
8.1
38.1
13
62
Fatal Chlor-
nated Organics
(x 10- '")
7.0
25
33 .
7.0
58
100
12
7.0
37
70
66
5R
7.0
25
66
37
25
7,0
19
7.0
12
19
7.0
1 7.0
718
269
136
85
123
33
19
7
7
7
32
Dyestuff
(x Id"3)
0.03
0.12
0.15
6.03 "
0.26
0.47
o.o.-;
0.03
0.17
0.32
0.30
0.2A
0.03
0.12
0.30
0.17
0.12
0.03
_Q.08
0.03
0.05
0.08
0.03
0.03
3.26
1.24
0.62
0.38
0.56
6.14
0.08
0.03
0.03
0.03
0.15 "
Total Hazardous
Constituents
(x lO"6)
43
1A9
212
43
370
660
72
43
241
450
420
370
43
169
420
241
169
43
116
43
72
116
43
43
4,611
1.753
870
536
794
201
116
43
43
43
212
* See Table 3-8 for definition of retained and wasted sludge.
3-27
-------
Table 3-10. Category B- Quantities of Potentially Hazardous
Wastewater Treatment Sludges From Wool Fabric
Dyeing and Finishing Operations, 1983 (KKG)
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
. IX Hawaii
X Idaho
V Illinois .
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississiopi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Hampshire
II New Jersey
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
Vl Oklahoma
X Oregon
III Pennsylvania
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
V"l Texas
VIII Utah
I Vermont
ill Virginia
X Washincrton
III West Virginia
V Wisconsin
VIII Wyoming
TOTAL
Region I
II
III
IV
V
VI
VII
___ f.
IX
X
Total Potentially
Hazardous Waste
Dry
270
980
1,200
270
2.300
4,000
460
270
1.400
2.700
2,500
2,300
270
980
2, £00
r400
270
270
T>n
270
460
720
270
270
77,Mn
'0,540
5,200
3,990
4,040
,270
770
?70 ,..
.270, .
270
,250
Wet
1.080
3,420
4,800
1,080
9r200
16,000
Ij840
If080
5.600
10,800
10,000
9r200
1,080
3,920
10.000
5.600 *
1.080
1,080
^9,880
l,08p
1.840
2,880
1.080
1,080
08,200
42.160
20.800
12r880
Ur160
5r080
9,880
Ir080
1.080
Ir080 .
5.PQO
Total
Heavy Metals
5.7
20
26
5.7
47
83
9.8
5.7
30
57
.•53
47
5.7
20
-53
30
5.7
5.7
15
5.7
9.8
15
5.7
•5.7
56.6.9
219.8
nn
68
84.4
26.9
K
5.7
5.7
5.7
9/5.7
Total Chlor
inated Organ! cs
(x 10-6)
30
100
140
30
250
440
50
30
160
300
280
250
30
100
280
160
30
30
78
30
50
78
30
30
2986
1160
580
358
450
140
78
30
30
30
130
Dyestu
14
49
60
14
120
200
23
14
70
140
120
120
14
49
120
70
14
14
36
14
23
36
14
14
1362
532
260
156
208
65
36
14
14
14
63
Total
Hazardous
Constituents
19.7
60
86
19.7
167
283
32.8
19.7
loo
197
173
167
19.7
69 ~
173
100
19.7 -
IV.7 '
51
19.7
32.8
51
19. 7 "
19.7
1928.9
751.8
370
224
292.4
91.9
51
19.7 "
19.7 "
19.7 '-
88.7
*lt was not possible to differentiate between the retained and wasted sludge for 1983, so the
estimated values for this year reflect the total quantity.
3-28
-------
Three of the plants' production equipment range are in the age range of
5 to 20 years. One of the remaining two plants' equipment is older than
20 years, the other's is newer than 5 years. Operations at these plants
normally run 3 shifts per day, 6 to 7 days per week, 50 to 52 weeks per
year. Two of the plants are older than 65 years, while the remaining
three are six years old. The number of employees range from 130 to 520,
and average 300. Annual production ranges from 2,700 to 49,000 metric
tons and excluding the largest plant, averages 4,400 metric tons. The
plants either produce knitted greige goods (three plants) or woven greige
goods (2 plants).
3.4.3.1 Process Description
A mass balanced flow diagram of the typical greige goods process
is shown in Figure 3-3.
Yarn preparation consists of several operations. The operations
performed are dependent on the type of fiber being processed. The following
generally sequential listing serves only to identify those operations
commonly in use in yarn preparation, beginning with staple and ending with
yarn ready for slashing or finishing prior to weaving or knitting: opening,
picking, blending, carding, drawing, roving, spinning, quilling, beaming
(warping) or winding. The reader should refer to the glossary for an
explanation of these processes involved in yarn preparation if more informa-
tion is desired. For the purposes of this report, it is sufficient to list
these operations here as part of yarn preparation without detailed dis-
cussion. Yarn destined for knitting operations is usually finished with a
lubricant, commonly an oil or a wax emulsion. Thread destined for sewing
leaves the process after finishing. Warp yarns, destined for weaving, are
slashed with compounds such as carboxymethyl cellulose (CMC), polyvinyl
alcohol (PVA), or starch, among others, in order to withstand the abrasion
of the shuttle as it passes over the warp yarns. (It is unnecessary to
slash the filling yarn which is carried by the shuttle.)
The slashed or finished yarns are either woven or knitted into
greige goods, the input for Categories D and E - Woven Fabric and Knit
Fabric Dyeing and Finishing, respectively. It should be noted that there
are basically five different types of plants in which greige goods operations
may occur, identifiable depending on where the operations stop. Plants may
end processing after: (1) yarn preparation, (2) knitting, or (3) weaving.
However, in larger "integrated" plants, greige goods production may occur
in a sequence of operations beginning with yarn preparation and usually
ending with either (4) dyeing and/or finishing the woven goods (Category
D) or (5) dyeing and/or finishing the knit goods (Category E). Few
integrated plants dye and finish equal amounts of knit and woven greige
goods.
3-29
-------
Figure 3-3. CATEGORY C - TYPICAL GREIGE GOODS PROCESS
LUBRICANT 10
STAPLE FOR
WEAVING YARN
1,049
STAPLE FOR
KNITTING
YARN 1.090
U)
o
ASTE FIBE
YARN*
CLOTH
10
YARN
PREPARATION
WARP SIZING 72
SALEABLE
FIBER +
YARN
WASTE 58
WASTE
FIBER +
YARN
32
SALEABLE
THREAD +
CLOTH
WASTE 10
WASTE
FIBER.
YARN, +
CLOTH
11
SALEABLE THREAD
WASTE 10
KNITTED GREIGE
GOODS 1,000
WOVEN GREIGE
GOODS 1,000
* SBSMWSS!S?BBB'IIV ** TOERE ARE N° PO™™LLy HAZARDOUS WASTES DEST.NED FOR LAND
-------
3.4.3.2 Waste Stream Descriptions
Ihis category's land-destined waste streams are:
Quantity (kg of waste/
Waste Source kkg of product)
Fiber and yarn yarn preparation 32
Fiber, yarn and cloth knitting 10
Fiber, yarn and cloth weaving 11
Much of the waste fibers and yarns in this category can be sold (for
garnetting) or reprocessed within the yarn preparation operation (especially
in wool yarn manufacture).
3.4.3.2.1 Potentially Hazardous or Non-Hazardous Constituents
No potentially hazardous wastes are destined for land disposal
from this category. All land-destined wastes are non-hazardous.
3.4.3.2.2 Sampling Results
Because there are no potentially hazardous wastes generated by
this category, no sampling was performed.
3.4.3.3 Rationale for Extrapolation of Waste Quantities to Entire
Industry Category
Waste quantities were keyed to production rates. Waste genera-
tion rates (53 kg of waste/metric ton of product) identified in Figure 3-3,
were applied to estimated production figures to yield total waste amounts.
3.4.3.4 Waste Quantities for 1974, 1977 and 1983
Because products in this category are ultimately used for
apparel, furnishings, and other consumer products, waste projections are
closely related to population growth. (A standard Census Department growth
factor of 3 per cent per annum was applied.) Estimated total waste quanti-
ties for 1974, 1977 and 1983 are shown in Table 3-11. Eighty-three per
cent of the total waste is generated in EPA Regions II, III and IV.
Region IV alone generates 47 per cent of the total.
3.4.4 Category D - Woven Fabric Dyeing and Finishing
The 22 plants visited in this category are located in Alabama,
Georgia, Massachusetts, North Carolina, South Carolina, Rhode Island and
Virginia. Their annual productions range from 2,700 to 82,000 metric tons.
The typical plant with wastewater treatment facilities produces 5,600 metric
tons annually. The number of employees at the 22 plants ranges from 75 to
2 000 and averages 650. Plant ages range from 11 to 75 years, averaging
39 years. Operations normally run 3 shifts per day, 5 days per week, 50
weeks per year. The typical product is a polyester-cotton blend fabric,
3-31
-------
Table 3-11. Category C. T Estimated Quantities of Total Wastes
from Greige Goods Operations, Dry Basis* (KKG/YR)
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georqia
IX Hawa i i
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississiooi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Hamoshire
II New Jerr.ev
VI Mew Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Pennsylvania
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III Vircinia
X Washinaton
III West Virginia
V Wisconsin
VIII V\'voraing
TOTAL
Reqion I
II
III.
IV
V
VI
VII
VIII
IX
X
1974
2,400
600
6,700
200
1,200
100
4,800
14,000
•
50
2,400
600
200
200
400
400
300
400
3,000
1,000
900
1,000
300
50
400
400
1,000
100
26,000
38.000
2,000
700
700
17,000
1,700
9,400
4.900
1,200
200
300
2,300
700
200
600
1 59 ,(500
6,900
37,000 '
20.000
74,900
7,500
3,000
1,100
450
6.700
1,450 T
1977
2,626
657
7,332
219
1,313
109
5,253
15,321
55
2,626
657
219
?19
438
438
328
438
3.283
1,094
985
1,094
328
55
438
438
12,038
109
28,453
41,585
2,189
766
, ?#
18,604
1,860
10,286
5.362
1.313
219
328
2,517
766
219
657
174,000
7,551
40,490
21.887
81,966
8,208
3,283
1,554
492
7,332
1,587
1983
3,125
781
8,723
260
1 ,562
130
6,249
18,226
65
3,125
781
260
260
5^1
521
391
521
3,906
1,302
1,172
1,302
391
65
M\
521
14,321
130
33,849
49,472
2,604
911
911
22,132
•t.2}3
12,23&
6.379
1.56?
260
391
2,994
911
260
781
207,000 —
8,983
48,1/0
26,038
97..510
9,764
3.906
1,432 '
586 ""~
8.723
1,888
* Dry basis equals wet basis
3-32
-------
although sane plants were visited that process solely 100 per cent cotton
fabric or solely 100 per cent synthetic fabric. A wide variety of
operations were viewed, including printworks, fabric bonders, and com-
mission finishers or converters.
3.4.4.1 Process Description
A mass balanced flow diagram of the typical woven fabric dyeing
and finishing process is shown in Figure 3-4. The individual operations
are addressed below.
Singe. Normally the first operation in the series of finishing
steps, the fabric usually passes rapidly over an open flame, thus
burning off any surface hairiness and giving a smoother surface to
the fabric. Singeing may be bypassed completely.
Desize. This step may also be bypassed. Some fabrics, such as denim
and drapery goods, are "loom finished" and the size remains on the
cloth permanently. Other fabrics, made of stronger warp yarns may
not require slashing and hence would not require desizing. In this
step, the cloth runs through a bath containing the desizing agent,
such as an enzyme for starch size or detergents or acid in other
cases, which assists in removing the size without damaging the cloth.
Scour. In processing cotton fabrics, the cloth may be kier scoured
(boiled) in a caustic bath to remove any unwanted impurities. If
polyester-cotton blends are involved, a separate type of scouring
is done. This process removes wax and non-cellulosic components and
prepares the cloth for dyeing.
Msrcerize. This operation is performed on some pure cotton fabrics.
The fabric is treated by a concentrated caustic bath and a final
acid (neutralizing) wash. Mercerization swells the cotton fiber,
imparting increased dye affinity, tensile strength, and luster to the
fabric.
Bleach and Wash. Fabric which is to remain white or to be dyed very
light shades is bleached and then washed to remove excess bleaching
chemicals.
Dye and/or Print. Fabrics which are to be dyed go to a dye beck,
jig, or continuous dye range, where an average amount of dye equiv^-
alent to 2 per cent of the weight of the fabric is used in the bath.
If the cloth was voven from pre-dyed yarn, or if the cloth was
bleached and is to remain white, this operation would be bypassed.
White or dyed fabrics which are to be printed may be flat-bed
printed, roller printed, or rotary screen printed. For
3-33
-------
Figure 3-4. CATEGORY D - TYPICAL WOVEN FABRIC DYEING AND FINISHING PROCESS
CHEMICALS 50
CHEMICAL CONTAINERS 0.8
DYE CONTAINERS 0.5
DYE (50% DYESTUFF) 20
WOVEN
GREIGE
GOODS
1.021
r1
co
POTENTIALLY
HAZARDOUS
CONSTITUENTS:
RESIDUAL
CHEMICALS 0.04
FINISHED
' WOVEN
FABRIC 1.000
I
WASTES KEY:
LW -
V
o
LIQUID WASTE
PROCESS WASTE TO LAND
WATER POLLUTION
ABATEMENT WASTE
TO LAND
POTENTIALLY
HAZARDOUS WASTE
STREAM TO LAND
SEE TABLE 3-14 FOR
SPECIFIC METALS
POTENTIALLY HAZARDOUS
CONSTITUENTS:
RESIDUAL DYESTUFF 0.0023
LW
*
PRETREATMENT
SCREEN
RETAINED SLUDGE*
SEE NOTE
WASTEWATER
TREATMENT
^ LIQUID
WASTED
SLUDGE*
20 DRY
2,300 WET
(NOT INCLUDED IN
MASS BALANCE)
NOTE: AN AVERAGE OF 67 KG (DRY), 7,300 KG (WET)
SLUDGE IS RETAINED CONTAINING 0.63 KG TOTAL
HEAVY METALS,** 1.0x1Q-3 KG TOTAL CHLORINATED
ORGANICS AND 3.4 KG DYESTUFF (NOT INCLUDED IN
MASS BALANCE).
POTENTIALLY HAZARDOUS
CONSTITUENTS:
TOTAL HEAVY METALS" 0.19
TOTAL CHLORINATED ORGANICS 300x106
DYE STUFF 1.0
-------
detailed information on dyeing and printing techniques and equipment,
the reader is referred to the two sections of the glossary (Appendix
A) entitled "dyeing" and "printing".
Applied Finish. Chemical finishes such as anti-statics, anti-soils,
fire retardants, softeners, water repellents and permanent press
resins may be applied. Additionally, fabrics may be bonded together
in this step. This process may be bypasssd altogether, or be either
preceded or followed by mechanical finishing.
Mechanical Finish. Brushing, napping, shearing, pressing, sanforizing,
tenterizing, heat setting, calendering, and sanding are cannon
mechanical finishing operations which remove wrinkles, improve the
hand of the cloth, its dimensional stability or shrinkage charac-
teristics, or alter its surface characteristics. The cloth may pass
through any one or usually several of these operations. Mechanical
finishing may be bypassed altogether or either preceded or followed
by chemical finishing.
3.4.4.2 Waste Stream Descriptions *
This category's typical plant land-destined waste streams are:
Quantity (kg of waste/
Waste Source kkg of product)
cloth singe and desize 0.2
cloth ; mercerize 0.1
cloth bleach and wash 0.2
cloth mechanical finish 6
flock mechanical finish 4
dye containers dye and/or print 0.5
chemical containers dye and/or print, applied 0.8
finish
fiber wastewater pretreatment 0.8 (dry)
screening 2.8 (wet)
wasted sludge wastewater treatment 20 (dry) 2,300 (wet)
retained sludge* wastewater treatment 67 kg (dry)
7,300 kg (wet)
* The retained sludge quantity is an accumulation over the life of the
pond.
3.4.4.2.1 Potentially Hazardous or Non-Hazardous Constituents
The flock, fiber and cloth wastes identified in Figure 3-4 are
considered non-hazardous. The dye and chemical container waste streams
are considered potentially hazardous, because they contain potentially
hazardous residual dyestuff and chemicals. The potentially hazardous
portions of the dye container and chemical container waste streams were
determined to be 0.0023 kg/kkg of product and 0.04 kg/kkg of product,
respectively.
3-35
* The reader is cautioned that no waste products from the textiles
industry have been demonstrated to be hazardous by this study.
EPA reserves its judgments pending a specific legislative mandate.
-------
Sludges in the wastewater treatment system also contain hazardous
constituents such as heavy metals (chromium, copper, zinc), chlorinated
organics and dyes tuff and therefore, are also considered potentially
hazardous.
3.4.4.2.2 Sampling Results
Table 3-12 lists the results of the analyses performed on the
composite sludge samples taken weekly over a period of four weeks from
five plants. In every instance metals or organics concentrations in the
solid phase of the sludge exceeded the drinking water limits. However,
the chlorinated organics concentration in the liquid phase of sludge was
less than the drinking water standard for total organics of 0.7 ppm in all
cases. The total heavy metals content (9,395 rogAg of dry sludge) was the
second highest, exceeded only by Category B - Wool Fabric Dyeing and
Finishing (20,900 mgAg of dry sludge). Iron accounted for 52 per cent
by weight of the total heavy metal content. Zinc accounted for 25 per
cent of the total heavy metal content. This may be due in part to the use
of zinc nitrate as a catalyst in the application of permanent press resins.
Analysis performed for total chlorinated organics showed 98.8 per cent by
weight of the total content (15.2 ppm) was found in the solid phase of the
sludge, with the remainder in the liquid phase. Detailed sampling results
may be found in Appendix C of this report.
An average of 67 kg (dry) or 7,300 kg (wet) of sludge is retained
in the typical plant's wastewater treatment system, containing 0.63 kg of
total heavy metals, 1.3 x 10-3 kg of total chlorinated organics, and 3.4 kg
of dyestuff.
3.4.4.3 Waste Quantities for 1974, 1977 and 1983
Because products in this category are ultimately used for apparel,
furnishings, and other consumer products, waste projections are closely
related to population growth. (A growth factor of 3 per cent per annum
was applied.) Table 3-13 quantifies the total wastes for this category
for 1974, 1977 and 1983.
Tables 3-14, 3-15 and 3-16 list,dye and chemical container and
potentially hazardous container residuals wastes for 1974, 1977 and 1983,
respectively.
Sludge quantities and its potentially hazardous constituents
amounts appear in Tables 3-17, 3-18 and 3-19 for 1974, 1977 and 1983,
respectively. Because there is little or no change anticipated in
textile wastewater treatment in 1977, it was considered valid to relate
sludge quantities to production for that year. However, it is antici-
pated that 1983 regulations will bring about a change in methods of
treatment. The best estimate of the effects of 1983 legislation was found
in the report prepared for the National Ccrtndssion on Water Quality
entitled "Textile Industry Technology and Costs of Wastewater Control"
(10). The figures for sludge generation in 1983 were based on the pro-
3-36
-------
Table 3-12
Category D - Woven Fabric
Dyeing & Finishing
Sludge Analyses
(mgAg of dry sludge)
Parameter .
Drinking Water
Limit* (ppm)
Rene
Average
(2)
Arsenic
Barium
Cadmium
Chromium
Cobalt
Copper
Iron
Lead
Mangenese
Mercury
Molybdenum
Nickel
Zinc
Total Heavy Metals
Aluminum .
Magnesium
Potassium
Sodium
Strontium
Total Chlorinated
Or gariics
Suspended Solids (%)
Total Solids (%)
(1) Range of the indivi
0.05
1.0
0.01
0.05
**
1.0
0.3
0.05
0.05
0.002
**
**
5.0
**
60.0
**
**•
**
0.7
**
**
dual plant averages
V ..,
< 0.6-< 1 .4
12-85
< 1.4-10.8
89-3,96?
< 2.8-1 09
193-1,130
917-13,600
< 16-68
42-318
0.1-0.7
<0.2-<28
12-88
318-7,791
1,420-12,800
1,340-5,730
1,420-6,350
19,400-94,700
2.4-21
4.3-27.8
0.42-1.34
0.72-2.04
39
4.4
1,196
26
652
4,910
36
128
0.35
<17
32
2,370
9,412
4,640
2,820
3,580
51,300
16
15.2
0.88
1.26
(2) Grand average of 20 measurements from five plants
(3) Less than values were considered to be at the maximum in computing
* U.S. Public Health Service. Drinking Water Standards. 1962.
** No drinking water
standards have been
set for these metals.
totals
3-37
-------
Table 3-13. Category D - Estimated Quantities of Total Wastes From
Woven Fabric Dyeing and Finishing Operations (KKG/YR)
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
Iv Georgia
.IX Hawaii
X Idaho
V Illinois .
V Indiana
VII Iowa
VII Kansas
IV Kentucky
Vl Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississipoi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Hamnshire
II New Jersey
VI New Mexico
II Nev; York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Pennsylvania
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III Virginia
X Washinaton
III West Virginia
V Wisconsin
VIII Wvoming
TOTAL
Region I
II
IIT
IV
V
VI
VII
VIII
IX
X
19
Dry
1/70 _ _._
40,
40
20
797
79
300
3,326
87R
120
40
I7n
240
19<5
3,314
79
40
79
An
717
7,99R
1,198
A A4.3
499
79
177
177
10.484
396
*313
79
396
40
35.616
4.814
4,196
847
23.018
1.649
932
100
70
40
74
Wet
73,282
1.631
1,631
855
34,A17
3.462
13,233
142.675
3ft. 697
5.093
1,631
5,093
9.986
8r552
142.553
3.362
1.631
3 3A7
7/47
9,774
137,237
50.930
77-5, n°
71.384
3,362
7.940
7.940
448.140
1A,313
34/78
3.362
16.313
1,631
1.522.477
207,732
183,167
36,267
977.228
71.798
39.621
4 17R
ft.S/5
1.631
19
Dry
1,7AA
42
42
21
R45
85
321
3,541
931
126
42
126
257
212
3.429
85
42
flS
A3
729
3,213
1,263
6,973
534
85
194
194
11.130
41R
866
85
418
42
37.702
5.038
4,476
909
24,359
1.760
992
ins
21
42
77
Wet
79,3R9
1.734
1,734
926
36/50
3.665
14,244
152,790
40.740
5,399
Ij734
5,3??
10,196
9.263
'4
-------
Table 3-14. Category D- Quantities of Potentially Hazardous Dye and Chemical
Container Wastes from Woven Fabric Dyeing and Finishing
Operations, 1974 (KKG/YR) Dry Weight*
Hazardous Hazardous Total Potentially Total
Dye Residual Chemical Residual Hazardous Hazardous
Contoine* Dyestuff Container Chemicals Waste Constituents
IV Alfibarr.fi
X Ala.'ii'.ii
IX Arizona
VI /i r Kansas
IX California
VIII Colorado
I Connecticut
Til Delaware;
IV IM.orioa
IV Gcorqia
IX Hawaii
X Jdijlio
V Illinois
V Indiana
VII 'Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Kaine
III Mar viand
I Massncnusot-.ts
V Michir;an
V Minnesota
IV MissisniiJ'ji
VII Missouri
V1IJ Montana
VII Nebraska
IX Nevada
I Ncv Harr.prshiro
II New Jcrscv
VI I!ow Me;:ico
II New York
IV North Carolina
VIII Kcrta Cahoto.
V Ohio
VI Oklahoma
X Orcfson
III i'oRnsylvf.ni'i
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI 'J'o>:a3
VIII Utah
1 Vermont
III VJroinia
X Wi.icJiis.cr to n
III Nest Vircrinia
V Wisconsin
Vltl V/yoma.iici
TOTAL
Region I
II
III
' " IV
V
VI
VII
VCII
IX
X
42
1
1
0.50
20
•)
7.5
85
22
3
1
3
6
5
d3
2
1
i
1.5
5.5
77
30
170
12
2
4.5
4.5
260
10
20
2
10
1
897
121
107
21.5
, 579.5
41
23
2 5
050
1
0.190
0.005
0.005
0.002
0.092
o.uov
0.034
0.39
0.10
0.014
0.005
0.014
0.028
0.023
0.38
0.009
0.005
0.009
0.007
0.025
0.35
0.14
0.77
0.058
,.-. CMJ09
0.021
. 0.021
1.2
0.04o
0.094
0.009
0.046
0.005
4.1 15
0355
0.4*
""'6.b99
2.653
0.191
..,,..0.108 ._
.0.0.12
0.002
6^005 "
67
1.6
1.6
0.80
32
3.2
12
140
36
4.8
1.6
4.8
9.6
8
130
3.2
1.6
3.2
2.4
8.8
170
48
270
20
3.5
7.2
7.2
420
16
33
3.2
_. 16
1.6
1.437.6
190.8
163
34.4
933
67.2
37.8
4
0.80
1.6
3.4
0.080
.0.080
0.040
1.6
0.16
0.60
6.8
1.8
0.24
0.080 .
0.?4
0,48
0.40
6.6
0.16
0.080
0.16
0.12
0.44
A
2.4
13
1
0,16
0.36
0.36
2!
0.80
1.A
0.16
0.080
0.080
70.56
9.64
8.4
1.0
46
3,36
1.84
0700
o:o40 "-
0.080
1 1 2.59
2.685
2.685
1.342
53.692
5.369
20.134
232.19
59.9
8.054
2.685
8.054
16.108
•~ 13.423
2)9.96 '
5.369
2.685
5.369
4.027
14.765
203.35
80.54
453.77
33.058
5.369
12.081
12.081
702.2
26.846
54.694
5.369
26.126
2.685
2,409 .JW
321.995
583.89
56.999
1,561.153
111.751
62.748
A 71?
1.342
2.685
3.59
0.085 :
0.085
0.042
1.692
0.169
0.634
7.19
1.9
0.254
0.085
0.254
0.508
6.423
6.98
0.169
0.085
0.169
0.127
0.465
6.35
2.54
13.77
1.058
0.169
0.381
0.381 !
22.2
0.846
1.694
0.169
0.126
74.675
74.675
10.195
R.RO
1.099
48.oS3
3.551
1.948
n ?i9
0.042
0.085' "•'
Dry Weight -Wet Weight
3-39
-------
Table 3-15. Category D - Quantities of Potentially Hazardous Dye ond Chemical
Container Wastes from Woven Fabric Dyeing and Finishing Operations,
1977 (KKGAR) Dry Weight*
IV Alabaira
X Alnr;):a
IX Arizona
VI Arkansas
IX California
VII I Colorado
I Connecticut
III lie lawn ro1
IV Florida
IV Goorqia
IX HawaJ i
X Idaho
V Illinois
V Indiana
VTT~ Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Ma i~nc
III Maryland
I M-israchu.se t".ts
V Michican
V MiYin^cota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Hanbshirn
II Hew Jersey
VI Hew Mr.xico
II How York
IV North Carolina
VIII i!orth Dakota
V Ohio
VI Oklahoma
X Oreqon
III Pennsylvania
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
1 Vermont
III Virqinia
X Wa.ohinnton
III West Virqinia
V Wisconsin
VIII Wvominci
TOTAL
Region I
II
I IX
IV
V
VI
" vii
vin
IX
... x-
Dye
Container
4")
'.J
1.1
..o,53
71
?.l
R n
9JJ
23
_..3.2
.,11
....3.2 — — |
6.4
5.3
88
2.1
1 1
2 ]
L£
5.8
R2
3?
J80
13
2_J
4.8
4.8
27A
11
21
2.1
11
1.1
752.63
128.1
114
_..23.,2. .
615.3
43.5
24.2
2.7
_0,53.
]-'
Hazardous
Residual
Dyestuff
Q,?o
0.0053
0.0053
0.0021
n f»R
0.010
0,036
0.41
0.11
fLOJS
0.0053
OnQ15
0.030
OJ124
0,40
0.0095
0-OfK3
0-0095
0.0074
0.627
0.37
0.15
0.82
. 0.062
O-.rm'i
0.022
0.022
1.3
0,049
0.10
0.0095
0.049
0.0053
4.393
0.5865
0.52
...0..105
2.8395
' 0.2071
0.1148
0.0127
OJJ02.L
.D^QD53
Chemical
Container
71
1.7
1 7
0.85
34
3.4
13
150
38
•i.l
1.7
5.1
TO
8.5
140
3.4
. J.7
3.4
2.5
9.3
130
51
290
21
3.4
7,6
7.6
450
17
35 • •
3.4
17
1.7
1.539.05
204.3
18L__
36.5
999.5
70.9
40.1
4.2
,_.Q.85 ,
J.7
Hazardous
Residual
Chemicals
3.6
0.085
0 085
0.042
1.7
....0.17
0.64
7.2
.9
0.25
0.085
0.25
IT5T
0.42
7.0
1 0.17
0.085
0,17
0.13
.47
6.4
2*5
14
71
0.17
738
.38
22
0.85
77
717
0.085
0.085
74.782
10.23
8.9"
1.055
48.71
3.59
1.955
0.31F
_. 0.042,..,.
0.085
Total Potentially
Hazardous
Waste
119.8
2.8903
2 8903
1.4241
5.798
5.68
21.676
247.61
63.01
8.565
2.8903
8.565
reTrc
.244
235.4
5.6795
2.8903
5,6795
4.2374
i.5y7
218.77
85.65
" W.82
35.162
5.6795
1 f2T§62
12.802
749.3
28.899
57.8
5.6795
" 287134
" 2.8903
2,570.855
343.2165
1 304.42
1 &&.,„.
1,666.3495
118.197) "
66.3698
0.1277
1.4241
. 2.8903
Total
Hazardous
Constituents
3.8
0.0903
n nom
0.0441
1.798
0.18
0.676
7.61
2.01
0.265
0.0903
0.265
0.54
0.444 ~
7.4
.1795
0.0903
.1795
6.1374~
0.497 '
6.7? ~
2.65
14.82 ~
1.162"
O.I79T-
0.402 "
0.402
23.3
" 0.899 "~
1.8
O.I79S~
0.134'
0.0903"
W.I75-
10.8165
9.45 -
1.16 ~
5l751?r
3.7971
2.0698"
0.2277
0.044I~~
0.0903"
•DRY Weight n Wet Weight
3-40
-------
Table 3-16.
Category D - Quantities of Potentially Hazardous Dye & Chemical
Container Wastes from Woven Fabric Dyeing and Finishing Operations,
1983 (KKGAR) Dry Weight*
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georqiii
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New HariDshire
II New Jersev
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Pennsylvania
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
f ' ffl!a£»
III West Viroinia
VIII Wyoming
Region I
IV
VI ~
VII
*Dry Weighf = Wer Wei
Dye
Container
53
.1.3
1.3
0.63
25
2.5
9.5
no
28
3.8
1.3
3.8
7.6
6.3
110
2,5 .
1.3
2.5
1.9
7.0
98
38
Hazardous
Residual
Dyestuff
0.24
0.0063
O.OfV,3
0.0025
0.12
-.-11
0.043
0.49
0.13
0.018
_ 0.0063
0.018
0.035
0.029
0.48
0.011
0,0063
0.011
0.0089
0.032
0.44
0.18
220 ! 0.98
IS ! n.073
? •?
5.7
5.7
330
13 -
25
2.5
13
T3
ma Qi
157.8
136
1 27.5 ]
741. R
51.9
28,8 _
3.2
0.63
J.3
glit
o.on
0 077
0.027
1.5
0.12
0.011
[ 0.058
0.0063
5. 19=9
0.705
0.62
0.125
3.34
0-2446
0.1373
0.0152
0.0025
0.0063
Chemical
Container
85
2.0
2.0
1.0
41
4.1
15
180
46
6.1
2.0
6.1
12
10
160
4.1
2.0
4.1
3.0
11
150
61
340
9S
_ 4.1
9. 1
5:1
530
42
4-1
L 20
2.0
_1812.9
237.2
211
43.2
1 180,2
85.2
48.1
5.0
1.0
2.0
Hazardous
Residual
Chemicals
4.3
0.10
0.10
0.051
2.0
0.20
0.76
8.6
2.3
0.30
0.10
0.30
0.61
0.51
8.4
0.20
0. 10
0.20
0.15
0.56
7.6
3.0
16
1 3
0.20
0 4A
0.46
27
1.0
2.0
0.20
0.10
0.10
89.761
12.23
10.6
58 16
4.3
2 3 -
0.25
0.051
1 O.JO 1
TotafPot.
Hazardous
Waste
142.54
3.4063
3 4063
1 .6835
68.12
6.811
25.303
299 09
76.43
10.218
3 4063
10.218
20.245
16.839
278.88
6.811
3.4063
6.811
5.0589
18.592
256.04
102.18
576.98
41 373
6.811
15.287
5.287
888,5
34.058
69.12
6.811
33.158
3.4063
3056.2869
407.935
358.22
72.095
98'_5__
141.6446
79.3373
8.4652
.6835
; .406c
Total
Hazardous
Constituents
4 ^4
0.1063
o i(v,ri
0.0535
2 12
0.211
0.803
9.09
2.43
0.318
0 1063
0.318
0.645
0.539
8.88
0.211
0. 1063
0.211
0.1589
0.592
8.04
3.18
16.98
1 373
Q.211
0 487
8: 48?
28.5
1 .058
2.12
0.211
0.158
0.1063
94.4569
12.935
11.22
"1 1 395 1
61 5
4.5446
2.4373
0.2652
~" 0.0535 '
0.1063
3-41
-------
tcfcle 3-17. Category D - Quantities of Potentially Hazardous Wastewater Treatment SlixJgei from Woven Fabric
Dyetng and Finishing Operations, 1974
IV Alabar.3
x Alaska
TX Arizor.a
VI Ar.'.arsas
IX cali^&i-r.ja
VIII Colorado
I ConTiicti-Cut
III Delaware
IV Florida
IV Gcor^-a
IX ll'ivitti;
x Idaho
V" 3i.lir.ois
V Indli'.r.o
VI I Iowa
VII Kansas
RETAINED SLUDGES1 (KKG)
Total
Dry
O.M
SLS15—
0.015
0.0076
n 31
n (Bi
0.11 _
13
0.34
a. (MA
0.015
IV Kentucky n r\m
VI Louisiana 1
I Maine 1 0.092
III .".srvif.::0 1
V :iic:.i-i-n
V Kir.r.eaj-a
IV Kississiaui
VH Kirir.ouri
VII iloiirs -:.-:<»
IX i:ovao-?.
I K'sr>:.re
II ;;ev Jor-~v
VI ;:-y.-. ::-.:.ico
II Uov: ^.cr.'. .
IV Kc.rtr. i:^i-oi-:>.i
VI7I '.'.'jcth t.i;:ota
V Ohio
vi o;-.ia:-.r;-a
X Oracch
III Pcnr.s-'ivrnia
I RhoSe Isir.iiQ
IV Scuti Cr^olvnc
VIII S"U>'. 2-.::o::r:
iV Ttr:-.??:?£e
VI TGIML:
Viil Uta.".
I Vevr.v.it
III Virqirir.
V Ki:-.o^:.i-;.n
VII J Ivvo-ino
TOTAL
Reaior. I
II
III
IV
V
VI
vii
VIII
IX
X
0.076
^3
0.031
n OlS
0.031
o n2i
0.084
JLJ
0.46
2 A
0.19
n.oai
0.069
TflJ)6SL_
4.1
3.15
0.31
0.031
0.15
. Q.OJL_
. LU2P.26.
1.884
1.66
1JJ24_
? "77
5.637
O.J5T
5.038
LCQ2L.
>,qis
Total
Wet
^
1.7
1.7
,87
is
1.S
13
ISO
3?
5 2
1.7
5 2
10
8.7
UO
3.5
17
3.5
2 A
9.i
130
52
293
22
3.5
7.8
7-fi
4AO
17
35
3". 5
17
J.J
M56
205.9
182
37
1.011.
73.1
40.2
4.3
0.87
1.7
Total
eavy Metals
(x 10-3)
6.0
0.14
0.14
0.07
1 1
0 29
10
1?
3.2
n 43
0.14
0 43
n.8A
QJQ
12
0,2?
n -IA
0.29
O 22
0.79
11
4.3
•>A
1.8
0.29
0.65
n A=;
38
1.4
2.9
0.29
1.4
0.14
128.85
17.49
15.3
3,04
83.12
4-5
3.53
0.36
0.07
o.u
otal Chlor-
nated Organics
(x 10-6)
.7
.22
0 22
i.ll
1 47
7
•n
5.2
170
).22
) 70
1.4
Dyestuff
_(x IO"3)
32
0.75
0.75
0.3?
16
l.A
Vi
AS
17
2.3
0.75
2.3
4.6
1.1 3.8
20 65
3.47
n v>
0.47
0 Ti
1.3
18
7.0
40
2.9
0.47
1.0
1.0
*2
2.2
4.7
0.47
2.2
0.22
211.41
28.87
25
4 77
136.77
9.71
5.39
0.57
(1 11
0.22
1.6
n 75
1.6
1 2
4.2
60
23
130
9.5
1.6
3.4
3.4
200
7.5
16
1.6
7.5
0.75
691.33
94.8
83
If, .1
443.9
31.9
18.35
l.M
n M
0.75
otol
hazardous
wOnst!tu«ntv
fxlO-3)
3R
5789
0.89
0.45
18.9
1.89
A. 5
77
20.2
2.73
O.R9
2.73
5.46
4.S
77
1.R9
0.89
1 R9
1 42
_4.99
71
27.3
ISi
11 t
1 R9
4.05
.,4.05
23R
8.9
. 18.9 .
1.89
B 9
0.89
. R70.18
112,29
98.3
19 .3.4
527.02
37.?
_J2!.68
2.31
0 4
-------
Table 3-18. Category D - Quantities of Potentially Hazardous Wastewater Treatment Sludges from Woven Fabric
IV Alabaza
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Dol3>;are
IV Gecro-ia
IX Hawaii
X Idaho
V Illinois
V Ir.diar.a
Vtl leva
VII Kar.sas
IV Kentucky
VI Ixauisiana
I Maine
III Maryland
I Hassac.-.usetts
V Michic^n
V Minr.psota
IV Misjis~iyr>i
VII Missouri
VI3I '-o.-.tari
VII ;:frbi3s:.:a
JX Itevada
I J!*v Harosiiire
II Kew Jersey
VI !7~v .-!i.::ic-o
II :-:sv Ycr:;
IV ::orth Carolina
VIII X'orih Dakota
V Ohio
VI 0.
0 (ITS
11
4.4
24
1.8
0.28
0 A5
38
1.4
3.0
0.28
1.4
0.14
128.41
16.748
1.5.4
3.04
83.22
6.0
3.42
0.35
0.072
0.14
Total
Chlorinated
Orgonics
(x IfjT3)
9.8
0.23
0.23
0.12
,. 4.7
0.47
l.S
20
5.3
0.72
0.23
0.72
1.4
1.2
19
0.46
n 73
0.46
. . Q.34
1.2
18
7.2
38
2.9
0.46
1.0
6?
2.3
4.8
0.46
7.3
0.23
209.26
27.76
75.2
4.?7
135.08
9.84
5.49
n 57
0.12
0.23
Dyestuff
32
0.75
0.75
0.39
16
1.6
6.0
65
17
2.3
0.75
2.3
4.6
3.9
60
1.5
0 75
1.5
1.2
4.2
60
23
125
10
1.5
3.6
200
7.5
16
1.5
7.5
0.75
682.44
89.9
83
16.6
439.3
32.3
18.25
1.95
0.39
0.75
Total
Hazardous
Constituents
33
0.89
0.89
0.162
18:9
1.89
7.1
77
20 2
2.74
• 0.8?
2.74
5.44
4.62
72
1.78
0 S3
1.78
1.41
4.279
71
27.4
149
11.8
1.78
4.75
238
8.9
19
i ./a •
8.9
0.89
810.851
106.649
98.42
1°.66
522.52
38.3
21.67
?.? .
0.462
0.89
Se* Table 3-8 far definition of retained and wasted sludge.
-------
Table 3-19. Category D - Quantities of Potentially Hazardous Wastewater
Treatment Sludges From Woven Fabric Dyeing and Finishing
Operations,* 1983 (KKG/YR)
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I MassachuB' "s
V Michigan
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Ilamoshire
II Hew Jersey
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oreaon
III Pennsylvania
I ' Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III Viroinia
X Washinaton
III West Viroinia
V Wisconsin
VIII Wvorninq
TOTAL
Region I
II
III
IV
V
VI
11
VIII
IX
X
*lt was not possil
so the estimatec
Total Potentially
Hazardous Waste
Dry
64
64
21 _
1.100
410
4.600
1,200
170
64
17Q
390
9RO
4,500
ino
64
100
84
_3QO_
4,200
1 ,600
9,100
650
mo
230
930
14 non
530
1.100 .
100
530
10Q
48,481
6,550
5,800
1,140
31,210
2,284
1,264
1 AQ '
21
64
jle to differen
values for th
Wet „
f« nn
9 9
0.256
0.256
Qrna4
AA
0.4
1 .64 I
J« 4
A3
f).68
0.256
0.68. 1
1 78
1.12
J8
n 4
0.256 .._..
.4
0.336
J-'
1A.8
*,4
36.4
2.6
0 A
0.92
0,99
cf.
2.12
A A
P.4
3.12
0.4
193.924
96.2
?1 '
A <5A
194.84
9 ISA
w$ —
j>,084
0,256
Total
Heavy
Metals
21
0.60
0.60
-^U
10
0.98
3.8
44
12
1.6
0.60
16
3.0
2.6
42
0.98
0.60
n 9R
0.78
9.8
39
15
84
6.0
0 98
2.2
2,2
40
5.0
10
0.98
5.0
0.98
462.06
60.98
„ 54
10.78
300.38
99.16
-^—
.0.20
0.60
Total
Chlorinatec
Organic
f* 10" J)
34
0.98
0.98
r> *?9
17
1.6
6.2
79
19
2,6
0.98
2.6
4,9
4.2
65
1.6
0.98
1 6
1.3
4.6
63
25
140
9.8
1.6
76
3.6
210
17
1.6
7.8
Ti6
734.84
96.7
88
17.2
474.2
35.58
19-SR . . ..
/ . ZO
0.32
0.98
Dyestuff
120
3.2
1 0
55
~~20
230
60
8.5
8.5
16
14
220
5.0
3.2
5.0
4.2
15
210
80
460
32
5,0
12
12
700
2o
55
5.0
26
5.0
2,428
323
290
?7TOTi
1,007.0
113.7
^4?
1.0
"373
otal
Hazardous
Zonstituenti
Hi
3.8
3.8
1 2
65
"2378
274
72
10.1
3.8
10.1
19
16.6
262
5.98
3.8
4.98
17.8
249
95
544
38
5.98
14.2
840
31
65
5.98
31
5798
2,890.06
383.98
344
67.78
1,869.88
135.86
-oW
1.2
tiate between the retained and wasted sludge for 1983
is year reflect the total quantity.
3-44
-------
jected figures from this report. It was not possible to differentiate the
amounts of retained and disposed of sludge for 1983 so the estimated values
for this year reflect the total amount.
3.4.5 Category E - Knit Fabric Dyeing and Finishing
The 20 plants visited in this category are located in Alabama,
Massachusetts, New York, North Carolina, Pennsylvania, South Carolina,
Tennessee and Virginia. Their annual productions range from 380 to 19,000
metric tons. The typical plant with wastewater treatment facilities pro-
duces 4,000 metric tons annually. The number of employees involved in wet
processing at the 20 plants range from 110 to 800, and average 390. One
plant, fully integrated from raw fiber to finished garments, employs 5,000
people. However, only 500 are involved in wet processing as contrasted
with 2,500 involved in sewing operations. Equipment is newer in this
category than in Category D (Vfoven Fabric Dyeing and Finishing) as illus-
trated below:
Category
No. of Plants with Equipment Ages E D
less than 5 years 4 o
6 to 20 years 10 10
greater than 20 years 6 12
This is to be expected, because of the relatively recent introduction and
popularization of knit (especially double knit) fabrics. Operations normally
run 3 shifts per day, 5 to 7 days per week, 50 weeks per year.
3.4.5.1 Process Description
A mass balanced flow diagram of the "typical" knit fabric dyeing
and finishing process is shewn in Figure 3-5. The knit industry is un-
doubtedly the most diversified category, in terms of products and processes,
of all seven of the industry categories. The various types of knitted
items range from hosiery and pantyhose, underwear and outerwear to circular
and warp knits. The reader should be cautioned that, while the descriptions
of the process flow and waste streams are sufficient for the purposes of
this report, it is more likely that, in reality, there may be as many
"typical" knit dyeing and finishing process descriptions as there are
plants in this category. Figure 3-5 presents a generalized overview of
the entire category, and its use for purposes other than those delineated
for this report may be misleading. Of the 20 plants reviewed, no thro
plants performed the same operations in the same sequence. Individual
operations are addressed below.
3-45
-------
Figure 3-5. CATEGORY E - TYPICAL KNIT FABRIC DYEING AND FINISH PROCESS
DYE CONTAINERS 03
DYE (50%DYESTUFF) 20
CHEMICALS SO
CHEMICAL CONTAINERS 0.9
4*.
at
FINISHED
KNIT
GOODS
1.000
FABRIC
903
WASTES KEY:
LW - LIQUID WASTE
PROCESS WASTE TO LAND
V-
o
- WATER POLLUTION ABATEMENT WASTE TO LAND
POTENTIALLY HAZARDOUS
WASTE STREAM
SEE TABLE 3-22
FOR SPECIFIC
METALS
LW
*
RETAINED SLUDGE*
SEE NOTE
PRETREATMENT
SCREEN
WASTEWATER
TREATMENT
POTENTIALLY HAZARDOUS
CONSTITUENTS:
RESIDUAL DYESTUFF 0.0024
POTENTIALLY HAZARDOUS
CONSTITUENTS:
RESIDUAL CHEMICALS O.OO15
LIQUID
EFFLUENT
NOTE: AN AVERAGE OF 64 KG (DRY), 9,600 KG (WET)
SLUDGE IS RETAINED CONTAINING 0.32 KG
HEAVY METALS," 4.1x10-3 KG TOTAL
CHLORINATED ORGANICS AND 3.2 KG OF
DYESTUFF (NOT INCLUDED IN MASS BALANCE).
-------
Slit. Circular knit fabric (fabric in a tubular form) may be slit
and opened to flat form at virtually any point in the process,
depending on requirements of the processing equipment (i.e., if the
equipment is not capable of handling fabric in a tubular form, it must
be slit and opened to flat form). At three of the plants processing
circular knit goods, slitting was the first stage of the operation.
Dryclean. This operation is included for the sake of completeness.
It is not, however, a very extensively used process (two of the 20
plants - or 10 percent - drycleaned only a portion of their output)
and is normally performed only on yarn-dyed fabrics knit of 100 per
cent synthetic yarns.
Scour. Natural waxes, lubricants, or tints applied to the yarn for
identification purposes are removed in this operation to prepare the
fabric for dyeing.
Bleach and Wash. Fabric which is to remain white or to be dyed very
light shades is bleached and then washed to ranrove excess bleaching
chemicals.
Dye and/or Print. Fabrics which are to be dyed go to a dye beck, jig,
or continuous dye range, where an average amount of dye equivalent to
2 percent of the weight of the fabric is used in the bath. If the
cloth was woven from pre-dyed yarn, or if the cloth was bleached and
is to remain white, this operation would be bypassed. White or dyed
fabrics which are to be printed may be flat-bed printed, or rotary
screen printed. For detailed information on dyeing and printing
techniques and equipment, the reader is referred to the two sections
of the glossary (Appendix A) entitled "dyeing" and "printing".
Chemical Finish. Chemical finishes such as anti-statics, anti-soils,
fire retardants, softeners, water repellents and permanent press
resins may be applied. Additionally, fabrics may be bonded together
in this step. This process may be bypassed altogether, or be either
preceded or followed by mechanical finishing.
Mechanical Finish. Brushing, napping, pressing, tentering, heat
setting and calendering are canton mechanical finishing operations
which remove wrinkles, improve the hand of the cloth, its dimensional
stability or shrinkage characteristics, or alter its surface charac-
teristics. The cloth may pass through any one or usually several of
these operations. Mechanical finishing may be bypassed altogether
or either preceded or followed by chemical finishing.
3-47
-------
Waste
3.4.5.2 Waste Stream Descriptions *
This category's typical plant land-destined waste streams are:
Quantity (kg of waste/
Source kkg of product)
cloth dye and/or print 2
cloth chemical finish 4
cloth mechanical finish 3
dye containers dye and/or print 0.9
chemical containers dye and/or print and 0.9
chemical finish
cloth wash 2 to) 4
fiber wastewater pretreatment 0.8 (dry) 2.8 (wet)
screening
wasted sludge wastewater treatment typically none
retained sludge* wastewater treatment 64 kg (dry)
3 9,600 kg (wet)
* The retained sludge quantity is an accumulation over the life of the
pond.
3.4.5.2.1 Potentially Hazardous or Non-Hazardous Constituents
The fiber and cloth wastes identified in Figure 3-5 are considered
non-hazardous. The dye and chemical container waste streams are considered
potentially hazardous because they contain hazardous residual dyestuff and
chemicals. The potentially hazardous portions of the dye container and
chemical container waste streams were determined to be 0.0024 kgAkg of
product and 0.0015 kgAkg of product, respectively.
Sludges retained in the wastewater treatment system (typically,
no sludges are currently disposed! also contain hazardous constituents
such as heavy metals (copper, zinc), chlorinated organics and dyestuff,
and therefore, are also considered potentially hazardous.
3.4.5.2.2 Sampling Results
Table 3-20 lists the results of the laboratory analyses performed
on composite sludge samples taken weekly over a period of four weeks
from three plants. In every instance where drinking water limits are
established, metals or chlorinated organics concentrations exceed these
limits. Iron accounted for 76 per cent by weight of the total heavy
metals content of the sludge. Analysis performed for total chlorinated
organics showed 99.4 per cent by weight of the total content (64.7 ppn)
was found in the solid phase of the sludge, with the remainder in the
liquid phase. Ototal chlorinated organics concentrations in this category
were the highest of all categories. This may be due in part to their use
as dye dispersants in dyeing the synthetic fibers which are ccnrnonly
3-48
The reader is cautioned that no waste products from the textiles
industry have been demonstrated to be hazardous by this study.
EPA reserves its judgments pending a specific legislative mandate.
-------
Table 3-20
Category E - Knit Fabric
Dyeing & Finishing
Sludge Analyses
(mgAg of dry sludge)
Parameter
Drinking Water
Limit* (ppm)
Total Heavy Metals
Total Chlorinated
Organ ics
0.7
Ranc
.(1)
2.24-181
Average
(2)
Arsenic
Barium
Cadmium
Chromium
Cobalt
Copper
Iron
Lead
Manganese
Mercury
Molybdenum
Nickel
Zinc
0.55
1.0
0.01
0.05
**
1.0
0.3
0.05
0.05
0.002
**
**
5.0
••••wvd^H
<0.85-<12
<15-<125
<0.7-<12
2.5-50.2
<3.7- 62
89-1,030
1,557-8,260
<7-<125
12.6-112
0.7-1.9
<15-<250
<3.7-<62
120-1,250
<4.8<3>
<53
<4.5
33
<23
410
3,840
<52
51
1.4
<94
<25
550
5,117
Aluminum •
Magnesium
Potassium
Sodium
Strontium
**
60.0
**
**
**
1,293-6,625
963-1,625
1,560-4,040
12,800-87,500
3.7-<38
3,180
1,210
2,850
54,200
15
64.7
Suspended Solids (%)
Total Solids (%}
**
**
0.02-1.1
0.08-1.35
0.69
0.87
0)
(2)
(3)
**
Range of the individual plant averages
Grand average of 12 measurements from three plants
Less than values were considered to be at the maximum in computing totals
U.S. Public Health Service. Drinking Water Standards. 1962
No drinking water standards have been set for these metals
3-49
-------
processed in this category. Detailed sampling results nay be found in
Appendix C of this report.
An average of 64 kg (dry) or 9,600 kg (wet) of sludge is retained
in the typical plant's wastewater treatment system, containing 0.32 kg of
total heavy metals, 4.1 x 10-3 kg of total chlorinated organics, and 3.2 kg
of dyestuff.
3.4.5.3 Waste Quantities for 1974, 1977 and 1983
Because products in this category are ultimately used for
apparel, furnishings and other consumer products, waste projections are
closely related to population growth. (A growth factor of 3 per cent per
annum was applied.) Table 3-21 quantifies the total wastes for this
category for 1974, 1977 and 1983.
Tables 3-22, 3-23 and 3-24 list dye and chemical container and
potentially hazardous container residuals wastes for 1974, 1977 and 1983,
respectively.
Sludge quantities and its potentially hazardous constituents
amounts appear in Tables 3-25, 3-26 and 3-27 for 1974, 1977 and 1983,
respectively. Because there is little or no change anticipated in textile
wastewater treatment in 1977, it was considered valid to relate sludge
quantities to production for that year. However, it is anticipated that
1983 regulations will bring about a change in methods of treatment. The
best estimate of the effects of 1983 legislation was found in the report
prepared for the National Commission on Water Quality entitled "Textile
Industry Technology and Costs of Wastewater Control" (10). The figures for
sludge generation in 1983 were based on the projected figures from this
report, it was not possible to differentiate the amounts of retained
and disposed of sludge for 1983 so the estimated values for this year
reflect the total amount.
3.4.6 Category F - Carpet Mills
The eleven tufted carpet dyeing and finishing plants visited
in this category are located in California, Georgia, North Carolina and
South Carolina. Their annual productions range from 4,000 to 70,000 metric
tons. The typical plant with wastewater treatment facilities produces
10,000 metric tons annually. The number of employees at the eleven
plants range from 55 to 900 and average 345. Eight of the eleven plants'
equipment ages are in the 5 to 30 year bracket, with one plant's equip-
ment newer and two plants' equipment older than this. Operations normally
run 3 shifts per day, 5 to 7 days per week, 50 weeks per year.
3-50
-------
Table 3-21. Category E - Estimated Quantities of Total Waste
from Knit Fabric Dyeing and Finishing Operations
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I • Connecticut
III Delaware
IV Florida
IV Georcia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Hampshire
11 New Jersey
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
•X Oregon
III Pennsylvania
1 Rhode Island
IV South Carolina
VlII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III Virginia
X Washington
III West Vircinia
V Wisconsin
VI 1 1 Wvcming .
TOTAL
Region I
II
in
IV
V
VI
VII
VIII
IX
— X
1974
.Dry
404
150
68
138
484
14
54
28
82
40
14
U.
20£;
14
68
54
68
542
957
4.163
54
14
14
887
126
819
518
54
14
288
14
52
10,448
498
1,499
1.203
6.662
272
108
28 .,
150
28
Wet
510
187
86
173
619
17
68
35
103
51
17
17
261
17
86
68
86
683
1,206
5.340
68
17
17
1,116
156
1.030
646
68
17
360
17
103
13,239
617
1,889
1,510
8.489
342
136
35
187
35
1977
Dry
428
162
72
149
508
15
' 58
29
86
43
15
15
220
15
72
58
72
576
1,015
4.404
58
15
'5
9' 5
137
865
552
58
15
300
15
86
11.073
531
1,591
1.275
7.050
289
116
29
162
30
Wet
537
200
91
185
656
19
72
37
109
54
19
19
274
19
91
72
91
721
1.154
5.710
72
19
19
1,184
Io2
1.092
684
72
19
384
19
109
14,065
656
1,975
1,606
9,045
363
145
37
200
38
1983
. Dry
1.908
706
306
662
2.412
54
259
145
404
201
54
54
986
54
306
259
306
2,592
4,360
20,300
259
34
54
4,226
570
3.936
2,456
259
54
1,348
54
404
50.002
2.276
6,952
5.682
32.337
1.282
514
145
706
108
Wet
6.188
2.296
978
2.162
7.912
168
839
480
1,314
658
168
168
3,186
168
978
839
978
8.392
14,160
66.100
839
65
68
13,646
1,810
12.736
7,946
839
168
4,338
168
1.314
162.272
7,288
22,552
18,320
105.197
4,138
1,665
480
2.296
33o
3-51
-------
Table 3-22. Category E - Quantities of Potentially Hazardous Dye and Chemical
Container Wastes From Knit Fabric Dyeing and Finishing
Operations, 1974 (KKG/YR) Dry Weight*
Hazardous Hazardous Total Pot. Total
Dye Residual Chemical Residual Hazardous Hazardous
Contqiner , Dyestuff Container Chemicals Waste
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois .
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michiqan
V Minnesota
IV Mississinpi
VJLI Missouri
VIII Montana
VII Nebraska
IX Nevada
I New JlartiDshire
II New Jersey
VI New Mexico
II New York
IV North Carolina
viii North Dakota
V Ohio
VJL Oklahoma
X Oregon
III Pennsylvania
I1 Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
Virginia
X Washington
III West Virainia
V Wisconsin
VII I Wyoming
TOTAL
Region I
II
III
IV
V
VI
VII
VIII
IX
X
27
9.9
4.5
9
32
0.90
3.6
1.8
5.4
2.7
0.90
0.90
14
0.90
5.4
3 A
_ 4.5
36
63
_ 280
__ 3.6
9.90
0.90
58
8.1
M
34
3.6
0.90
19
0.90
* A.
694.4
32.9
99
78. 8
- 4/15.
18
7 ?
1.8
9.9
1 fl.
0.072
0.026
0.012
0.024
0.086
0.002
0.010
0.005
0.014
0.007
0.002
0.002
0.0.%
0.002
0.012
o 010
0.012
0.096
0.17
o 74
oroio
0.002
0.002
0.16
O.O^
OJ4
0.091
0.010
0.002
0.050
O.C02
0.014
1.845
0,086
0.266
0.714
1 177
0.048
n.ni9
0.005
0.026
0.004
27
9.9
4.5
9
32
0,90
3.6
1.8
5.4
2.7
0.90
0.90
14
0.90
4.5
3. 6
4.5
36
63
280
3.6
0.90
0.90
58
8.1
54
34
3.6
0.90
19
0.90
5.4
694.4
32.9
99
78.8
4/5
18
7.2
1.8
9.9
l.fi
0.045
9,01$
0.008
0.015
0.054
0.002
0.006
0.003
0.009
0,004
0.002
0.002
0.022
0.002
0.008
0.006
0.008
0.060
0.10
0.46
0.006
0.002
0.002
0.098
0.014
0.090
0.057
0.006
0.002
0.032
0.002
0.009
1.152
0.056
0.16
0.134
0 736
0.031
0.012
0.003
0.016
0.004
54.117
19,842
9.02
18.039
64.14
1.804
7.216
3.608
10.823
5.411
1.804
1.804
28.058
• 1.804
9.02
7.216
9.02
72.156
126.27
561.2
7.216
18704
18.04
116.258
16.236
108.23
66.148
7.216
1.804
38.082
1.804
10.823
1,391.797
65.942
198.426
157.948
891913
36.079
4.431
C .608
19.842
3.608
0.117
0.042
0.02
0.039
0.14
0.004
0.016
0.008
0.023
0.011
0.004
0.004
0.058
0.004
0.02
0.016
0.02
0.156
0.27
1,2
0,016
Ul004 "~
0.004
0.258
0.036
Q.23
0.148 ~
0.016
0.004
0.082
0.004 "
0.023
2.997
0.142
0.426
0.348
1 913
0.079
0.031
UlUOS —
0.642
0.008
*Dry Weighty Wet Weight
3-52
-------
Table 3-23. Category E - Quantities of Potentially Hazardous Dye and
Chemical Container Wastes from Knit Fabric Dyeing and
Finishing Operations, 1977 (KKG/YR) Dry Weight*
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michiqan
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Harrvoshire
II New Jersey
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Okianoma
X Oregon
III Pennsylvania
I, Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III Virginia
X Washinaton
III West Virginia
V Wisconsin
VIII Wyoming
TOTAL
Region I
II
III
IV
V
VI
VII
— VIII
IX
X
Dye
Container
29
11
4.8
9.5
34 ,
0.095
3.8
1.9
5.7
2.9
0.95
0.95
15
n 95
4 8
3.R
4.8
3ft
67
3.nn
.TR
0 95
0.95
. . £2.
a A
_57_
36
3.R
0.95
90
0.95
5.7
739.645
35.1
105
a1?. 9
475
19.05
7.65
1 0
11
i.n^i
Residual
Dyestuff
0.076
0.028
Ot013
0.025
0.091
0.0021
0.011
0.0053
0.015
0.0074
0.0021
0.0021
0.038
0.0071
0 013
0.011
0.013
0.10
0.18
o /a
0.011
0.0021
0.0021
10.17
j.rm
n 15
0.096
0.011
0.0021
0.053
0.0021
0.015
1 .9525
0.0912
n 9ft
0.2272
1.244
0.0521
0.0205
n orra
0.028
n 00,19
Chemical
Container
29
11
4.8
9.5
34
0.095
3.8
1,9
5.7
2.9
0.95
0.95
15
0.95
^ e
3.8
4.8
38
67
300
3.8
0.95
0.95
62
R.A
57
36
3.8
0,95
20
0.95
5.7
739.645
35.1
105
83.9
475
19.05
7.65
1.9
• 11
1 .0/15
Hazardous
Residual
Chemicals
0.048
0.017
0.0085
0.016
0.057
0.0021
0.0064
0.0032
0.0095
0.0042
0.0021
0.0021
0.023
0.0021
n nns*;
0.0064
0.0085
0.064
0.11
0.49
0.0064
0.0021
0.0021
0.10
0.015
0.095
0.060
0.0064
0.0021
0.034
0.0021
0.0095
1 .2233
0.0592
0.174
0.1382
0.78)9
0.0329
0.0127
0.0032
0.017
1 0.0042-
Total Pot.
Hazardous
Waste
58.124
22.045
9.6215
19.041
68.148
0.1942
7.6174
3.8085
11.4245
5.8116
1 .9042
1 .9042
30.061
1.9042
9 A? 15
7.6174
9.6215
76.164
134.29
601.27
7.6174
1.9042
1 .9042
^124.27
17.238
114.245
72.156
7.6174
1.9042
40.037
1.9042
11.4245
1,482.465
70.3504
210.454
168.165;
952.0259
38.185
15.3332
3.8085
22.045
2 0984
Total
Hazardous
Constituents
0.124
0.045
0.0215
0.041
0.148
0.0042
0.0174
0.0085
0.0245
0.0116
0.0042
0.0042
0.061
0 0042
0 0915
0.0174
0.0215 .
0.164
0.29
1.27
0.0174
0.0042
0.0042
0.27
0.038
0.245
0.156
0.0174
0.0045
0.087
0.0042"
0.0245
3.1758
0. 1504
0.454
0.3654
2.0259
0.085
0.0332
0.0085
0.045
O.OOS4
'Dry Weight = Wet Weight
3-53
-------
Table 3-24. Category E - Quantities of Potentiolly Hazardous Dye and Chemical
Container Wastes from Knit Fabric Dyeing and
Finishing Operations, 1983 (KKG/yR) Dry Weight*
IV Alabama
X Alanka
IX Arizona
VI Arkansas
fx Californ i a
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georcua
Tx Hawaii.
X Idaho
V" Illinois
V Indiana
vll Iowa
vil Kansas
5V Kentucky
vi Louisiana
J. Maine
III Maryland
I Massachusetts
V Micnician
V Minnesota '
IV Missis<*>io*'>i
Vil Missouri J
VlJ.1 Montana
. VII Nebraska
IX Nevada
I New Harooshirfi
II New Jisriin"
Vi New Mexico
£V [forth Carolina
vlll North Dakota
V OhTo
Vi Oklahoma
X Orcscfon
III Pennsylvania
I Rhode Island
IV South Cr.roiTna
VIII South Dakota
IV Tennessee
VT Texas
VI I"I lit ah"
i Vermont
III Virqin,ia
5( Washington
III West Virginia
VIII Wyomincj
TOTAL
Recrion I
II
III
IV
VT
Vi J
" "' ' vrii
IX
X
Dye
Container
34
13
5.7
11
1 "
1.1
I A. A
2.3
.,,6,8
3.4
1 '-1
1.1
IB
1.1
I Sal ,
.6
5.7
tt.
_._ 350
4.6
LJ
LJ
in
6fl
43
4.6
1.1
24.
ITT
A. 8
874.6
41.6
I9A
I/O
99.2
.Mfi.4
22.S
?i3
13
2.2
Residua!
Dvestuff
0.091
0.033
0.015
n.030
0.11
0,0025
| 0.013
0.0063
0.018
0.0089
0.0025
Otp025
0.046
0.0025
0.015
.OIJ
0.015
0 19
— 5T5
0.94
0.013
n finy.
0.0025
— o'^o
0.02R
0.1B
0.12
0.013
0.0025
0-063
0.0025
0.018
2.34?2
0.109
.34
0.2oR
,1.502
CUJ6.1S ..
d. 0244
O.Q063
o.m 4
On 005
Chemical
Container
34
13
5.7
11
41
Ti
4.6
T3
o~3
J^ '
1.1
l.
18
1.
5.7
4 A
1.O
5.7
46
50
350
4.6
73
10
68
43
4.6
1.1
24
TTT
6.8
874.6
41.6
.. !26
99.2
558.4
J22.8
2.3
13
2.2
Hazardous
Residual
Chemicals
0.057
0.020
0.010
0.019
0.068
0.0025
0.0076
0"."0038
— oTo"lT
— (37DD5T
0.0025
0.0025
0.028
0.0025
— crrrro
o nn7fi
0.010
0.076
0.58
— 57507S
-»-
— CTT2
0.018
~^m
. 0:072 —
OT0073
0.0025
0.041
070025
B70TI
L4503
0.071
.106
0.16
-------
Table 3-25. Category E - Knit Fabric Dyeing and Finishing Wastewoter Treatment Sludges, 1974
IV Alabama
X Alaska
IX Ari/ona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georqxa
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Hampshire
II Now uorspy
VI New Mexico
II Nev; York
IV North Caro-Lina
VIII North IX-.koua
V Ohio
VI Oklahoma
X Oregon
III Pennsylvania
1 Rhode Island
IV South Carolina
VIII South I.V.Kota
IV Tennessee
VI Texas
VIII Utaii
I Vermont
III Virginia
X Washington
III West Virginia
V Wisconsin
VIII Wyoming
TOTAL
Keaion I
II
III
IV
V
. VI
VII
VIII
IX
X
RETAINED SLUDGES (KKG)*
iNO WASTFD KLUDGES)
otal Dry
0.32
0.12
0.053
0.10
0.36
0.010
0.042
0.021
0.063
n.rm
0.010
0.010
0.16
0.010
0.053
0.042
0.053
0.42
0.74
3.3
0.042
0.010
. . 0.010
0.69
n.n95
0.63
0.40
0.042
0.010
0.22
n.nm
n
-------
Table 3-26. Cqregory £ - Knit Fabric Dyeing and Finishing Wastewater Treatment Sludges, 1977
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX Caliiorn.i A
VI I J Colorado
I Connecticut
III Delaware
IV Florida
lv Goorqia
IX Hawaii
X Idaho
V Illinois
V Indiana
Vll Iowa
VII Kansas
IV Kentuckv
VI Louisiana
I Maine
^•11 Maryland
!_ Massachusetts
V Michigan
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VTI Nebraska
ix Nevada
I New Itarocshirrj
n New Jersey
VI Now Mexico
J.J. New York
IV__ North Carolina
VIII North Dakota
V oni.o
VI UK JLahona
X Oregon
III Pennsylvania
I Rhode island
IV South Carolina
Vila. s.outh Dakota
IV Tc-nnassoo
VI Texas
Vlll Utah
I Vermont
III Virgini a
x wasfiinoton
III h'ost Vircrinia
V ~WJ.acor.sin
Vlll Wyominq
TOTAL
Region I
11
III
IV
V
VI
Total Dry
0.34
0.13
0.056
0.11
0.3fl
0.011
0.044
0.022
0.067
0.034
n.nn
0,011
0^17
0.011
0.056
0.044
0.056
0.44
0 7R
3.5
0.044
0.011
0.011
0.73
0. in
O.A7
0.42
0.044
0.011
J).?3
0.011
0.067
RETAINED SLUDGES (KKG) *
fNO WASTED SLU GES)
Total Wet
49
IS
8.2
16
58
1.6
6.5
3.2
9.8
4.9
l.A
1 A
94
1.6
8.2
6.5
8.2
65
i?n
510
6.5
1.6
1.6
110
11
9ft
i2
6.5
Total
Heavy Me ta
fx 10"J)
1.7
0.64
0.29
0.53
1.9
0.053
0.22
0.11
0.34
0.17
n rvtf
O.OS3
O.R5
0.053 . _
0.29
0.22
0.29
2.2
3 9
17
0.22
0.053
0.053
3.7
o
-------
Table 3-27. Category E - Quantities of Potentially Hazardous Wastewater
Treatment Sludges from Knit Fabric Dyeing and Finishing
Operations,* 1983 (KKG/YR)
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississiooi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Hampshire
II New Jersey
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Pennsylvania
I • Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III Virginia
X Washington
III West Virainia
V Wisconsin
VIII Wvoming
TOTAL
Region I
II
III
IV
V
VI
VII
•~ viii
IX
X
Total Potentially
Hazardous Waste
Dry
1 Ann
520
220
490
1.800
37
190
110
300
150
37
37
720
37
220
190
220
i 9nn
•
15,000
190
37
37
r^ion
410
7 900
1r800
190
37
980
37
300
36,796
1,644
5,100
4, I'M
93,aaO
937
377
110
52.0 ,
74
Wet ,
(x 103)
5.6
2.08
0.88
1.96
7.2
0.148
0.76
0.44
1.2
0.6
0.148
0.148
2.88
0.148
0.88
270.76
0.88
7.6
12.8
60
0.76
0.148
0.148
12.4
1.64
11.6
7.2
0.76
0.148
3.92
0.148
1.2
147.184
6576
?0.4
1A..616
95..')?
3.748
1.508
0.440
Total T
Heavy C
Metals C
7.2
2.6
-1
2.4
8.8
0.20
0.95
0.56
1.5 .
0.75
0;20
0.20
3.6
0.20
.1
0.95
1.1
9.5
16
75
0.95
0.20
0.20
15
2.1
14
9.1
0.95
0.20
4.9
0.20
1.5
T83.21
8.3
25.5 , ,
20.3
IIR..?.")
4.7
1.9
0.56
2.08 1 2.6
0.296 | 0.40
otol
Chlorinated
)rganics
(x I0~3)
92
34
14
32
10
2.4
12
7.1
19
9.7
2.4
2.4
46
2.4
14
12
14
120
210
970
12
2.4
2.4
200
26
180
120
12
2.4
63
2.4
19
2367
104.8
330
267.6
1 535
57.4
24.1
7.1
34
4.8
Dyestuff
70
26
1
24
?o
1.8
9.5
5.5
15
7.5
1.8
1.8
36
1.8
11
9.5
11
95
160
750
9.5
1.8
1.8
160
20
140
90
9.5
1.8
49
1.8
15
1,838.4
81.6
255
212.6
lrlflfi.5
46.8
18.8
5.5
26
3.6
otal
tezardous
Constituents
77.3
28.6
12.1
26.4
98.9
2.0
10.46
6.07
16.5
8.26
2.0
2.0
39.6
2.0
12.1
10,46
12.1
104.6
176
826
10.46
2.0
2.0
175
22.1
154.2
99.2 •
10.46
2.0
54.0'
2.0
16.5
2.023.37
89.9
280.6
233.0
1.308.96
51.52
20.72
6.07
28.6
4.0
*lt was not possible to differentiate between the retained and wasted sludge for 1983, so
the estimated values for this year reflect the total quantity.
3-57
-------
3.4.6.1 Process Descriptions
A mass balanced flew diagram of the typical tufted carpet dyeing
and finishing process appears in Figure 3-6. The individual operations
are addressed below.
Tufting. Yarn is tufted through the primary backing, usually
polypropylene, by the many needles of the tufting machine.
Dye. Carpet which has not been tufted with pre-dyed yarn may be
piece dyed or dyed in a kuster dye range (TAK dyed) before the
secondary backing is applied. Slightly more dye - an estimated
3 per cent of the weight of the yarn as opposed to the usual
2 per cent - may be used in dyeing due to the generally deeper
dyeing of carpets. Anti-soil and anti-static agents may be
applied after the carpet is dyed and before finishing.
Finish. Latex and a secondary backing such as jute are applied in
a continuous operation to lock the tufted yarns into the primary
backing. A rubber foam backing may be applied as an alternative
to the jute secondary backing.
Print. Mitter-Stalwart, or Zimmer printing machines are used in
this operation. Mostly foam backed carpet is printed, however,
shags and plushes may also be printed.
Selvage Trim. Approximately 5 centimeters or 2 inches of selvage
is trimmed from each edge of the carpet to assure uniformity of
width.
Fluff and Shear. The carpet is beaten to fluff the yarns into an
upright position. The carpet is then sheared to give it a uniform
surface.
3.4.6.2 Waste Stream Descriptions
In this category the typical plant land-destined waste streams
are:
3-58
-------
Figure 3-6. CATEGORY F - TYPICAL TUFTED CARPET DYEING AMD FINISHING PROCESS
DYE CONTAINERS 0.13
DYE (50% DYESTUFF) 30
CHEMICAL CONTAINERS 0.18
CHEMICALS 50
LATEX AND
SECONDARY BACKING 402
U1
VO
POTENTIALLY HAZARDOUS
CONSTITUENTS:
RESIDUAL DYESTUFF 0.0007
WASTES KEY:
LW - LIQUID WASTE
POTENTIALLY HAZARDOUS
CONSTITUENTS:
RESIDUAL CHEMICALS 0.00075
LW
V-
o
i
RETAINED SLUDGE'
SEE NOTE
- PROCESS WASTE TO LAND
WATER POLLUTION ABATEMENT
WASTE TO LAND
PRETREATMENT
SCREEN
WASTEWATER
TREATMENT
LIQUID
•EFFLUENT
• - POTENTIALLY HAZARDOUS WASTE STREAM
*• - SEE TABLE 3-30 FOR SPECIFIC METALS
NOTE AN AVERAGE OF 5.2 KG (DRY), 22,000 KG (WET) SLUDGE IS
RETAINED CONTAINING 0.41 KG HEAV Y METALS,"
140x10* KG TOTAL CHLORINATED ORGANICS. AND
0 26 KG OF DYESTUFF (NOT INCLUDED IN MASS BALANCE).
LATEX
SLUDGE
DRY 23
WET 45
-------
Quantity (kg of waste/
Waste Source kkg of product)
yarn and sweeps tufting 1.0
selvage selvage trim 26
flock fluff and shear 4
dye containers dyeing and printing 0.13
chemical containers dyeing and printing 0.18
fiber wastewater pretreatment 1.2 (dry)
screen 2.0 (wet)
latex sludge wastewater treatment 2.3 (dry) 4.9 (wet)
wasted sludge wastewater treatment typically none
retained sludge* wastewater treatment 5.2 kg (dry)
22,000 kg (wet)
* The retained sludge quantity is an accumulation over the life of the
pond.
3.4.6.2.1 Potentially Hazardous or Non-Hazardous Constituents *
The yarn, sweeps, selvage, flock, fiber and latex sludge wastes
identified in Figure 3-6 are considered non-hazardous. The dye and chemical
container waste streams are considered potentially hazardous because they
contain hazardous residual dyestuff and chemicals. The potentially hazardous
portions of the dye container and chemical container waste streams were
determined to be 0.007 kg/kkg of product and 0.00075 kg/kkg of product,
respectively.
Sludges retained in the wastewater treatment system also contain
hazardous constituents such as heavy metals (zinc), chlorinated organics
and dyestuff, and therefore, are also considered potentially hazardous.
This industry category does not ordinarily waste sludge.
3.4.6.2.2 Sampling Results
Table 3-28 lists the results of laboratory analyses performed
on composite sludge samples taken weekly over a period of four weeks
from two plants. In every instance where drinking water limits are
established, metals or organics concentrations exceed these limits. Iron
accounted for 64 per cent by weight of the total heavy metals content.
Analysis performed for total chlorinated organics showed 99.6 per cent
by weight of the total content (26.2 ppm) was in the solid phase of the
sludge, with the remainder in the liquid phase. The average solid phase
concentrations of total chlorinated organics and heavy metals exceeded
the drinking water limits at both plants. The liquid phase concentrations
of chlorinated organics were all below drinking water standards. Detailed
sampling results may be found in Appendix C.
3-60
* The reader is cautioned that no waste products from the textiles
industry have been demonstrated to be hazardous by this study.
EPA reserves its judgments pending a specific legislative mandate.
-------
Table 3-28
Category F - Tufted
Carpet Dyeing & Finishing
Sludge Analyses
(trig/kg of dry sludge)
Parameter
Drinking Water
Limit* (pprn)
(D
Average
(2)
Arsenic
Barium
Cadmium
Chromium
Cobalt
Copper
Iron
Lead
Manganese
Molybdenum
Nickel
Zinc
Total Heavy Metals
Aluminum
Magnesium
Potassium
Sodium
Strontium
Total Chlorinated
Crqanics
Suspended Solids (%)
Total Solids (%)
0.05
1.0
0.01
0.05
**
1.0
0.3
0.05
0.05
**
**
5.0
**
60.0
**
**
**
0.7
**
**
<7-<12
. <70-<120
<7-<12
100-123
<36-212
22-400
660-9,750
<70-150
101-412
<145-<250
<36-<62
254-3,325
1,740-7,120
1,580-2,060
1,490-6,540
41,000-91,250
29-<38
1.03-51.4
0.016-0.03
0.08-0.14
<10
<95
<10
112
124
211
5,200
110
256
<198
<49
1,790
8,117
4,430
1,820
4,020
667100
33
26.2
0.024
0.11
(1) Range of the individual plant averages
(2) Grand average of 12 measurements from three plants
(3) Less than values were considered to be at the maximum in computing totals
* U.S. Public Health Service. Drinking Water Standards. 1962
** No drinking water standards have been set for these metals
3-61
-------
An average of 5.2 kg (dry) or 22,000 kg (wet) of sludge is
retained in the typical direct discharge plant's wastewater treatment
system, containing 0.41 kg of total heavy metals, 1.4 x 10-lf kg of total
chlorinated organics, and 0.26 kg of dyestuff.
3.4.6.3 Waste Quantities for 1974, 1977 and 1983
Waste generation rates (kg of waste/metric ton of product) identi-
fied in Figure 3-6 were applied to production rates to give wastes quanti-
ties. Increases in production of 12.5 per cent in 1976 and 10.5 per cent
in 1977, projected by the Carpet and Rug Institute (1) were applied to all
current year waste quantities to give 1977 amounts. The contractor estimated
that an average annual increase of 12 per cent would be maintained until
1980, at which point a downturn to 9 per cent would take effect, due to
the continuing demand for smaller housing units and the impact of declining
birth rates affecting the total number of households in the 1980's. This
rationale was followed in projecting 1983 container and innocuous wastes.
Table 3-29 quantifies the total wastes for this category in 1974
1977 and 1983. Tables 3-30, 3-31, and 3-32 list dye and chemical con-
tainer and potentially hazardous container residual wastes for 1974, 1977
and 1983, respectively.
Sludge quantities and its potentially hazardous constituents
amounts appear in Tables 3-33, 3-34 and 3-35 for 1974, 1977 and 1983,
respectively. Because there is little or no change anticipated in textile
wastewater treatment in 1977, it was considered valid to relate sludge
quantities to production. However, it is anticipated that 1983 regulations
will bring about a change in methods of treatment. The best estimate of
the effects of 1983 legislation was found in the report prepared for the
National Commission on Water Quality entitled "Textile Industry Technology
and Costs of Wastewater Control" (10). The figures for sludge generation
in 1983 were based on the projected figures from this report. It was not
possible to differentiate the amounts of retained and disposed of sludge
for 1983 so the estimated values for this year reflect the total amount.
3.4.7 Category G - Yarn and Stock Dyeing and Finishing
The eleven plants visited in this category are located in
Alabama, Connecticut, Georgia, North Carolina; South Carolina and
Tennessee. Two of the plants are integrated, beginning with stock and
endirig with woven fabric, while three others begin with stock and end with
yarn. The^remaining six plants begin with greige yarn and end with bleached
or dyed, finished yarn. The number of employees at these plants range
from 120 to 1,500 and average 620. Plants usually operate 3 shifts per
day, 5 to 6 days per week, 50 weeks per year. Excluding the two integrated
mills, annual yarn production ranges from 540 to 13,000 metric tons.
3-62
-------
Table 3-29. Category F - Estimated Quantities of Total Waste from
Tufted Carpet Dyeing and Finishing Operations
(KKG/YR)
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georqia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
TV Mississinni
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Hcnoshire
II Hew Jersev
VI New Mexico
II New York
IV North Ciirolinei
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Pennsylvania
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III Virqinia
X Washington
III West Vircinia
V Wisconsin
VIII Wyorainq
TOTAL
Region I
II •
III
IV
V
VI
VII
VIII
IX
X
19
Dry
313
,313
2,824
141
14,127
i
141
313
313
141
141
454
938
141
313
767
938
626
313
141
141
23,539
313
595
903
17,396
423
939
141
2T824
'74
Wet
356
356
3,234
157
16,707
157
356
356
157
157
512
1,046
157
356
868
1,046
71)
356
157
157
27,359
356
669
1,025
2U,379
471
1,068
159.
3,234
19
Dry
394
394
3,531
182
18.159
182
394
394
182
182
565
1,211
182
394
959
1,211
787
394
182
182
30,06!
394
747
1,141
22,338
548
1,182
182
3,531
77
Wet
450
450
4,071
199
21,428
199
450
450
199
199
637
1,359
199
450
1,048
1,359
888
450
199
199
34,344
450
836
1,247
25,594
597
1,350
199
4,071
IS
Dry
912
912
8,155
404
40,790
404
912
912
404
404
1,289
2,679
404
912
2,614
2.679
1,793
9)2
404
404
67,849
912
1,693
1 2,568
50,169
\j_2\2
2,736
404
8,155
>83
Wet
1.570 •
1,570
13,955
667
70,290
667
1.570
1.570
667
667
2,229
4.559
667
1.570
3,708
4,559
3jJ33
1,570
667
667
116,522
1,570
2t896
' 4,375'
86,348
2,001
4.710
667
13,955
3-63
-------
Toble 3-30. Category F -Quantities of Potentially Hazardous Dye and
Chemical Container Wastes from Tufted Carpet Dyeing and
Finishing Operations, i?71 (KKG/YP.) D-y Weight*
Hazardous Hazardous
Dye Residual Chemical Residual
rnn'nirier « Dvestuff Container Chemicals
IV Alabar.a
X Alaska
IX ArJ zotirt
VI Ai-kanr-aw
IX Calilornia
VI 11 Colorado
I Connecticut
III Delaware-
IV Florida
IV Gcornia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa" '
VII Kansas
IV Kentucky
VI Louisiana
1 Manic
III Maryland
I M.issciclii'.aotts
V M.'.chican
V Minnesota
IV Miss >.s.-;.M.>pi
VI r. Missouri
VIII Montana
Vll Kebraiik'a
IX Nevada
I New .'.'rtr.-.Mshire
II Uow Jersey j
VI N5w .".cxico
II Kow Vork
IV North Carolina
VIII North Dakota
V Ohio
VI OUaho:-vV
X Orerron
III PonnsvAVnnia
I Hliocie Island
IV4 Scmtn Carolina
VIII Sox:th Dakota
IV Tonnes sen
VI Texas
VIII Utah
I Vermont
III Virqir.ia
X War:.!il]-.<'ton
II f Wont V.U-oinia
V Winconain
VIII \vyoinintT
TOTAL
Reqion I
II
111
IV
V
VI
'VI!
— " vi 1.1
IX
X
1.2
1.2
10
0.52
55
0.52
1 •)
1.2
0.52
0.52
1.7
3.5
0.5?
1.2
2.9
3.5
2.3
1.2
0.52
0.52
H7.74
1.2
2^22
3.42
£5.22
1.56
3.^6
0.52
10
O,OOA
0.006
0.057
0.003
0.29
0.003
n noA
0.006
0.003
0.003
0.009
0.019
0.003
0.015
0.019
0.013
' 0.006
0.003
0.003
,0.479
0.006
0.012
0.018
0.356
0.009
0.018
0.003
0.057
, , .
l.A
1.6
14
0.72
74
0.72
l.A
1.6
0.72
. 0.72
...0.007 .
0.007
0.061
0.003
0.31
0.003
0.007
^.007
0.003
0.003
2.3 ; 0.010
4.9
0.72
1.6
4
4.9
3.2
1.6
0.72
0.72
_. 121,94
1.6
3.02
4.72
" 90.92
2.16
" 4.8
0.72
14
0.020
0.003
O.OO/
0.016
0.020
0.014
o.oO/
0.003
0.003
0.514
0.007
0.013
0.019
0.381
0.00V
U7021
0.003
tf.Ool
Total Potentially Total
Hazardous Hazardous
Waste ronstih^nts
2.813
2.813
24.118
1.246
127.6
1.246
2.813
2.813
1.246
1.246
4.019
8.439
1.246
2.813
6.931
8.439
5.527
2.813
1.246
1.246
210.673
2.813
_ 5.265
8.177
156.877
3-72§
8.439
1.246
24.118
0.013
0.013
0.118
0.006
0.6
0.006
_... 0.013
0.013
0.006
"" 0.006 "
0.019
0.039
0.006
6.013
0.031
' 0.039
0.027
0.013
0.006
U.UOi '
6.993 ••"•
0.013
0.025
0.037
0.737
0.018
07339
O.DOo"
0.118 '
Dry Weight -Wet Weight
3-64
-------
Table 3-31. Category F - Quantities of Potentially Hazardous Dye and
Chemical Container Wastes from Tufted Carpet Dyeing and
Finishing Operations, 1977 (KKG/YR) Dry Weight*
Hazardous Hazardous Total Potentially Total
Dye Residual Chemical Residual Hazardous Hazardous
Contniner i Dvestuff Container Chemicals Waste Constituents
TV Alabama
X Alaska
IX Arizona
VI Arkansas
ItX California
VJII Colorado
1 Connecticut
III Delaware
IV Florida
JV Gcoruia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kan s a s
"IV Kentucky
VI Louisiana
I Maine
III MarvJonci
I Massachusetts
V Michlcan
V Minnesota
IV MisJ.issieni
VII Missouri
VIII Montana
VII Nebraska
IX Nevana
I New Hair.nshire
II New .lersey
VI New fic-xlco
II Nev; York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Ponnsvlvania
I Rhode Is 3 and
TV South carolinr
VIII South Dakota
TV Tennessee
VI Tnxac
VIII Utah
I Vermont
III Vivrpnxa
X Washington
III West virqinia
V Wisconsin.
VIII Wyoming
TOTAL
Heaion I
II
l.tl
IV
V
VI
VI]
V11I
IX
X
1.5
1.5
13
0,65
66
O.A5
1.5
1.5
0.65
0 AS
2.1
4.4
0.65
1.5
3.6
4.4
5.9
1 S
n./«
0.65
109.95
15
7.75
4.25
fil.35
L-95
_ _4.5
0.65
13
0.0075
0.0075
0.072
0.0038
0.36
0.003R
0.0075
0.0075
0.0038
0 0038
0.011
0.024
0.0038
0.0075
._ 0.019
0.024
0.016
0.0075
0.0038
0.0038
0.5976
0.0075
0.0148 ,.
0.0224
. 0.4428
0.0114
.. Q.J32.2S
. ...0.0038
J1.072
2.0
2.0
18
0.90
93
0.90
2.0
2.0
0.90
0.90
2.9
6.1
0.90
2,0
5.0
6.1
4.0
2.0
0.90
0.90
153.4
2.0
3.8
5.9
, 114,1
2.7
6.0
- 0.90
......18
J.0088
JJ)088
D.077
0.0038
0.39
0.0038
0.0088
D.OO&S
0.0038
0.0038
' 0.013
0.025
0.0638
0.0088
0.020
0.025
0.018
0.0088
0.0038
0.0038
0.6474
0.0088
0.0168
0,0238
0.4794
0.0114
0.0264
.0.0038
0.077
3.5163
3.5163
31.149
1 .5576
159.75
1.5576
3.5163
3.5163
1 .5576
1.5576
5.024
10.549
1.5576
3.5163
x
8.639
10.549
6.934
3.5163
1 .5576
1 .5576
264.595
3.5163
6.5816
10.1966
196.3722
4.67?8
10.5489
1 .5576
31.149
0.0163
0.0163
0.149
0.0076
0.75
0.0076
0.0163
0.01 63
0,0076
0.0076
0.024
0.049
0.0076
0.0163
0.039
6.041?
' 0.034
0.0163
0.0076
0.0076
1.245
0.0163
0.0316
0.04*'.6
0.9222
0.0228
0.0489
0.0076
0.149
Dry Weight = Wet Weight
3-65
-------
Table 3-32. Category F - Quantities of Potentially Hazardous Dye and
Chemical Container Wastes from Tufted Carpet Dyeing and
Finishing Operations, 1983 (KKG/YR) Dry Weight*
IV Alabama
X Alaska ,
IX Arizona ,
VI Arkansas .
IX California
VIII. Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois
V~~ Indiana
VII Iowa
VII Kansas
IV Kentucky
Vl Jjoui.Tidna
III MnryJ'and
I Mfiar.aohusatts
V Michigan
V Minnesota
IV MTssisfiiDni
V~il Missouri
VIll Montana
.VII Nebraska
IX Nevada
I New Hcinnshire
II New Jersey
V.I Ne'-j Mexico
II NC-. • York
IV llorth Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Ponnsylvsria
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texan
VITT Utah
j. Vo;:r.iont
III Virginia
X Washington
III UVf.t Virginia
V Wisconsin
VII J Wvoming
TOTAL.
Rpg i on I
"" 11
i J i
— iv
V
V T.
- VI I
VIII
IX
— x
Dye
Container '
2 7
7.7
_23 1
_L2
120
1 1-2
•> 7
1.2
3.9
fi-0
1.9
2.7
i -8J3
c, 7
"> 7
1 2
1 2
199.3
•) 7
S 1
7 ft
147 ft
3.6 ,. ,
8...1
_..1.2
23
Hazardous
Residual
Dyestuff
r~n,ou [
0-014
0.13
_ 0 . 0068
0,66
0-0068
0-014
OJU4
0.0068
0.0068
p n?l
0.043
0,0068
0.014 I
... Q.Q3.4 :
0.043
0 030
P.Q'4
0.0068
0.0063
1.0926
O.OU
0 027B
jaJMQ8_
0 R'Oft
0,0204 .
. Q.042
.dJK&ft,
0,13
Chemical
Container
_3,6
3 A
,12.
176
170
1.6
3.6
rO
1.A
~T76
5.2
11
~-tt
9.1
11
7.3
3.6
1.6
1.6
278.4
3.6
6,8
10.7
?t)fl.1 .. .
4.8
.'iP • _
32
Hazardous
Residual
Chemicals
0.016
0.016
0.14
0.0068
0.71
0.0068
0.016
0.016
0.0068
0.0068
0.093
0.046
0.034
0.046
0.032
0.016
0.0068
0.0068
.1766
0.016
0,0298
0.0428
n R79B
0.0204
QD4A
n onAfl
._Q,0068_
Total Potential
Hazardous
Waste
6.33
6.33
2.613o
291.37
2.8136
6.33
6ltt
2.8136
2.8136
9 144
19.089
OT36
6.33
15.77§
9.089
12.562
6.33
2.8136
2.813«
479.9692
6.33
11,9576'
18.5836
357^836
8.4408
18 99
.HIJ6 1
55.27
y Total
Hazardous
Constituents
1 535155 1
0.030
Ol27 T
0.0136 ~
1.37
0.0136
0.030
0.030
0.01 3A
0.0136
0.044
0.089
0.0136
53530
57575
TOM
53565
6330
0.0136
0.0136
2.2692
0.030
0.0576
0.0836
1.6836
0.0408
0 575
0.0136
0.27
• Dry Weight-Wet Weight
3-66
-------
Table 3-33. Category F - Tufted Carpet Dyeing and Finishing Wastewater Treatment Sludges, 1974
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III DeJ.av;aro
TV Florida
IV Georqia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michiaan
V Minnesota
IV Mississippi
VII Kistiouri
VIII Montana
VII Nebraska
IX Nevada
I New Hsr.M'shirR
II New Jersey .
VI New Mes-lco
II Hew York
IV North Carolina
VIII North Dakota
V OJiio
VI Oklahoma
X Oregon
III Pennsylvania
I Rhode .island
IV South Carol ina
tfill South Dakota
IV Tennessee
VI Texas
VIII Utah
~T Vermont
III Virginia
y Nashinoton
"i'll Went Virginia
U Wisconsin
V"TII wvbroinq
TOTAL
Bnnion I
11
III
— jy
V
vi
— - v~ii
vTTf-
IX
RETAINED
( NO WAS
Total Dry
(x 10-3)
3,0 ,
3.0
?7
1.4
'138 ' '
1.4
3.0
3.0
1.4
1.4
4.4
9.)
74
3.0
7.4
9.1
6.1
3.0 ,
1.4
1.4
228.9
3.0
5.8
?L8_ .
1AO 7
4.2
9.0
1.4
27
Total Wet
13
13
l|fi
5.6
580
5.6
13
13
5. A
5.6
18
38
5.6
'3
31
38
25
13
5.6
5.6
957.2
13
23.6
36.6
712 6
-*H —
•us —
SLUDGES (KKG) *
ED SLUDGES)
Total
Heavy Metals
(x 10-6)
24
-TA
210
1
hoo
11
24
_. 24 _
11
11
35
72
11
24
59
72
48
24
11
11
1817
24
_46
70
1351
IO3I
-£
--
210
Total Chlor-
inated Organics
(x 10-9)
79
79
7lO
37
3600
37
79
79
37
37
120
240
37
79
190
240
160
79
37
37
5993
79
--,-- 157
227
—&—
Dyestuff
(x 10-3)
0.1S
n.i.s
1.4
0.07
6.9
0.07
0.15
0.15
0.07
0.07
0.22
0.46
0.07 n
0.15
0.37
0.46
0.30
0.15
0.07
0.07
r
11.5
0.15
0.29
0.44
.49
P-21
0.45
37 0,07
710 ~| T4 r
1 ^n
Total
Hazardous Constituents
(* Id"6)
174
174
1610
81
8000
81
174
174
81
81
255
532
81
174 .
499
532
348
174
81
81
13r317
174
336
510
9R4J
243
522
81
U10
1 Soa Table 3-8 for definition of retained and woifed iludge.
3-67
-------
Table 3-34. Category F - Tufted Carpet Dyeing and Finishing Wastewater Treatment Sludges( 1977
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III DcO.avrarc;
IV Florida
IV Goornia
IX Hawc'.ii
X Idaiio
V Illinois
V Indiana
V}I Iowa
VII Kansas
IV Kentucky
Vl Louisiana
I Maine
III Maryland
I Massachusetts
V Michioan
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I Now Hamoshire
I I Now Jersey
VI New Mexico
II New York
IV North Carolin.-i
VIII North Dakota
V Ohio
VI Oklahoma
X Oreoon
III Pennsvlvania
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III Virqinift
X Washington
III West Virginia
V Wisiconsin
VIII Hvomimi
TOTAL
Recjion I
' II
III
IV
V
VI
VII
VIII
IX
X
RETAINED SLUDGES (KKG)*
(NO WASTED SLUDGES)
Total Dry
(* 10-3)
3.8
3.8
34
1 ft
17O
1.8
3,8
3 R
1 8
1.8
<; 5
11
1.8
3.8
9.3
11
7.6
3.8
1 ft
1.8
283.8
3.8
7.3
11.1
909
5.4
l',4
l.fl
34
Total Wet
16
16
140
70
7.10
7.6
16
U
7.O
7.0
99
48
7.0
16
39
48
31
16
7 n
7.0
1*03
16
99
46
fl96
21
4fl
7
140
Total
Heavy Metals
fx ICT^
30
30
260
14
1400
14
30
30
14
14
44
90
14
30
74
90
60
30
14
14
2296
30
.SB
88
..17.14_
42
..90
14
260
Total Chlor-
inated Organics
(* lO-9)
99
99
8°0
46
4SOO
46
99
. 99
46
46
150
300
46
99
240
300
200
99
46
46
7496
99
196
286
5544
138
297
f,t>
890
Dyestuff
fx 10-3)
0.19
0.19
1.8
0.088
8.6
0.088
0.19
0.19
0.088
0.088
0.28
0.58
u.oya
0.19
0.46
0.58
0.38
0.19
0.088
0.088
I4.4J6 ~
0.19
0.368
0.548
10.608
0.264
0.57
0.088
1.8
Total
Hazardous Constituents
(x 10-6)
220
220
2060
102
10.000
102
220
220
102
102
324
A70
102
220
^
534
. 670
44D
220
102
102
16732
220
496
636
12,322
3rv,
660
102
2060
* See Table 3-8 for definition of retained and wasted sludge.
-------
Table 3-35. Category F - Quantities of Potentially Hazardous Wastewater
Treatment Sludges From Tufted Carpet Dyeing and Finishing
Operations,* 1983 (KKG/YR)
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois
V Indiana
vTl Iov?a
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland I
I Massachusetts
V Michigan
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New HarrtDShire
II New Jersey
VI New Mexico
Tl New York
IV North Carolina
VIII North Dakota 1
V Ohio
VI Oklahoma
X Oregon
m Pennsylvania
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III Virginia
X Washington
III West Virginia
V Wisconsin
VIII Wyoming
TOTAL
Reciion I
II
III
IV
V
VI
VII
VIII
__ j^
Total Potential
Hazardous Wastes
Dry
196
196 .
81
«
81
196
196
81
81
9an
560
81
196
448
-------
3.4.7.1 Process Description
A mass balanced flow diagram of the typical yarn and stock
dyeing and finishing process is shown in Figure 3-7. The individual
operations are addressed below.
Mercerize. This operation is performed on cotton yarn by only a
few plants. The yarn is treated by a caustic bath to swell the
cotton fiber. This imparts increased dye affinity, greater
tensile strength, and luster to the yarn.
Bleach. If the yarn is to remain white or to be dyed a very light
shade, it may be bleached to remove its natural yellowish color.
Dye. Stock is dyed in becks, as is yarn. Yarn is usually package
dyed, skein dyed, or beam dyed.
Dry. The dyed stock, which has matted into a cake in the dyeing
operation, is broken up and oven dried. After drying, it may be
blown into a bin and await yarn preparation (as discussed in
Section 3.4.3.1, Greige Goods Process Description) or it nay be
baled and sold or stored. Yarn may be oven dried or dried in the
beck in which it was dyed.
Finish or Slash. Yarn may be finished with a lubricant prior to
knitting or sewing, or beamed and then slashed with conpounds such
as carboxymethyl cellulose (CMC), polyvinyl alcohol (PVA), and
starch prior to weaving, or may bypass this step entirely.
Beam, Quill, Wind, etc. These operations are mechanical handling
operations intended to ready the yarn for the loom or knitting
machine.
3.4.7.2 Waste Stream Description
The land-destined waste streams from a typical plant in this
category are:
Quantity, (kg of waste/
Waste Source kkg of product)
yarn bleaching/dyeing 0.7
yarn beaming/quilling/ 5.4
winding, etc.
dye containers dyeing 0.87
chemical containers dyeing and finishing 2.2
fiber wastewater pretreatment 9.0 (dry)
screen 33 (wet)
wasted sludge wastewater treatment typically none
retained sludge* wastewater treatment 2.9 kg (dry)
20,000 kg (wet)
* The retained sludge quantity is an accumulation over the life of
the pond.
3-70
-------
Figure 3-7. CATEGORY G - TYPICAL YARN AND STOCK DYEING AND FINISHING PROCESS
DYE CONTAINERS 0.87
DYE (50% DYESTUFF) 20
CHEMICAL CONTAINERS 2.2
CHEMICALS 50
STOCK
1,000
YARN
956
FINISHED YARN TO
WEAVING OR
KNITTING 1,000
DYED STOCK TO
YARN PREPARATION
1,000
LW
POTENTIALLY HAZARDOUS
CONSTITUENTS:
RESIDUAL DYESTUFP 0.002
WASTES KEY:
LW -LIQUID WASTE
PROCESS WASTE TO LAND
WATER POLLUTION ABATEMENT WASTE TO LAND
-POTENTIALLY HAZARDOUS WASTE STREAM
- SEE TABLES 3-38 FOR SPECIFIC METALS
POTENTIALLY HAZARDOUS
CONSTITUENTS:
SlUUALCHfcMICALS C
PRETREATMENT
SCREEN
.02
RETAINED SLUDGE*
SEE NOTE
WASTEWATER
TREATMENT
o
NOTE: AN AVERAGE OF 23 KG (DRY), 20,000 KG (WET) SLUDGE IS RETAINED
CONTAINING 0.01 KG HEAVY METALS," 120x10-6 KG TOTAL CHLORINATED
ORGANICS, AND 0.14 KG OF DYESTUFF (NOT INCLUDED IN MASS BALANCE).
-------
3.4
.7.2.1 Potentially Hazardous or Non-Hazardous Constituents *
The fiber and yarn wastes identified in Figure 3-7 are considered
non-hazardous. The dye and chemical container waste streams are considered
potentially hazardous because they contain hazardous residual dyestuff
and chemicals. The potentially hazardous portions of the dye container
and chemical container waste streams were determined to be 0.002 kg/kkg
of product and 0.02 kg/kkg of product, respectively.
Sludges retained in the wastewater treatment system (typically,
no sludges are currently disposed) also contain hazardous constituents such
as heavy metals (copper, zinc), chlorinated organics and dyestuff, and
therefore, are also considered potentially hazardous.
3.4.7.2.2 Sampling Results
Table 3-36 lists the results of the analyses performed on com-
posite sludge samples taken weekly over a period of four weeks from two
plants. In every instance the average metals or chlorinated organics
concentrations in the sludge solids exceeded the drinking water quality
limits. Iron and zinc together accounted for 87 per cent by weight of the
total heavy metals content of the sludge. Analysis performed for total
chlorinated organics showed 99.9 per cent by weight of the total content
(40.1 ppm) was found in the solid phase of the sludge. The remaining
0.1 per cent (0.03 ppm) of chlorinated organics found in the liquid phase
does not exceed drinking water standards for total organics. Detailed
sampling results may be found in Appendix C of this report.
An average of 2.9 kg (dry) or 20,000 kg (wet) of sludge is
retained in the typical plant's wastewater treatment system, containing
0.01 kg of total heavy metals, 1.2 x 10-" kg of total chlorinated organics,
and 0.14 kg of dyestuff.
3.4.7.3 Waste Quantities for 1974, 1977 and 1983
Because much of this category's products are processed by
Categories D and E and are ultimately used for apparel, furnishings and
other consumer products, waste projections are closely related to popula-
tion growth. (A growth factor of 3 per cent per annum was estimated by
the contractor). Table 3-37 quantifies the total wastes for this category
for 1974, 1977 and 1983.
Tables 3-38, 3-39 and 3-40 list dye and chemical container and
potentially hazardous container residuals wastes for 1974, 1977 and 1983,
respectively.
Sludge quantities and its potentially hazardous constituents
amounts appear in Tables 3-41, 3-42 and 3-43 for 1974, 1977 and 1983,
respectively. Because there is little or no change anticipated in textile
wastewater treatment in 1977, it was considered valid to relate sludge
3-72
* The reader is cautioned that no waste products from the textiles
industry have been demonstrated to be hazardous by this study.
EPA reserves its judgments pending a specific legislative mandate.
-------
Table 3-36
Category G - Yarn & Stock
Dyeing & Finishing
Sludge Analyses
(mg/kg of dry sludge)
Parameter
Drinking Water
Limit* (ppm)
Ranc
(1)
,(2)
Arsenic
Barium
Cadmium
Chromium
Cobalt
Copper
Iron
Lead
Manganese
Mercury
Molybdenum
Nickel
Zinc
Total Heavy Metals
Aluminum
Magnesium
Potassium
Sodium
Strontium
Total Chlorinated
Organ ics
Suspended Solids (%)
Total Solids(%)
0.05
1.0
0.01
0.05
**
1.0
0.3
0.05
0.05
0.002
**
**
5.0
**
60.0
**
**
**
0.7
**'
**
V,
<0.01-<5
<0.1-<50
<0.01-<5
24.4-38
<0.05-<24
105-423
605-2,715
<25
<2.5
31
12
264
1,660
<25
66
0.66
50
12
1,505
3,656
1,320
3,590
4,770
359,000
40
40.1
0.015
0.165
(1) Range of the individual plant averages
(2) Grand average of 8 measurements from two plants
(3) Less than values were considered to be at the :naxirr;um in computing totals
* U.S. Public Health Service. Drinking Water Standards. 1962
No drinking water standards have been set for these metals
**
3-73
-------
Table 3-37. Category G - Estimated Quantities of Total Waste from
Yarn and Stock Dyeing and Finishing Operations
(KKG/YR)
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michiqan
V Minnesota
IV Mississiooi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Harp.nshire
II New Jersey
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Pennsvlvania
•I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III Virginia
X Washington
III West Virainia
V Wisconsin
VIII Wvominq
TOTAL
Region I
II
III
IV
V
VI
VII
VIII
IX
X
Dry
687
' 687
529
3, 600
687
181
181
1,679
91
181
434
2,420
3,240
7,460
348
9)
91
2,770
2,160
l!566
687
181
181
30,132
4,983
5r660
2,951
14.181
1,037
91
181
687
91
1974
Wet
1,646
1 ,646
1,211
8.450
1,646
428
428
3,948
219
428
1,032
5,820
7,670
17,570
812
219
219
6.590
5,157
3,732
1,646
428
428
71.367
11,770
13.490
7.018
33.472
3,105
219
428
1.646'
219
1
Dry
724^
724
565
3.840
724
192
192
1,794
98
192
458
2,550
3.470
7.930
372
98
98
2,900
2^290
1,681
724
192
192
32,000
5,299
6.020
3,092
15.091
1,386
98
192
724
98
977
Wet
,755
1,755
1,318
9,000
1,755
450
450
3,967
231
450
1,097
6,160
8,110
18.660
857
231
231
7,030
5,486
3,957
1,755
450
450
75,599
12,318
14.270
7,480
35,571
3,293
231
450
1.755
231
Dry
1,462
1,462
,133
7.560
1,462
389
389
3,550
190
389
934
5,130
6.880
15,860
743
190
190
5.990
4,660
3,336
1,462
389
389
64.139
10,$66_
12r010
6,379
30.069
2,784
190
389
1.462
190
1983
•Wet
^,412
4,412
3,353
22.560
4,412
fTl69
1.169
10,550
566
1.169
2,814
15.630
20,780
47,565
2,213
566
566
18.190
14,060
10,236
4,412
1,169
1,169
193.137
3 Ir946
36.410
19,359
90,349
8,360
566
1.169
4,412
566
3-74
-------
Table 3-38. Category G - Quantities of Potentially Hazardous Dye and
Chemical Container Wastes from Yarn and Stock Dyeing and
Finishing Operations, 1974 (KKGAR) Dry Weight*
Hazardous Hazardous Total Potentially Total
Dye Residual Chemical Residual Hazardous Hazardous'
Container Dvestuff Container Chemienls Waste Constituents
IV Alabama
X Alaska
IX Arizona
VI "Arkansas
IX California
VIII Colni-oiio
I Connecticut
III Dol
-------
Table 3-39- Category G - Quantities of Potentially Hazardous Dye and
Chemical Container Wastes from Yarn and Stock Dyeing and
Finishing Operations, 1977 (KKGA*) Dry Weight*
JV Alabama
X AJei:;k;.
Vl Arkan:;^;
IX CiOitc.rnia
VIII Colo.-v.do
1 Connecticut
III Do] av.-aro
IV Florida
IV Gr-or'ii.a
IX Hawai.-
X Idaho
V Illinois
V Indiana
VII lov.'a
V3 1 Kr.nKns
IV Kentucky
V"I Louisiana
I Maine
Mary tana
I Massachusetts
V Michigan
V Minnesota
IV Miscissiis»i
VII Missouri
VIII Montana
VII Nebraska
IX Nevnr.a
I New l-niTir-.sliire
II New Jersey
VI Nev; Mc-::ico
II Nev; York
IV North Carolina
VIII North Dakota
V Ohio
Vl Okla'iona
X Orcr-on
III Pennsylvania
I Rhode Island
IV .South Cr.ro.l ina
VIII South LYilrotn
IV Tennessee
VI 'J'exar-
VIII Utah
I Vermont
III Virginia
X Wanlnnatcn
tIT VJofjt: \7ivninia
V Wisconsin
VJII WVOlV.ilKJ
TOTA)..
Rofjjon I
n
III
IV
V
VI
VJ'I
V.ill
~ I"
X
Dye
Container
Ji
3.-5
27
180
35
9.2
9 "L
84
4 7
9 2
22
160
380
17
4.7
4.7
140
1 10
Rl
35
9.2
9.2
1,531.1
252.2
290
149.7
720.9
4"i.9
4J
9.2
35
4,7
Hazardous
Residual
Dyestuff
._JQJ»] ....
_jum.
0.062
0.41
0.081
0.021
0-021
0-19
0.011
0.021
n.nsi
0,'9
n 3H
O.R7
0.040
0.011
0.011 .
n IT
0.2S
0.18
0.081
0.021
0.021
3.515
O.o7 !
0.351
1 TA43
0.153
0.011
0.021
0.081
0.011
Chemical
Container
J?..
.._.. 8?
68
460
53
n
210
\7
23
56
320
410
950
45
12
12
360
280
200
89
23
23
3.866
637
730
383
1B11
169
12
23
89
.. 12
Hazardous
Residual
Chemicals *
0.81
"0.81
0.62
__
0 81
"TTTfl
0 91
1.0
0.11
0.21
. n.51
2.9
3.B
B.7
0.40
o.n
0.11
1 1
2.5
1.8
0.81
0.21
0.21
35.15
5.74
6.7
3.51
16.43
1.53
0.11
0.21
0.81
0.11
Total Potentially
Hazardous
Wastes
— ^5WI I
TCO9T
95.682
OT3T
124.891
323TI
32.431
296.09
16.821
32.431
78.561
453.19
574.18
1,339.57
62.44
16.821
16.821
503.63
392.75
282.98
124.891
32.431
32.431
5,435.765
895.514
1,027.37
536.061
2^549.273
236.583
16.821
32.431
124.891
16.821
Total
Hazardous
Constituents
1 oTsvi
on
0.682
' 4.51
0 891
ton
0.231
2,09
0.121
0.231
0.561
57T9
4.18
9.57
0.44
0.121
0.121
3.63
2.75
1.98
0.891
0.231
0.231
38.665
6.314
7.37
3.861
18.073
1.683
0.121 -
0.231
0.891
0.121
Dry Weight = Wet Weight
3-76
-------
Table 3-40. Category G - Quantities of Potentially Hazardous Dye and
Chemical Container Wastes from Yarn and Stock Dyeing and
Finishing Operations, 1983 (KKG/YR) Dry Weight*
IV Alabama
X Alaska
IX Arizona
VI Arkannau
IX CaJ.iforni.-.
VI 1 1 Colorado
I Connecticut
Til Delaware
IV Florida
TV (Jc'orcia
IX Hawaii
X Idaho
V Illinois
V Indiana
Vil Iowa
VII Kansas
IV Kentucky
VI Louisiana
1 Maine
III Maryland
I Massachusetts
V Michiqan
V Minnesota
IV Mxacicsiopi
VII Missouri
VIII Montana
VII Nebraska
TX . Nevada
I New llar.-3Hh.ire
II New Jersey
VI New Mexico
II !!sv Vor!;
IV North Carolina
Vlli North Dakota
V on io
VI Oklahoma
X Orcqon
III l-'nr.isvl v ci r. i ?x
I Rhode Is. Land
IV Soutn Carolina
VIII South Tahota
TV 'i'ennessee
ty! Voxas
Oil I Utah
T Vermont
YTT VJ rqinxa
X" Washirictoii
f't'l Kent Virginia
V Wisconsin
VIII T'K'bminq
TOTAL
Bogipn I
ii
1 1 1
IV
• v
— vi
VII
-vfii
:ix
x . ...,. , ,
Dye
Container
4' - -
A?
32
220
42
11
11
mo
5.6
11
27
150
190
460
20
, fi.f,
5.6
] 160
: wo
96
42
11
11
1,824.8
300
340
171
871
78.6
. 5^.
11
42
. 5.6
Hazardous
Residual
,Dyestuff
0 (VPA
0.096
0.073
0.49
0.096
0.025
0.025
0.23
0.013
0.025
0.061
0.34
0.46
1.0
0.048
0.013
0.013
0.39
n.M
0.22
.. 0,096_
O.OM
0.025
4-160
0.689
0.80
0,415
1.927
0.182
0.013
0.025
0.096
. 9,013
Chemical
Container
nn
110
81
540
lib
28
26
250
14
28
67
380
490
1100
53
14
14
430
330
._. 240
110
28
28
4,583
756
870
458
2128
205
14
28
no" ™
14
Hazardous
Residual
Chemicals
0.96
0.96
0.73
4.9
o:96 "
0.25
0.25
2.3
Ojl3
0.25
6.61
3.4
4.6
10
0.48
a is
0.13
3.9
3.0
2.2
0.96
0.25
0.25
41.60
6.89
8.0
4.15
19.27
1787
0.13
U.i!5
U.V6
0:13 •
Totat Potentially
Hazardous
W™K.
153.056
153.056
113.803
765.39
153.056
39.275
39.275
352.53
19.743
39.275 '
94.671
533.74
685.06
1,571
73.528
19.743
19.743
594.29
463.3
338.42
153.056
39.275
19 775
6r453.56
1,063.579
1,218.8
633.565
3rO?0.197
285.602
19.743
39.275
153.056
19.743
Total
Hazardous
Constituents
1.056
1.056
0.803
5.39
1.056
0.275
0.275
2.53
0.143
0.275
0.671
3.74
5.06
11
0.528
0.143
0.143
X.29
3.3
2.42
1.056
0.275
0.275
45.76
7.579
7^79
8.8
21.197
2.002
0.143
"' U.2/5
1.056
0.143
Dry Weight « Wet Weight
3-77
-------
Table 3-41. Category G - Quantities of Potentially Hazardous Wastewater
Treatment Sludges From Yarn and Stock Dyeing and Finishing
Operations, 1974
IV A..abama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
Vl Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississicoi
VII Missouri
VIII Montana
Vll Nebraska
IX Nevada
I New Hampshire
II New Jersey
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
k Oregon
III Pennsylvania
I Rhode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III Virginia
5c Washington
III West Viroinia
V Wisconsin
VIII Wvomina
TOTAL
Region I
II
III
IV
V
VI
VII
VIII
IX
X
RETAINED SLUDGES (KKG)* (NO WASTED SLUDGES)
Total Pot. Haz. Wastes
Dry .3
fx 10 J)
4.3
4.3
3.3
22
4.3
1.1
1.1
10
0.56
1.1
2.7
!.<;
20
46
9.1
n.56
0.56
17
14
9.8
4.3
1.1
1.1
186.28
31.1
35
18.1
87.5
ft. 06
n 56
1.1
4.3
n <;A
Wet
?9
_22
22
150
29
7.5
7.5
69
3.8
7.5
18
100
130
310
14
3.8
3.8
120
91
66
79
7.5
7.5
1254.9
207.5
230
177.5
591.5
54.3
3.8
7.5
29
3 R
Total
Heavy
Metals
fx 1CT6)
16
lo
12
79
16
4.0
4.0
36
2.0
4,0
9.7
54
72
160
7.6
2.0
2.0
61
50
35
16
4.0
4.0
666.3
111.7
126
65
310
29\6
2.0
4.0
16
? n
Total
Chlorinated
Organic?
fx i(T)
170
17O
l/u
130
880
170
44
44
400
22
44
110
600
800
1.800
84
22
22
680
560
390
170
44
44
7,4m
1,244
1 400
724
3 454
320
22
44
179
22
Dyestutf
fx 10" 3)
0.22
0 22
0.16
.1
0.22
0.055
0.055
0.50
0.028
0.055
0.14
0.75
1.0
2.3
0.10
0.028
0.028
0.85
2' 7&
0.49
0.22
0.055
0.055
9.329
1.555
1.75
0.905
4.385
0.403
0.028
0.055
0.22
0.022
Total
Hazardous
Constituents
(x 10-6)
236
236
i72
1.180
236
59
59
536
30
59
149.8
805
Ir073
2r462
107.7
30
30
912
751
525
236
59
59
lo,002.5
1,667.8
1 87fi
971
4698
432.7
30
59
236
30
•See Table 3r8 for definition of retained and wasted sludge.
3-78
-------
Table 3-42. Category G - Quantities of Potentially Hazardous Wasrewater Treatment Sludqes
from Yarn and Stock Dyeing and Finishing Operations, 1977
IV Alabama -
X Alaska
IX Arizona
VI Arkansas
IX Ca l.r torn in
VIII CoJ.ora-lo
I Conno.cti.cut
III Delaware
IV Florida
IV Georqia
IX Hawaii
X Idaho
inois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Marvlsnd
I Massachusetts
V Micliiaan
V Minnesota
IV MississiorTT
VII Missouri
VIII Montana
VII Nebraska '
IX Nevada
I New Hanoshire
II New Jersey
VI New Mexico
II New VorK
IV NortlT Carolina
VIII North Dakota
9 Ohio
VI Oklaho:™
X Oreqon
III Pennavlvariia
I Rhccle Inland
IV South Carolina
IV Tennessee
VI Texas
VIII UtaR
I Vermont
III ' Virginia
X Washinaton
III Nest Virginia
V Wisconsin
VIII Wyoming
TOTAL ,
Reefion I
II
in
IV
• ' v '
v.c
VII
viii
• IX
x~
RETAINED SLUDGES* (KKG)
(NO WASTED SLUDGES)
Total Pot. Haz. Waste
Total Dry
(* 10-3t
.4.6
4.6
3.5
2'J,
4. A
1.2
1 2
0,59
.1.2
2.9
"21
49
22
0.59
JL5.9.
15
_15.
10
4.6
.1.2
T2
217.57
.31,6
.37
19.7
.92,4
28.30
0 19
1.2
4,6
n so
Total Wet
31
31
23
160
31
8.0
g O
.. Ai
1.4.0
.8.0
"19
.110. ,.
~140
330
15 '
Q.O 1
u.o
130
96
JO
Ji
To
IJE>__
1,342
219
.250
J38
630
58
4
5
—
[A
Total
Heavy Metals
(x 1CT6)
17
17
13
84
17
4.2
— 28
2.1
4.2
~~T5
57
76
170
" 8.1
2.1
2.1
65
53
37
17
.
4.?
4.2
706.4
118.?
133
-8&—
31.4
9 1
4.2
17
Lij _|
Total Chlor-
inated Organics
•(x 10"9)
180
180
140
930
180
47
y=
__422
23
47
I"1 120 1
640
850
1800
—59
2j
23
720
590
410
180
47
47
7^733
1 317
L490
_Z6Z_
3,547
339
23
47
180
23
Dyestuff
(x 1CT3)
0.23
0.23
0.17
1.2
0^23
0.058
0.058
Q.S3
~ "0.030
0 058
" 0.15
0.80
).)
2.3
0.11
0.030
0.030
0.90
0.74
0.52
0.23
0-058
"0.058
r 9.82
1.648
1.9
0.958
4t53S
0.428
0.030
0.05"5
6.23
0.030
Total Hazardous
Constituents
(x 10-3)
0.247
0.247
0.183
1.26-5
0.247
0.062
.568
0.032
0.062
GV160
0.858
1.177
2.47"
0.118
0.032
0.032
.. 0.966
&
0.247
0.062
0.662
"10.53
1.767
2.035
1.028
4.868
0.459
6.062
' 0.247
0.032
See Table 3-8 for definition of retained and wasted sludge.
3-79
-------
Table 3-43. Category G - Quantities of Potentially Hazardous Wastewater
Treatment Sludges From Yarn and Stock Dyeing and Finishing
Operations,* 1983 (KKG/YR)
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois .
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michiaan
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I New Hampshire
II New Jersev
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
Ifl Pennsylvania
I Rhode Island
IV South Carolina
VIII South Dakota
TV Tennessee
VI Texas
VIII Utah
I Vermont
III Virginia
X Washington
III West Virginia
V Wisconsin
VIII Wvoming
TOTAL
Region I
II
III
IV
V
VI
VII
VIII
IX
X
Total Potentially
Hazardous Wastes
Dry
590
•
590
460
3.000
•590
160
160
1 400
74
160
3RD
2,100
2,800
A;500
300
74
74
2,500
1,900
1,400
590
160
160
26,122
4,300
4,900
2X660
12,240.
1,124
74
160
590
7 A
Wet
(x IOJ)
236
2.36
1.84
12
7.36
0.64
0.64
5.6
0.296
0.64
1.52
8.4
11.2
26
1.2
0.296
0.296
10
7.6
5.6
2.36
0.64
l
0.64
104.488
17.2
19.6
10.64
AH QA
4.496
0.2?6
0.64
2.36
f],?96.
Total
Heavy
Metals
2.1
2,1
1.6
11
21
0.58
0.58
5.0
0.27
0.58
1.4
7.6
10
23
1.1
0.27
0.27
9.0
6.8
5.0
2.1
0.58
0.58
93.61
15.38
17.6
9.58
,43.78
4.05
0,2,7
0.58
2.1
0.27
Total
Chlorinated
Organic*
(x 10" 3)
24 1
_24
18
120
24
6,4
6.4
56
3,0
6.4
15
84
110
260
12
3.0
3.0
100
76
56
24
6.4
6.4
1.044
171.4
194 ,
106.4
490,4
45.4
3.0
6,4
24
3.0 '
Dyestuff
30
30
23
150
30
8.0
8.0
7«>
3.7
8.0
19
100
140
320
15
3.7
3.7
120
95
70
30
8.0
8.0
1,293.1
215
240
128
*na
56,7
3.7
8.0
30
3.7
Total
Hazardous
Constituent
32.1
32.1
24.6
161
32.1
8.59
8.59
75.1
3.97
8.59
20.4
107.7
150
343
16.1
3.97
3.97
129.1
101.9
75.1
32.1
5.59
8.59
1,387.26
230.59
257.7
137.69
6.5.1,89 .
60.76
3.97
8.59
32.1
3.97
*lt was not possible to differentiate between the retained and wasted sludge for 1983, so
the estimated values for this year reflect the total quantity.
3-80
-------
quantities to production. Hcwever, it is anticipated that 1983 regulations
will bring about a change in methods of treatment. Ihe best estimate of
the effects of 1983 legislation was found in the report prepared for the
National Commission on Water Quality entitled "Textile Industry Technology
and Costs of Wastewater Control" (10). The figures for sludge generation
in 1983 were based on the projected figures from this report. It was not
possible to differentiate the amounts of retained and disposed of sludge
for 1983 so the estimated values for this year reflect the total amount.
3.5 Total Waste Quantities in the Textiles Industry for 1974, 1977
and 1983 ~~ " ' ~
To properly interpret data in the tables of this section, the
reader should be aware that not all digits are significant figures. Digits
beyond the first two significant figures were entered simply as an aid in
totalling columns, and should not be construed as having a higher degree
of accuracy than is actually the case.
The estimated quantities of total wastes generated by the textiles
industry for 1974, 1977 and 1983 appear in Table 3-44.
Total container wastes and potentially hazardous container residuals
for 1974, 1977 and 1983 appear in Tables 3-45, 3-46 and 3-47, respectively.
It should be noted that by cleaning the residual from these containers, this
entire waste stream could be quickly, simply, and inexpensively rendered
innocuous.
Total sludges and their potentially hazardous constituents for
the years 1974, 1977 and 1983 appear in Tables 3-48, 3-49 and 3-50,
respectively. Again, the best estimate of the effects of 1983 legislation
was found in the report prepared for the National Conndssion on Water
Quality entitled "Textile Industry Technology and Costs of Wastewater .
Control" (10). The figures for sludge generation in 1983 were based on the
projected figures from this report. It was not possible to differentiate
the amounts of retained and disposed of sludge for 1983 so the estimated
values for this year reflect the total amount. Tables 3-44 through 3-50
were generated by simple addition of the quantities in corresponding
tables found in Section 3.4 of this report.
3.6 Rationale for Determining Waste Streams for Technology and
Cost Analysis
The land-destined waste streams considered potentially hazardous
in this study are the textile dyeing and finishing plant Wastewater
treatment sludges, the dye containers with residual dyestuff and the
chemical containers with residual chemical.
3-81
-------
Table 3-44. Estimated Quantities of the Total Wastes Generated
by the Textiles Industry
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illinois
V Indiana
VII Iowa
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississipoi
VII Missouri
•VIII Montana
VII Nebraska
IX Nevada
I New Hampshire
II New Jersey
VI New Mexico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Pennsvlvania
I Khode Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont
III Virginia
X Washington
III West Virginia
V Wisconsin
VIII Wvoming
TOTAL
Region I
II
III
IV
V
VI
VII
VIII
IX
X
1974
Dry
5,474
953
10,590
220
3,28H
179
5,379
36,417
64
4,019
861
417
240
1,096
440
2.307
20,541
1,549
1,288
1,133
541
50
400
2,121
24,988
100
33,630
58.776
3,224
1,197
1,4971
23 3821
23,8991
7,316
9,883
530
708
3.809-
889
214
310.173
38,328
52,618
28,193
151,090
11,763
12,573
1.598
800
10.590
2,450
Wet
78,194
2,587
13.814
1,055
38,674 +
3.562
18.363
184,426
67
42,811
5.850
651
1,831
6,380
451
14.266
232,155
5,244
3,252
4.430
3.275
50
400
13,079
154,060 __.
100
90.270
340.621
24,837
4,6-54
2,496 +
37,466 +
464.908 +
?4,632
94,795
773
4.387
20.701 +
1.116
217
2.098.575
353,689
244,330
70.915
1.215.954
85,172
• 02,587
fi.157
1. 880
13.814
3.680
1977
Dry
5,^38
1,093
1 1 ,980
240
3,487 +
194
5.905
42,249
70
4,339
965
437
261
1,236
481
2.364
21,147
1,691
1,386
1.237
583
55
438
2,204
26.446
109
36.547
63.675
3,524
1,3/58
1,571+
25.383+
25.865+
8,032
10,134
590
743
4.112
955
234
336.274
39,633
56,992
30.588
165.737
13.073
13.174
1,719
884
11.980
2.596
Wet
84,757
2,841 1
15.509
1,145
40,884 +
3.774
19.881
201.172
74
45,193
6.255
, 673
1,953
6,846
492 ^
14.532
236,850
5,586
3,458
4.731
3.427
55
438
13,900
165,728
109
96.395
366,313
26,140
5.031
2,572 +
40.372 +
496.824 +
26,441
97,040
835
4.621
22,029 +
1,183
238
.221.399
358.924
262,122
76.133
,300.439
89.999
105.513
A 491
9(134
15.509
3,835
1983
Dry
1,045
1,789
19.601
297
6,4091
294
7.970
78,358
119
6,750
1. 45 1
864
356
2,492
722
5.226
29,351
2,699
1^2251
1.725
912
65
521
4,636
33,682
130
53.218
107,643
5,509
2,231
2,8271J
39.618+
45.61 H
13,405
10,203
1,123
1,384
7.21 1+1
1,370
314
533.602
59,930
86,900
47,999
274,844
20,796.
15.076
?/,
-------
Table 3-45. Total Quantity of Potentially Hazardous Dye and
Chemical Container Wastes Generated by the
Textile Industry, 1974 (KKGA&) Dry Weight*
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Color&cio
I Connecticut
III Delaware
IV Florida
IV Georgia
IX Hawaii
X Idaho
V Illxnois
V Indiana
VII lown
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII. Nebraska
IX Nevada
I Now Harr-.pshiro
II New Jersey
VI Now Mexico
11 New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Orotfon
III Pennsylvania
I Khotie Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont.
Ill Virginia
X Washinaton
III West Virginia
V Wisconsin
VIII Wyoming
TOTAL
Region I
:ri
III
IV
V
VI ^~,
VII
VIII
IX '
X
Potentially Hazardous Dye
and Chemical Containers
280
•5
170
1
180
5
39
IfW)
2
180
9
12
3
52
5
120
15
650
23
36
12
35
140
780
830
^^4U
110
25
49
690
/ 30
1090
230
86
10
'ii
120
9
2
53
9910
1550
1610
830
5100
AlO
120
50
10
W-
W
Hazardous Constituents
4.6
0.1
1.2
0.04
?-4
6.17
0.68
13
0.004
2.8
0.26
0.08
0.08
0.51
0.01
1.3
0.43
10
0.3
0.29
0.18
0.35
1.4
10
7.5
25
1.6
0.3
0.39
4.8
3.4
25
1.9
1.9
0.08
0.3
0.63
0.07
0.004
0.4
123
19
18
6
70
6
2_
"0-.51 '— "H
0.1
J
_ (L-t
Dry Weight - Wet Weight
3-83
-------
Table 3-46. Total Quantity of Potentially Hazardous Dye and
Chemical Container Wastes Generated by the Textiles
Industry, 1977 (KKGAR) Dry Weight*
Potentially Hazardous Dye
IV Alabama
X A In. ska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Connect: Jct.it
III Delaware
IV Florida
IV Gc:orqia
IX Hav/aii
X Idaho
V Illinois
V Indiana
VII Iov;a
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I MasGcichunetts
V Mj.chican
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX Nevada
I Nf>v,' iiT^.nsh.ire
II NOV.' .Jersey
VI NT,.- Mtjxico
II Mow York
IV North Carolina
Vo.ll i-iorth Dakota
V Ohio
VI Ok.Tahoma
.X Orcqor.
Ill Pennsylvania
I Rhone isJ.anci
IV South Carolina
VIII. South Dakota
IV Tennessee
VI Te?:ns
VI 11 Utah
I Vermont
III Virginia
X Washihqton
III \7c.it: Virqinia
V WJ.rsnonsin
VIII Kyor.iing
TOTAT,
Region I
II
III
IV
V
vi
vti
VI. 1 1
IX
X
and Chemical Containers
300
4
6
190
1
190
6
42
1150
0.2
190
10
12
3
55
6
120
16
680
23
38
13
36
150
730
870
2480
no
28
51
730
470
1 160
240
90
10
22
120
9
2
55
10,414
1630
1600
870
5440
430
130
52
""12
190
60
Hazardous Constituents
4.8
O.ll
1.2
0.04
2.6
0.18
0.72
13
0.004
2.9
0.27
0.08
0.14
0.54
0.01
1.4
0.45
11
0.31
0.35
0.20
0.37
1.5
11
7.8
26
1.7
0.32
0.40
5.0
3.6
' 26
2.1
2.0
0.08
0.31
0.60
0.07
0.004
0.42
130
20
19
6.2
74
6
2.5
0.5
0.1
1.2
0.5
Dry Weight a Wet Weight
3-84
-------
Table 3-47. Total Quantity of Potentially Hazardous Dye and
Chemical Container Wastes Generated by the Textiles
Industry, 1983 (KKG/YR) Dry Weight*
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX California
VIII Colorado
I Conn Qoti cut
III nrjlnv.Mre
IV Florida
IV Goorqia
IX Hawaii
X Idaho
V Illinois
V India nci
VII Iowa
VII Kansas
IV Kentucky
VI Jjouisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Micsisniopi
VII Mis;;ouri
VIII Montana
VII Nebraska
IX Nevada
I Hew HaTnn«5hi.rc
JI New ijGrscv
VI New T'oxico
II New York
IV North Carolina
VIII North Dakota
V Ohio
VI Oklahoma
X Oregon
III Pennsylvania
I Rhocto Island
IV South Carolina
VIII South Dakota
IV Tennessee
VI Texas
VIII Utah
I Vermont.
Ill Virginia
X Kashinciton
III Nest Virginia
V Wisconsin
VIII Wyoming
TOTAL
Reqion I
II
•III.
IV
V
VI
V.I I
V 3. 1 1
IX
X
Potentially Hazardous Dye
and Chemical Containers
360
' IU
240
2
220
7
49
1460
2
240
13
13
3
69
7
130
18
790
26
43
16
44
170
960
880
2910
130
35
54
850
540
1380
290
110
12
23
150
^
2
65
12.332
1873
1840
1027
6534
517
162
60
14
240
65
Hazardous Constituents
5.8
0.14
1.6
0.05
3.0
0.21
0.87
16
0.005
3.5
0.33
0.08
0.11
0.65
0.01
1.5
0.54
13
0.35
0.35
0.23
0.43
1.7
13
9.3
30
2.0
0.39
0.42
5.8
4.2
. 32
2.4
2.4
0.09
0.34
0.74
0.07
0.005
0.48
154
23.4
22.1
7.4
88.1
7.1
3
0.6
0.2
i!6 '
0.5
Dry Weight » Wet Weight
3-85
-------
00
o\
IV Mabana
IX Ari/cn-i
VI Ar!:;;r.:.is
IX cSTltorria.
VIII Coloru.-lo
I Conr.'jcjuicut
III Dcl-.-.-.-aro
IV tier i'_.-.
IV Goorr-'ia
Tx Hav.-aU
V Illir.iis
V Ir.dTSna
VTr low.
VII Xuisas
VI Louis -c.r.a
I Mair.c
I .".assr-.v-sctts
V Mir.r.csata '
IV Hissisrinoi
VII Kissoori
VII ircijroska
IX i:ev.iv;-.
I N=t.- !-:-:-.r.>ihire
II lit'-' J^rsev
VI i:cv: ::7::ico
IV i,or+.lt Cv'olina
VIII Uoi-r..*. ca.-.ota
V b:iio
VI dk'3.'.-.j:o?3
X Ol"-D-l
111 P»r.n."-iv3nis
IV So".r.h Carolina
VIII so-.:rh Ds-tota
IV Vanr.sssoc
V~i f£5S3
VIII Ufa>.
I Vex -one
III Viiair.ia
X i-'apru nwton
III V;c^t; .-ir^ir:.ia
V Kiscor.cin
VIII Kyor.i.-.y
TGT/U,
Real or. I
II
III
IV
V
Vi
VII
VIII
IX
"X
Table 3-48. Total Quantity of Potentially HoIOrdo« W«rewater Treatment
Sludges Generated by the Textiles Industry, 1974
Total
Dry
~O7 —
0.018
~6.V7 '
0.0076
_JL3_7+
0.031
0.21
1.82
0.39
0.05
0.022
0.02
0.1 1
0.03
~o.n
0.09
3.5
0.04
0.06?
0.07
.0,024.
0.14
1.44
1.23
5.9A
0.24
..0.0 45_
._fl.au5
Q.72jt-
JLJ.fi +
4.75 +
0.5y_
J.3»
0 007
0 04
_£L37 +
^QOQ6_
0_01
0.08
-»:?
i.3_
2.?
.ill
_15J3__
-H-
0 (V,
0.01
-QJR
,-l.OS ..
Total
Wet
"~I61
14.7
~T65
"""oTeT"
92.7+
3,5
33.6
970
1.5
74.1
10.8
10.6
1.7
34.9
~TZ —
-*b-
374
23.6
20.8
9.6
10.1
75.3
373
_3&]
1181
55.3
~2T78"1
33.3+
330 +
153 +
_ia.4+_
^??,i
13.7
1H
82.1 +
7.6
K5
26
5800
18QO
560
440
aim
170 I
2SO
1?
3
35
2flO
Total
Heavy Meta
Ix 10-3)
7.64
0.164
0.96
0.07
3.2+
0.29
15
0.05
3.4
0.14
0.78
~criz
1.0
0.75
23
0.37
0.42
0.22
1.14
13.3
8.22
4n 3
~O4
0.37
0.1+ .
4.38 +
1.25 +
41.4 +
8.17
0.023
0 3A
2.55 +
0.012
0 05
0.48
203.4
36
20
16
107
6.1
9 5
0.41
O.M8
1.2
7.1
Total Chlor-
inated Organic
fx 10-6)
30.9
0.3
8 9
0.11
B •»
0.47
8 24
47.5
n f.*,
8.1
-H4
0.22
-«"
H£
33.1
1.16
3 A
3.2
0.39
A R
45.A
55.9
5.72
1.22
0 A7 +
46.9 +
7.7 +
104 +
8.8
n 037
1.1
16.3 +
0 M
4.4
756.6
58
^00
23
or
1.5
0.2
4.6
2fi
Dyesruff
f» 10-3t
48.4
09
8.4
0.38
10 Of
I.A
10 6
91.1
0.5
19 3
74
1.0
0.75
-H —
S.4
4.3
74 1
2.2
3.5
3.7
1.3
7 •>
fl?.0
Al.S
293
~nj§
2.28
n A4
40
9.1
233
28.0
18.3
0.1
99
18.7
003
0.5
4.0
1117
198
1DR
86
59 1
33.7
en
7.7
0.4
6.7
39
Total
Hazardous
Const ftuen
jx_ir3)
56
i i
9.4
-Q^__
•>•> •) +
_US2___
17 1
irv,
n,*t5
77 7
•> R
1.1
0.89
-W
6.4
5.0
97 1
2.6
30
47
1.5
R 3
95 4
49.7
333
13.8
2^4.
0 74 +
44.3 +
10.3 +
274
26.5
0 17
2.5
0.042
0.55
4.5 .
1321
234
102
A9B
40
7 A
0.4_
8.0
4A
Total
Dry
610
14
14
7.2
29
110
1200
320
44
14
44
~P4
72 -
Hjp-
~~14
29
21
-froo-
440
2400
-&-
*
_65 +
65 +
3800+
40
..5900.
-2? ..
140 +
14
8,400
2,446,
—JiSCL
7706-
15^232+
— 601-
35
7 2
. 14 ...
OPP±.
Total
Wet
(x I03)
1.6
K6
0.84
34 +
3.4
13
140
_3B
-S,2
TT"
5.0
~?^
~C4
214
3.3
1.1.6
15
?3"ti
iO
270
&—
*
I_7.8 +
7.8 +
440 +
~T6
on
3.3
•Ut
1 A
1750
401
180
109.6 +
1033,34
4.1
0.84
-ioV-
VVAilt
Total
Heavy Metals
•m —
6.065
2.7 +
-w* —
_iJ!
0.41
0.13
0.41
~IT78
0.65"
_50
0.27
[0.13
0.27
0,20
^QZ2
-2V-
-A*
*
_0.61 +
576T+
3A +
^~O
31.8
13 +
0.13
121,000
71,436
TO
41.83 +
-&^
-T03
0.065
~67!3
U ILUOOti (KKG;
Total Chlor-
inated Orgonies
^,0-3,
0.21
~O^T
"0.11
1 4.4 +
0.44
.7
4.9
0.65
1 0.21
0.65
~T5
~n
27 1
0.44
_(L2J
0.44
~O5
T7
6.5 ~
3*
2.7
0.44
0.98 +
— U.98*
_ 58 +
271
11.8
0^44
2.1 +
— 5^1
23C
-40-32. _
73.S
13.72 +
136.09 +
9.1)
12^5
n 53
n 11 I
n.5i
"YR) "
Oyestuff
'36 J
~o^o
TC73
~os
14 +
5.5
60 ~
~i«
~5T5
O.70
~?:2
4.2
3.6
60
1.4
0.70
-4
~3l9
^*5
IM
~9T5
-4^
3.2 +
3.2 +
90 +
7.0
5
~T73
7.0 +
0-70
' 645 "I
86.7
7.7
15.7
416.1
_30
17.1
1.7
0.36 1
0.70
Total
Hazardous
Cor.stiruents
1O3
~C^3
U.595 "
1 16.7-f 1
T67
"5^3
~R
2.61
0(0
1 1
4. 98
3.95
110
1.67
-1.67
1 7
3.?7
"26.)
~OT
1.67
226 + !•
L8.3
1- 46.8
-*«±^
0.83
158.2
~9lTT '
57 +
«8 +
ToTo" I'
__49.3
-2.03
— OL-425___
0.83
* Data withheld due to Its proprietary nature
+ Waste quantities from Wool Scouring Operation! not included, see Table 3-2
** See Table 3-6 for definition of retained and wasted sludge
-------
TobU 3-49.
Estimated Total Quantity of Potentially Hazardous Waste
Sludges Generated by the Textiles Industry, 1977.
:water Treatment
IV AlaL»3r-i
X M».sy.n
IX Arizona
VI Arkansas
IX C^i ifornia
VIII Colorado
I COi*:'iecticuL
111 Uolavnre
ix — n^rn
X Idaho
V 111 inoin
V Indiana
VI I Jowrf
VII 1'ir.s-iS
IV Kc-ntuchy
VI Louisiana
I Maine
III .''arviand
1 ;'.issach;Asatts
V ?•;?. chiaan
V Kinr.esGta
TV r'.i K *. i s.~ .r nr>i
V.TI nfsscuri
VIII Montana
IX KovaiK
I >;ew -ij-.r'-.^nire
II !!c-vr Jersey
Vi IJov; Mexico
II i.e.'-: iork
IV i.crt.': .pvroiinci
VIII i:cj-:th Cal;o:a
V Ohio
VI Oitlahona
III PcTnF"lv5r.ia
I r.hcde Island
IV Sou^'n Carol inn
VIII £c-i-t.i Du!.ota
IV vcnncssea
VI Toxas
VIII Utah
I VGiT:Ort
III Virc:x::ia
X Karhincrton
III l-.tst Vir.iisiia
V Ivisisi.oih
VIII v:vc.sinij
TOT/.t.
Region I
11
III
IV
V
VI
VII
Vlli
IX
X
RETAINED SLUDGES (KKG) **
Total
Dry
~1
-0.02
-ft*H
0.37 +
0.03
0.22
1.9
0.01
, 0.39
0.05
_OJ22_
_2,02_
-J3J2
n m
0 11
0.09
3 5
0.04
. . 0.08.
0.03
I 0 n?
._fl_L5_-
1.7
1.3
A. 2
0.26
n rw
0 S3-
0.1?+.
i R +
JJ,58_
. 1.4
Q-Q02-
n.04
n 4 +
_Qjm:
0.01
n ns
.29
5.4
9 O
7 3
IA
0.9
J.S
n rv.
p 01
0. 18.
1.0
Total
Wet
" 160
" ~~
--S%-
96 +
3.5
36
1100
TT~
76
12
11
I,7 .
33
4 9
87
10
son
19
22
10
11
,Z5_.
.T50
410
1200
59
f-
360+
160+
71fH-
150
99
15
19
87+
8.1
1.6
7S
6300
814
RT1
473
-.3500
_223_
140
•>A
1A
200
49
Total
Heavy Metals
(x lO-3^
7.7
0.17
1.1
0.07
3.2 +
0.29
1.5
15
Os
3.4
0.44
0.12
0.14
0.8
Total Chlor-
inated Organic;
(x 10-')
32
(T32
9.6
0.11
8.4 +
0.47
9.1
49
" O9
8.3
0.75
1.5
. 0.22
5.1
017 I I.-)
1 1 2.1
0.75
73
0.58
0.45
0.44.
n n
T?
13
8.4
41
2.1
n ss
4.6 +
1.3 +
42 +
3.6
a •>
0.03
0.36
2.7 +
0.01
V-05
0 5
206
36
V)
13
lift
7.3
8.9
n •;
._DJ .
1.1
5.7
1.8
7A
1.2
3.8
34
0.4
5
48
59
260
•; o
1.3
50 +
8.1 +
110 +
31
9
0.05
1.2
17 +
Nil
0.69
4.6
790
60
107
72
498
25
13
1
0.2
9.6
2.7
Dyestuff
(x 10-3)
49
0.94 .
9.2
0.38
19
1.6
!1
94
0.53
19
2.4
1.1
0.75
A. 7
1.7
5.4
4.3
7S
2.3
3.7
3.8
1-3
__LJ
83
64
300
1?
2.4
50
9.4
240
29
18
0.12
2.2
20
n m
0.53
4.2
1150
117
147
68
732 .
44
23
3.1
0,5
9.2
1.2
Total
Hazardous
Constituent*
(x 10-3)
57
~T7I
"10
-sW—
T.?
12
no
~075S
23
2.8
1.2
0.89
6.8
1.9
6.5
5.1
98
Hfc
4.3
1.5
-2,8
97
73
340
14
2.7
47 +
11 +
600 +
33
_27
0.14
2.5
22 +
0 "4
0.58
4.7
1
1350
55
169
82
849
51
32
3.6
0.6
10
6.4
WASTED SLUDGES (KKG/YR) -•
Total
Dry
650
"is
— U> 10 VJ -
-O — — • .n
o o CO
1300
340
46
15
46
07
78
8600
31
~T5
30
23
~84
Total
Wet
(xlO3)
_ _Z8
~ XT
17
Oi]
36
3.6
14
im
40
5.3
1.7
5.3
in
9.1
214
-w—
as
2.6
~o —
1200 740
460
9^nrt
200
_30
72
72
4000
53
790
22
3.5
8.4
8.4
470
150 __ 17
5920 1 92
30
iin
15
39,100
12,500"
1660
3730
12,800
—6-46.. _
5965
38
7.8
15
1000 +
3.5
17
"1.7
' '1840
315
193
72
1070
74
97
4 2
0.9
i ^
10 +
1
Total
Heavy Metals
. _4
~ ~57T4
0.14
0.07
2.9
0.29
1.1
15
3.2
0.44
0.14
0.44
n KA
^
0.28
0 14
-m —
~DT3
n
. 4.4
24
1.8
"6.28
0.65
0.65
38
M
32
0.28
1 4
O.U
260
73
15
22
200
6
32
_r 0.35
0.07
n 14
9 +
Total
Chlorinated
Organics
(x 10-3)
_ 9.3
0.23 "
0.23_ ._.
0.12
47
0747
1.8
20
5.3
0.72
0 73
0.72
1 4
1.2
1 28
0.46
0 23
2.46 1
0 1A
~ T2
18 " ' "
I
Dyestuff
6~75
0.7S
0.39
16
TS
6 0
65
17
2 3
C 75
2$
4 6
3.9
60
"1.5
i'is
1-2
4.J
60
7.2 1 23
38 125
Total
Hazardo-js
Constituents
— 35
— 5~g?
0.89
0.44
19
1.2
7 ]
77
20
2 7
0 69
2 7
5 4
4.6
116
— rs
0 89
i. a
1.4
4.3
71
27
. u$.,..
2.9 10 12
0.4&
1.0
1.0
A?
2.3
1?
0.46
2.3
0.23 _ .
240
42
25
9
140 .
9.8
1--5
1.8
3.6 4.2
3.6 4.2
900
7.5
1A
""IS
7.5
0.75
68D
90
83
17
A An
v>
13 " 18
0.57 I 2
0.12 1 0.4
0.23 1 08
2+ 1
'32 i
— 8.5— f
43
1.8
8.9
0 PO
1
940
160
98
39
543
38
l\
2.3
0,46
0.89
9 +
Data withheld due to ih proprietary nature
See Table 3-8 for definition of retained and wasted sludge
Waste quantities from Wool Scouring Operations not included/ see Table 3-2
-------
Table .3-50 . Estimated Total Quantity of Potentially Hazardous Wastewater Treatment
Sludges Generated by the Textiles Industry, 1983
IV Alabama
X Alaska
IX Arizona
VI Arkansas
IX caJi 'orrilc;
VIII Colorado
I Cr>nn<- ;t.i.cut
III i)t.O.awai:e
IV Florida
IV Gco'x qia
IX Huv.-aii
X Idaho
V Illinois*
V Indiana
VII low;-,
VII Kansas
IV Kentucky
VI Louisiana
I Maine
III Maryland
I Massachusetts
V Michigan
V Minnesota
IV Mississippi
VII Missouri
VIII Montana
VII Nebraska
IX IJovaoc-.
I Now Msippshire
IJL Nev; Jersey
VI Nev; He::ico
II Mew York
IV Kot th Carolina
VIII North Dar.ota
V Ohio
VI Oklahoma" "
X Or
-------
3.6.1 Potentially Hazardous Waste Streams *
3.6.1.1 Wastewater Treatment Sludge
The first waste stream worthy of study is the sludge arising
from the treatment of textile mill effluents. Wastewater treatment
sludges are the most complex waste frcm dyeing and finishing mills, and
includes such components as heavy metals, adsorbed dyes and chemicals,
and chemical and biological solids. While this waste stream contains
some hazardous components (heavy metals, residual and adsorbed dyestuffs
and chlorinated organics), it also contains a significant percentage of
non-hazardous constituents, such as canton salt, sodium sulfate, and
chemical and biological solids.
Heavy metal concentrations present in wastewater treatment
sludges were found from samples in all categories except C, Greige Goods,
to exceed drinking water limits. The total heavy metals found in the
various categories range from 3,606 ppm in Yarn and Stock Dyeing and
Finishing to 20,990 ppm in Wool Fabric Dyeing and Finishing. Average con-
centration ranges for various metals of concern (see Section 3.2) found
in analyzed sludges are given below.
Fange of Average Drinking Water
Metal Concentration, ppm Limit, ppm
As <0.1 to <17 0 05
Cd 1.2 to <17 0.01
Co 4.2 to 212 0 2*
Cr 19 to 1,196 o!o5
Cu 18 to 652 10
Fe 1,000 to 5,200 0.3
Pb <25 to <170 0.05
Zn 106 to 2,370 5.0
* Limit for agricultural waters
The bulk of the heavy metals which end up in land-destined sludges
are washed or rinsed from fabric into the mill's wastewater treatment
system from such operations as scouring incoming greige goods, dyeing
cloth, and applying various finishes. The free metal ions may then be
adsorbed onto the biological (or chemical) sludge generated in aeration
ponds. Any metal which is structurally chelated within a dye is not
free to leach from the landfilled sludge unless degradation of the dye
occurs. Once this happens, however, the bound metals are released and can
leach through soils and eventually reach an aquifer or ground water.
•mere is "also the possibility of ion exchange occurring if free cations
such as Fe+ or Fe+3 are available. This further increases the probability
of other heavy metals reaching ground water supplies in significant
quantities.
3-89
* The reader is cautioned that no waste products from the textile
industry have been demonstrated to be hazardous by^this studv
EPA reserves its judgments pending a specific legLlaJive Sate.
-------
Dyestuffs are also considered a hazardous component of waste-
water treatment sludges because they present the environment hazards
cited in Section 3.2. These hazards include toxicity and non-bio-
degradability problems as well as the possibility of anaerobic degradation
of dyes in a sanitary landfill to toxic or carcinogenic intermediates.
Residual organics are also a hazardous component of textile
sludges.
The analysis of sludges for specific organic compounds was
beyond the scope of this study. However, total chlorinated organics were
identified. The analyses from all subcategories except C showed total
chlorinated organics present in sludges ranging in value from 0.11 to
64.7 ppm. The drinking water limit for total organics is 0.7 ppm, and
the average values for each category exceeded this limit. Since the
number and variety of these dyeing and finishing chemicals is so large
and in the light of the concern generated by recently completed and
ongoing studies (26, 27, 28) of organic compounds as wastewater pollutants,
we include these chemicals as being hazardous constituents found in
wastewater treatment sludges.
3.6.1.2 Dye Containers
The second land-destined waste stream considered potentially
hazardous is the dye containers and the residual dyestuff contained
therein. A discarded dye container carries approximately 28 to 56 g
(1 to 2 oz) of residual dyestuff to the disposal site, which_in these
industries is often a county or municipal landfill. The residual dye-
stuff which ended up in a landfill for the year 1974 amounted to 11.7 kkg,
and this figure is projected to increase to 12.5 kkg for 1977 and 14.8
kkg for 1983. The dyestuff component of this waste stream presents the
same environmental hazards cited in Section 3.2 (i.e., toxicity and bio-
degradability hazards and the possibility of anaerobic degradation of
dyes in a landfill to toxic or carcinogenic metabolites). Therefore, as
stated in Section 3.2, all dye-bearing waste streams are considered
potentially hazardous.
3.6.1.3 Chemical Containers
The third potentially hazardous waste stream includes chemical
bags or drums containing residual chemicals. Such items as dichromate
salts (oxidizing agents); sodium hydrosulfite (reducing and stripping
agent); zinc nitrate and magnesium chloride (catalysts); polyvinyl
chloride, tetrakis (hydroxymethyl) phosphonium chloride, chlorinated
paraffins and organic phosphorus compounds (flame retardants); silico-
fluoride compounds, sodium pentachlorophenate and phenylsulfonic acid
derivatives (mothproofing agents); and urea-formaldehyde, dihydroxy-
dichlorodiphenylmethane, mixture of zinc salts of dimsthyldithiocarbamic
acid, 2-mercaptobenzothiazole, and copper naphthalene (mildewicides) come
in bags or drums. Any of these materials which reach a landfill in dis-
carded packaging present a potential hazard as cited in Section 3.2, for
processing chemicals from dyeing and finishing mills.
3-90
-------
=-i4-QO -i ^ °f residual hazardous chemicals which reach landfill
sites in discarded packaging amounted to 111.7 kkg in 1974 and is SoScted
to increase to 117.4 kkg in 1977, and 139 kkg in 1983. BecSSe of Se
oSSc chStT 1StL°f ^ "** Dining Chemicals arTch?orSated
organic chemicals used in the textiles industry and known persistency and
fSSn^f CHtieS,°f ^ °f them' chemcafLntainerTw2e
a potentially hazardous waste stream warranting further study.
3.6.1.4 Other Potentially Hazardous Wastes
^ ,.- -M also found isolated and atypical instances of
potentially hazardous wastes such as solvent wastes and still bottom from
specialized processes and yarn and lint wet with non-fixS dye^d^e-aS
oFerations
Yarn and fiber wet with non-fixed dye and dye-assist chemicals
were found in one facility dyeing and finishing tufted carpets. SS^nly
other area where this could be a problem is yarn and stockdylng/^d no
evince was found that it is a problem. If this wet yarn a^int^s
corbined with other mill trash and sent to a landfill with no attempt
Sf^v6"0^ ^ss^e 1i?uor or chemical, the problem arises of the
SLon, S S ^T °? le^g t0 ^ landfi11 environment. For the
reasons cited in Section 3.2 pertaining to dyes and other chemicals, this
° hazardous aS will also be diseased Sin
In sumtiary, the following waste streams are considered poten-
tially hazardous for the purpose of this study:
chlorinated organic chemicals organics
Dye containers with residual dyestuff AEMI studies (14)
Water Standards for
organics
solvent and still bottom DOT Flashpoint Standard (100F) (25)
Drinking Water Standards for total
organics
Fiber wet with dye and dye-assist ADMI studies; Drinking Water
011611110918 Standards for total organics
3-91
-------
3.6.2 Non-Hazardous Waste Streams
Initially there was concern that waste dyed fibers and rags
from seam and selvage trim might warrant classification as potentially
hazardous in the event that the dye might leach into the landfill, posing
environmental hazards. Dyes, however, are generally formulated to be
lightfast and washfast. Industry contacts have indicated that when dye
is affixed to a fiber and no excess remains, only under contact with
chemical stripping agents, which is highly improbable in, a landfill,
might the fixed dye be leached or released from dyed fiber. Normal
acidic landfill conditions will not release affixed dye from fiber.
Fly, flock, and cotton dust, due to their fine particulate
natures, are usually handled and landfilled in containers such as
polyethylene or polypropylene bags or cardboard boxes. As a result, these
present little fire or explosion hazard during or after landfilling.
While it has been shown that increased exposure to cotton dust
has been associated with an increase in the prevalence of byssinosis in
textile mill workers (29), exposures for personnel involved with the
management of these wastes (landfill operators, waste collectors) are
both brief and intermittent. Ihe cotton waste handling and disposal
methods employed (containerized) reduce the risks of contracting byssinosis
even further. The possibility of harming human health through ingestion of
cotton dust was dismissed after contacting experts (30, 31) who reported
there is no evidence that any disease can be caused by ingestion of cotton
dust. In addition, the cellulosic structure of cotton is extremely bio-
degradable and the possibility of cotton dust in leachate from a landfill
reaching an aquifer is very slight. For these reasons, landfilled cotton
wastes are classified as non-hazardous.
There was also some concern about latex wastes because of the
position the state of Georgia (32) has taken on the handling and dispo-
sition of such wastes. A 1971 leachate study by Roy F. Weston (33) on
landfilled latex wastes showed a small percentage of dissolved zinc
(0.0039 per cent by weight of the dry latex cake). Thus a latex cake
dewatered to 30 per cent solids would have 1.3 ppm of zinc which could
leach from the cake under the stated study conditions. This is less than
the drinking water limit of 5 ppm for zinc. This leaching occurred under
the following conditions: the latex with a normal pH of 11.2 was sub-
jected to acid landfill conditions and 26 consecutive days of intimate
water contact. No subsequent studies have been undertaken to confirm and
expand this finding and, as such, the results are inconclusive. The
state of Georgia has taken a conservative stance and requires dewatering
and segregation of latex in a sanitary landfill (34) because of the high
concentration (60 per cent of production) of the carpet industry centered
in Georgia contributing significant amounts of latex wastes to state,
county, and municipal landfills. However, the state of California, for
example, does not consider latex wastes to be potentially hazardous.
3-92
-------
The problem of zinc in latex occurs only in natural and synthetic
latex foams using sulfur crosslinking for curing and requiring zinc oxide
as a curing aid. Latex foams represent about 18 per cent of the backings
used in the carpet industry. The amount of zinc oxide used is approximately
5 parts per 100 of dry latex. Thus, since the amount of zinc shown to leach
(1.3 ppm) is well within the drinking water limit, in the absence of any
conclusive leachate studies and the stance of other states on the subject,
we are considering dewatered latex to be non-hazardous.
For the reasons cited above, we are considering the following
waste streams as non-hazardous:
dry, dyed fabric, stock and yarn
flock fran itechanical finishing of cloth (shearing, sueding, etc.)
fly (including cotton dust) which may or may not be dyed, from
carding picking, spinning, weaving, knitting
rags f ran seam and selvage trimming
latex
3-93
-------
4.0 TREATMENT AND DISPOSAL TECHNOLOGY
4.1 Introduction
Land-destined potentially hazardous wastes from the textile
industry are of two principal types depending on their^igS - Socess
wastes, and wastewater treatarent wastes. Both types of wattes
S
-
ly hazardous process wastes consist mainly of residual
srs-
moisture content and are handled as part of plant trash. Y
in ther case t
. -, mgn ll* »n^jus>i_»^i-c u^uiucui. eve.
itrifuging and are handled separately from plant
Aside from moisture content, process wastes differ markedly
from wastewater treatment wastes: UJ-J-WMT nturKeoay
• Process wastes can be reduced or eliminated through housekeeping
Snn^9**1011 practi«* whereas wastewater treatment sSSS^
Cannot. -1
effluents contain some of the wastewater
PrOCeSS wastes «» ^^Hy ^ estimated
in general, neither type of waste is currently considered to be hazardous
by the textile industry. Therefore, the current treataentlnd dSSd
22nS^^^h^V±aflpoint' PrOCeSS wastes a^suSly^iSd
3^^
PrOCeSS wastes
*
4-1
-------
4.2 Waste Management Practices in the Textile Industry
The following waste management practices pertinent to land
disposal were found to be currently used in the textile industry.
4.2.1 Oontrol Practices
To avoid sending residual dyestuffs and chemicals to disposal,
many plants send returnable drums back to the supplier, others wash out
the drums. Waste lint, yarn and fabric containing excess dye solution are
sometimes segregated from other solid wastes and disposed of separately.
This segregation, while ret used for isolation of potentially hazardous
wastes, constitutes a first step in applying any future treatment/disposal
technology.
4.2.2 Lagoon Storage or Retention of Sludges
Wastewater treatment sludges are now being stored or retained
in the wastewater treatment systems, either in disposal ponds or in the
bottom of ponds or lagoons that are used for aeration and activated sludge
treatment. As this sludge builds up, it will eventually reach the level
where other storage or disposal will become necessary.
4.2.3 Land Dumping
Disposal by land dumping of both wastewater sludges and process
wastes is practiced by sate textile plants. Sometimes the dumping of sludges
is on-site. Usually process wastes go to local public facilities.
4.2.4 Land Spreading
Wastewater treatment sludges have some fertilizer value. Therefore,
these sludges in sane instances are being sprayed or spread on land. Various
techniques are used, often utilizing farm-type equipment or irrigation-type
spray units.
4.2.5 General Purpose Landfills
Some of the wasted sludge and most of the process wastes go into
general purpose landfills. General purpose landfills are characterized
by their acceptance of a wide variety of wastes, including garbage and
other organic materials, and usually by the absence of special oontaxrment,
monitoring, and leachate treatment provisions. General purpose landfills
are environmentally inadequate for disposal of hazardous wastes because
their use for this purpose may lead to contamination of both surface and
ground water in the area.
4-2
-------
4.2.6 General Purpose Approved Landfills
Only one instance was encountered where an approved landfill
was used for the disposal of potentially hazardous textile industry wastes.
A plant disposed of dewatered sludge in an approved landfill in EPA
Region III. An approved general purpose landfill is defined to neet the
following criteria:
(1) The composition and volume of each hazardous waste is known
and approved for site disposal by pertinent regulatory agencies.
(2) The site is suitable for hazardous wastes.
(3) Provision is made for monitoring wells and leachate control and
treatment if required.
The advantages of approved landfill sites include:
(1) Many potentially hazardous wastes may be disposed of in a
controlled and environmentally safe fashion.
(2) Approved landfills are more readily available than secured land-
fills.
(3) Disposal costs for transporting to the site and landfilling are
closer to those for general purpose sites than for secured
landfills.
General purpose approved landfills differ from general purpose
landfills in construction by having (1) an impermeable barrier to retain
leachate, (2) monitoring installations to make sure of the barrier inte-
grity, and, (3) leachate control and treatment facilities, if needed.
The following are types of general purpose approved landfills:
(1) Impermeable natural clay or rock basins .in dry climates where
leachate may be contained without collection, treatment or
disposal. These sites are usually found in the arid southwestern
and western parts of the U.S.
Impermeable basins lined with clay, asphalt, plastic, rubber,
concrete or other material in dry climates where runoff control
l a Tva/"*aeeav*r
(2)
is necessary
Many landfill areas currently labelled as "approved" do not
conform to the definition given above. All references to "approved land-
fills in this report pertain to facilities with the safeguards listed
and not to local terminology.
4.2.7 Incineration
A few textile industry plants incinerate process wastes. There
are two areas of potentially hazardous pollution involved in incineration
air pollution and contaminated ash containing dye and chemical carrier
4-3
-------
residues and leachable heavy metals. The Remissions probably do not
SfferVeatlv from those of incinerating municipal trash or activated
Sudoe since the dyes and chemicals usually constitute a minor portion
of the'wastes. Therefore air pollution abatement facilities of normal
™J^i itSTwill be required. However, ash from the incinerator will
nrobablv contain significant quantities of heavy metal contaminants, and
should be considered a potentially hazardous material. Disposal of the
E"~f
high costs of environmentally adequate incineration equipment and the high
cost of fuel.
4.2.8 Wet Oxidation
At least one plant is known to have installed a wet oxidation
process for treatment of wastewater sludge. This process, which uses
lS3d phase oSdSion of wastes at high temperatures and pressures, has
SfopeSS^Sexibility of achieving either partial or nearly conplete
oxidation, as needed. Wet oxidation reduces the ^mt^of jj.udge and makes
the remaining -1"-3 aa*^ ^ **iater. It also
biodegradable
components or
system makes the equips*
4.2.9 Reclaiming
either from still bottom or f ran
son inishing operations f'^SSS'^^S^
of the textile fibers. The solvent conponent of this atypical waste is
reclaimed by contractors specializing in waste recovery.
4.3 Current Hazardous Waste Management Practices
Table 4-1 summarizes the treatment and disposal practices currently
employed by the textile plants studied.
4.3.1 Category A - Wool Soouring
Category A plants do not generate dye and chemical container
wastes.
Three of the four plants visited have wastewater treatment
one of which sends their overflow from the sludge basin to
^ fourth plant discharges without treatment. Two
sludge have concrete lined retention basins.
4-4
-------
Table 4-1. Summery of Treatment/Disposal Practice* at Visaed Textile Plants
Category/
Plant
A-]
A-2
A-3
A-4
B-l
B-2
B-3
B-4
B-5
B-6
B-7
t D-7
Ul
D-2
D-3
D-4
t>-5
B-6
D-7
D-S
0-9
D-10
D-I1
D-12
D-I3
D-U
EPA
Region
IV
IV
III
1
1
1
1
1
1
IV
IV
IV
IV
IV
IV
1
1
IV
IV
IV
IV
IV
IV
IV
—
Disposal Sites
Discharge Containers Sludn.
TM« On Off On " ' r,«
Treatment NA NA
plus
municipal
Direct NA NA
Direct NA NA
Direct, no NA NA
treatment
Municipal x
Direct, no x
treatment
Direct x
Direct, no x
treatment
Municipal x
Municipal x
Direct x
Direct x
Direct x
Direct ' x
Direct x
Direct x
Direct x
Municipal x
Direct ~ x
Direct y
Municipal x
Direct x
Direct x
Municipal x
Direct x
X
X
NA NA
NA NA
Atypical
solvent
None wasted
NA NA
NA NA
NA NA
None wasted
X
None wasted
None wasted
None wasted
None wasted
None wasted
NA NA
X
NA NA
None wasted
None wasted
NA NA
X
Contractor
NA No
NA
NA
NA
Yes
No
No
No
No
No
Yes
No
Yes
No
Yes
Yes
Yes
Yes
Yes
Mo
No
Yes
Yes
No
Yes
No
No
NA
NA
No
NA
NA
NA
NA
NA
No
NA
NA
NA
NA
NA
NA
No
No
NA
NA
NA
NA
Yes
Type
Containers
NA
• NA
NA
NA
SLF
Dump
SLF
SLF
Dump
Dump
SLF
•— — — — — — — __
SLF
SLF,
Private LF
Private LF
SLF
SLF
SLF
SLF
SLF
SLH
SLF
SLF
SLF
SLF
SLF
•
of Site
Sludce
O.n-s^e
land?! lied
Cn-s''«
londfiHed
Comcony
owned
icrm
NA
NA
Dump
NA
NA
NA
NA
Dryirg bed
NA
NA
NA
NA
NA
NA
Legocn
SLr
NA
NA
NA "
NA
Form
-------
Table 4-1 . Summary of Treatment/Disposal Practices at Visited Textile Plants - continued
Disposal Sites
Category/
Plcnt
D-15
D-16
D-17
D-18
D-19
0-20
rwoi
LJ— ^1
D-22
E-l
E-2
E-3
E-4
E-5
* E-6
E-7
E-8
E-9
E-10
E-11
E-l 2
E-l 3
£-14
E-l 5
E-l 6
E-17
E-l 8
E-l 9
E-20
EPA
Region
IV
IV
IV
IV
IV
III
IV
1
IV
IV
IV
III
II
1
IV
IV
IV
IV
IV
IV
IV
IV
IV
IV
IV
IV
IV
III
Discharce Containers
Type On Off
Direct X
Municipal X
Direct X
Direct X
Municipal X
Direct X
Direct
Direct X
Municipal X
Municipal X
Direct X
Direct X
Municipal X
Direct, no X
treatment
Municipal X
Municipal X
Municipal X
Municipal None disposed
Municipal . X
Municipal X
Municipal X
Direct X
Municipal X
Direct X
Direct X
Direct X
Direct X
Direct X
iludge
Contractor
On Off Containers
X
NA NA
None wasted
None wasted
NA NA
X
No Data
Unknown Unknown
NA NA
NA NA
None wasted
None wasted
Atypical
NA NA
NA NA
NA NA
NA NA
NA NA
NA NA
NA NA
NA NA
None wasted
NA NA
None wasted
None wasted
None wasted
None wasted
X
Yes
Yes
Yes
Yes
No
Yes
No
No
Yes
Yes
No
Yes
Yes
No
Yes
Yes
NA
Yes
Yes
Yes
Yes
Yes
No
Yes
Yes
No
Yes
Sludge
No
NA
NA
NA
NA
Yes
No
NA
NA
NA
NA
Yes
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Yes
Type of 5
Containers
SLF
SLF
SLF
SLF
SLF*
SLF
Dump
SLF
SLF
SLF
SLF
SLF*
SLF
SLF .
SLF*
SLF*
None
disposed
SLF
SLF
SLF*
Private SLF*
SLF
SLF
SLF
SLF
SLF
SLF*
ite
S!ucV.e
Field on
plant site
NA
NA
NA
NA
Unknown
Unknown
NA
MA
NA
NA
Incinerj'ion
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
ALF
-------
Table 4-1. Summary of Treatment/Disposal Practices at Visited Textile Plants - continued
Category/
Plant
F-l
F-2
F-3
F-4
F-5
F-6
F-7
F-8
F-9
F-10
F-ll
G-l
G-2
: G-3
G-4
G-5
G-6
G-7
G-8
G-9
G-10
G-ll
01 Mu
Disposal Sites
EPA
Region
IV
IX
IV
IV
IV
IV
IV
IV
IV
IV
IX
IV
1
IV
IV
IV
IV
IV
IV
IV
IV
IV
Discharge Containers
Type On
Municipal
Municipal
Direct
Municipal
Municipal
Direct
Municipal
Direct
Direct
Direct
Municipal
Municipal
Municipal
Direct
Direct Sold
Municipal
Municipal
Municipal
Municipal
Municipal
Direct Sold &
washed
Municipal
Utr
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
X
Sludge
On
NA
NA
None wasted
NA
NA
None wasted
NA
None wasted
None wasted
None wasted
NA
NA
Atypical
None wasted
None wasted
NA
NA
NA
NA
NA
None wasted
NA
OH
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Contractor
Containers
No
Yes
Yes
Yes
Yes
No
Yes
Yes
No
No
Yes
No
Yes
Yes
NA
Yes
Yes
Yes
Yes
Yes
No
Yes-
Sludge
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Type
Containers
SLF
SLF
SLF
SLF
SLF
SLF
SLF
SLF
SLF
SLF
Private LF
SLF
Dump
SLF
NA
SLF
SLF
SLF
SLF
SLF
SLF*
SLF
of Site
Sludae
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Scoring in
55-gal drums
NA
NA
NA
NA
NA
NA
NA
NA
NA
(2) Direct - wastewater discharged to surface water.
(3) NA - Not applicable because of information given earlier in table. For example, discharge of wasfewater to municipal system indicates no sludge, no sludge disposal and
no contractor for sludge.
(4) SLF- Sanitary landfill.
(5) ALF - Approved landfill.
(6) "Containers washed prior to disposal.
-------
All three plants landfill the sludge; two on-site and the other off-site
on fSSTLnd owned by the cotpany. No environmental precautions are taken
for the disposal of the wasted sludge.
No atypical potentially hazardous wastes were found in this
industry category.
4.3.2 Category B - Wool Fabric Dyeing and Finishing
The seven plants visited in category B dispose of their dye and
chemical containers with other plant trash off-site with no environmental
precautions taken, -ttiree plants use open dumps and four plants used sani-
Swlardfillfl The plants using open dumps are located in EPA Region I
S^ sSSIX; re^Tall open du^s to be converted to sanitary land-
fills over the next few years.
Three of the seven plants send their wastewater to municipal
treatment systems. Two discharge without treatment to surf ace water.
The regaining two have their c*n treatment facilities and re^ J**3J
in unlined aeration basins. Neither of these latter plants has found it
ne\^ssar7tTdispose of sludge because of the low solids build-up in their
treatment systems.
Two of these seven plants have atypical still bottom wastes
from the recovery of chlorinated organic solvents used for dry cleaning
offabric. Bothplants seal this waste in drums. One sends the drums to
a dSTaSd tnl other uses a municipal landfill for d"P«al.^i disposal
methods are environmentally inadequate should the drums be broken.
4.3.3 Category C - Greige Goods
There are no potentially hazardous waste streams in category C.
4.3.4 category D - Woven Fabric Dyeing and Finishing
Twenty of twenty-one plants in category D landfill their container
wastes off-site in general purpose landfills. Only one of the ta^enty
wShS Sir conSiSrs priorto disposal. The twenty-first plant sends
?S£ containeTwastes to an open dump. A twenty-second plant visited
S^TSSSSj^Ssed to allow use of the waste treatment and disposal
information that was obtained.
Seventeen of these twenty-two plants have their own wastewater
treatment facilities and, therefore, retain sludge in aeration ponds. No
S^ndfwere encountered in category D. This prcportim of plants
with tStment systems is misleading with respect to the entire category
S DlSS PlanS^ere selected to visit with an emphasis on those having
^S^ireaSL The estimated percentage of plants in this category
^PSchSing to municipal treatment systen* isonly 32 per cent as
indicated in Table 4-3 appearing later in this report.
4-8
-------
Of the seventeen plants with treatment systems, six disposed of
sludge, nine did not and no data could be obtained from two. Of the six
with sludge disposal, three dispose of the sludge on-site and three off-
site. On-site disposal at two plants consisted of land spreading on fields
around _the treatment facilities. The third plant stores their sludge in
an unlined lagoon. One of the three plants using off-site disposal of
sludge allows an employee to haul the sludge to his farm for use as
fertilizer. A second plant uses a general purpose municipal landfill to
dispose of its sludge. No disposal site information was available from
the third plant.
Two instances of atypical potentially hazardous wastes were
encountered in this industry category. The hazardous constituent of both
were flammable hydrocarbon solvents. These wastes are presently mixed
with plant trash and disposed of in a general purpose landfill.
This category of the textile industry is the one with the
largest production. No evidence was found of any precautions in the
disposal of potentially hazardous waste streams.
4.3.5 Category E - Knit Fabric Dyeing and Finishing
All the plants visited in category E that dispose of their
container wastes, dispose of them in general purpose landfills, usually
operated by municipalities or counties. Only one of the twenty plants
visited did not landfill container wastes. This plant used the containers
for trash barrels or allowed employees to take them hate apparently for
the same purpose. Six of the nineteen plants that use landfill as a dis-
posal method wash their containers free of residual dyes and chemicals
prior to disposal. This practice converts the containers into innocuous
waste.
Eight plants have treatment systems and are accumulating sludge
in their aeration ponds, only one of which, was concrete lined. One plant
discharges wtihout treatment to surface water, and eleven plants discharge
to municipal treatment systems. The coment in Section 4.3.4 regarding
the_ratiojof direct discharges to municipal dischargers applies here also.
It is estimated that only 17 per cent of the plants in this category have
their own treatment systems.
TVo of the eight plants with treatment systems dispose of sludge.
One plant stores its wasted sludge in an unlined lagoon on-site and the
other dewaters its sludge to 20-25% solids and disposes of it in an
approved landfill.
Two plants were found with atypical wastes. One plant generates
a still bottom waste from acetone recovery and disposes of it through
incineration by a hazardous waste disposal contractor. The other plant
generates a still botton waste fran perchlorcethylene recovery which is
sent to a contractor for reclamation.
This category of the industry has demonstrated the most interest
in the environmentally adequate disposal of its potentially hazardous
waste streams.
4-9
-------
A.3.6 Category F - Carpet Dyeing and Finishing
All eleven plants visited in category F dispose of their dye
and-chemical container wastes off-site in general purpose landfills.
NcnTof the plants cleaned the containers prior to disposal.
Five of these plants have treatment systems and are accumulating
iSTsludge in their aeration basins, which are an unlined.
.llant disposes of sludge, which is a very small amount to an on-
site sludge drying bed.
Three of the eleven plants have an a^pical potentially hazardous
waste consisting of lint that is wet with non-fixed dye aolutun. All
three landfill this waste with plant trash.
4.3.7 Category G - Yarn and Stock Dyeing and Finishing
Nine of the eleven category G plants visited dispose of their
dye and chanical container wastes in general P^seJ^fi^s. one
plant sends container wastes to an open dunp ^l^f^diSSal
tainers. Only one plant washes the containers prior to disposal.
Three plants were found to have ^^g^^^^jfj
accumulating sludge in unlined aeration ^5asinf' ,?^eJL2^in ^
posal in this category because of very slew SOJ_LOS DUJ-L« i*
systems.
One of these eleven plants has an atypical . ir— -«^ GfrsrV n and F 80
G - Yarn and Stock D and F
The disposal sites are all local, usually within 16 kilometers (10 miles)
of the plant.
4-10
-------
4.4.2 Sludge Wastes
Plants with wastewater treatment systems all retain sotve sludoe
i f ^S P01**- Disp°sal of slud^ is neoessarTSly^enlhr
solids level m the wastewater treatment system builds to a poLt where
the efficiency of the biological system would be affected. Se
is a sumnary of those plants which were visited that dispose of
Percentage
PlanSwith
Category
A
B
F
G
NA
Treatment That
Waste Sludge
100
0
41
o
Plant
On-Site
67
NA
50
NA
s Wasting
Off-Site
33
NA
50
NA
Using
Contractors
0
NA
33
NA
(10 miles)
ol ' U8ually within 16 o
of the plant. Some of the plants that presently use on-site
wasted sludge would prefer to dispose of the sludges off^sinta
landf Uls and are currently seeking permission from local aSho?iS to do
4.4.3 Atypical Wastes
«.
4.5 Safeguards Employed by the Textile Industry
mterials Most plants conbine these a
A few wash or clean the containers prior to disposal, reuse
return. Ihe others leave a small amount of reSSS
clinging to the surfaces of the disposed containers.
sludges are usually land disposed without any environnental
?"V?? P Sfc ""? fOU^ to disP°se of dewat^red sludge in an apped
landfill. Several retain their sludges in concrete lined basiS.
4-11
-------
4.6 Hazardous Waste Management by Private Contractors
Many plants dispose of process and wastewater treatment wastes
contractors. Generally these contractors haul wastes to a disposal
sTwSe one or more of the disposal practices ^^^!£o^
is carried out. A list of these contractors appears as Appendix B.
Three types of services are performed by different contractors:
(1) Haulers who perform no function other than transporting the
wastes to thfnearest public landfill. These contractors are
normally the ones that handle trash including dye and chemical
containers.
(2) Private landfill disposal by operators who my also do
hauling. The wastes that these operators will accept
depending on the location and nature of their disposal area
This includes "unlicensed" contractors who remove sludge and
spread it on their own land as a fertilizer.
(3) Hazardous waste contractors disposal. These contractors accept,
Seat, and dispose of hazardous materials as a manor portion of
SSr 'bSnesfand are equipped to handle them Hazardous
waste contractors presently are rarely used by the textile
industry except for solvent-containing wastes.
Private contractors handling dye and chemical containers mixed
with trash take no environmental precautions.
t
posed of in an approved landfill.
In a number of cases the waste solvents and solvent sludges are
handled in an environmentally adequate fashion by reclaiming and
incineration.
4.7 Treatment and Disposal Technologies for Potentially Hazardous
~ waste Streams by industry category *
For purpose of presenting potentially hazardous land-destined
textile wastes and their levels of treatment and disposal in an orderly
fashion, three categories of wastes are considered:
• Containers with residual dyes and chemicals,
• Wastewater treatment sludges,
• Other atypical, potentially hazardous wastes.
4-12
* The reader is cautioned that no waste products from the textiles
industry have been demonstrated to be hazardous by this study.
EPA reserves its judgments pending a specific legislative mandate.
-------
The container wastes and wastewater treatment sludges are both canton to
most of the industry and, to avoid needless repetition, their treatment
and disposal technologies are presented on an overall industry basis. The
atypical wastes are covered individually, identified as to origin and
specific Garments made as to pertinent technology. The three technology
levels are defined as follows:
Level I - Technology currently employed by typical facilities; i.e.,
broad average present treatment and disposal practice.
Level II - Best technology currently ertployed. Identified technology
at this level must represent the soundest process, from
an environmental and health standpoint, currently in
use in at least one location.
Level III - Technology necessary to provide adequate health and environ-
mental protection. Identified technology may include
pilot or bench scale processes provided the exact stage
of development is identified. Level III technology
as defined in this report represents contractor judgment,
and not that of the EPA. This level of technology as
defined for a particular potentially hazardous waste
stream is merely an attempt by the contractor to define
an environmentally acceptable technology. Thus, the
technology level defined should not be interpreted as a
basis for future regulations. It is not basis for future
regulations. It is not based on cost-benefit, economic, or
other analysis required to appropriately define Level III
technology.
The levels of technology determined for the potentially hazardous
land-destined waste streams in this industry are presented in Tables 4-2
and 4-3. Table 4-2 deals with dye and chemical containers with residual
contamination and Table 4-3 deals with wastewater treatment sludges.
Table 4-4 summarizes the other atypical, potentially hazardous waste streams
and their treatment and disposal. Figures 4-1, 4-2 and 4-3 illustrate
the three levels of technology for the treatment and disposal of potentially
hazardous land-destined wastes in the textiles industry.
4.7.1 Dye and Chemical Container Wastes
Category A (wool scouring) generates no dye and chemical container
wastes. All other textile industry plants that dye and finish their
products have container wastes. Most of these facilities dispose of
these containers with their small amounts of residual dyes and chemicals
in sanitary landfills. This constitutes Level I technology. Levels II and
III technologies are similar with the exception of washing and cleaning
the containers prior to disposal. This practice adds a small amount of
raw waste to the wastewater going to treatment, but transforms a potentially
hazardous land-destined waste stream to innocuous trash.
4-13
-------
Table 4-2. Levels of Technology for the Dye and Chemical Container Waste Streams
Factor
Treatment/Disposal
Technology
Estimate of Number
and (Percentage)
of Plants Now
Using Technology
Present Adequacy
of Technology
.1
" Future Adequacy
of Technology
Description of
Residual Potentially
Hazardous Wastes
(kg/kkg of production)
Level 1
Landfilling
Category: Technology
Landfilling
B 64 (57)
D 620 (95)
E 480 (65)
F 144 (100)
G 252 (73)
Disposal practices environmentally
inadequate
Environmentally inadequate
Category: Dyes Chemicals
Container Dyestuff Container Chemical
B 1.3 0.006 1.6 0.02
D 0.47 0.0023 0.77 0.04
E 0.9 0.0023 0.92 0.0015
F 0.13 0.0007 0.18 0.0008
G 0.87 0.002 2.2 0.02
Level II Level III
Washing and cleaning of containers prior Same as Level 11
to disposal
Category: Technology Same as Level II
Wash & Clean
B 0 (0)
D 33 (5)
E 220 (30)
F 0 (0)
G 31 (9)
Environmentally adequate Same as Level II
Environmentally adequate Same as Level II
No potentially hazardous wastes Same as Level II
Physical and
Chemical Properties
Containers have residual solid and liquid
dyestuffs and chemicals clinging to their
surfaces
Containers are clean - there are no
remaining residues
Same as Level II
-------
Table 4-2. Levels of Technology for the Dye and Chemical Container Waste Streams - continued
Factor
Level I
Level II
Level III
Factors Affecting
Hazardousness
(1) Composition and amount of
potentially hazardous dyes and
chemicals used in plant.
(2) Ambient conditions for landfills-
pH level, leachate character,
soil permeability
None
Same as Level II
Reliability of
Technology
Technology not reliable for maintaining
environmental safeguards
Reliable
Same as Level II
M
01
Limitation of
Technology
Allows potentially hazardous residual
dyes and chemicals to be landfilled
None
Same as Level
Problems and
Comments
Container residues are presently handled
as non-hazardous materials
Simple washing and cleaning of
containers transforms potentially
hazardous waste into environmentally
safe innocuous waste
Same as Level II
Compatibility with
Existing Facilities
Disposal facilities already exist
No new facilities needed
Same as Level II
Non-Land Environ-
mental Impact
Possible ground and surface water
contamination
Will slightly increase raw waste
load to water treatment system
Same as Level II
Energy Requirements
Slight - containers represent only a small
portion of landfilled trash
None
Same as Level II
-------
Table 4-2. Levels of Technology for the Dye and Chemical Container Waste Streams - continued
Level II
Leve
Monitoring and None employed
Surveillance Techniques
Visual check of containers prior to Same as Level II
disposal
Installation Time for None needed
New Facilities
None needed
Same as Level II
-------
Table 4-3. Levels of Technology for the Wastewater Treatment- Sludges
Factor
Level I
Level II
Level III
Treatment/Disposal
Technologies
(1) Retention of sludge in treatment
ponds
(2) General land disposal of wasted
sludge
(1) Retention of sludge in lined treatment
ponds
(2) Disposal of wasted sludge in approved
londfill
(1) Same as Level II
(2) Same as Level II »
(3) Incineration plus ash disposal in approved
landfill (alternate method for technology
2)
Estimated Number
and (Percentage}
of Plants Now
Using Technology
Present Adequacy
of Technologies
Future Adequacy
of- Technologies
Category: Technology
Retention of Land Disposal of
Sludge Wasted Sludge
A 8 (50) 8 (100)
B 39 (35) 0 (0)
D 208 (32) 86 (41)
E 125 (17) 0 (0)
F 43 (30) 0 (0)
G 65 (19) 0 (0)
Retention and disposal practices are
environmentally inadequate
Adequacy of practices will not be
improved as wastewater treatment
Category: Technology
Lined-Pond Approved Land-
Retention fill Disposal of
of Sludge Wasfed Sludge
A 5 (67) 0 (0)
B 0 (0) 0 (0)
D 0 (0) 0 (0)
E 15 (12) 15 (12)
F 0 (0) 0 (0)
G 0 (0) 0 (0)
Retention of sludge in lined ponds and
approved landfiiling are environmentally
adequate.
Will depend on the type and effectiveness
of the pond lining. Approved landfiiling
(1) Same as Level II
(2) Same as Level II
(3) Incineration plus disposal
landfill - 0 plants (0%) al
of ash in approved
1 categories
(1) Same as Level II
(2) Same as Level II
(3) Incineration will require adequate contain-
ment of air pollutants plus safe disposal of
ash.
(1) Same as Level II
(2) Same as Level II
BPTCA and BATEA technologies are
required and sludge volumes increase
will be environmentally adequate.
(3) Incineration will require adequate contain-
ment of air pollutants plus safe disposal of
ash.
-------
Table 4-3. Levels of Technology for the Wastewater Treatment Sludges - continued
Factor
Level II
Level
Description of
Residual Potentially
Hazardous Wastes
(1) Retained sludge in kilograms/typical
Physical and
Chemical
Properties
plant
Category:
A
B
D
E
F
G
Dry
780
1.6
67
400
5.2
2.9
Wet
7800
20,000
7300
60,000
22,000
20,000
(1) Same as Level I
(2) Same as Level I
Except that wasted sludge would have a
higher solids content depending on the
degree of dewatering before approved
land filling.
(1) Same as Level I
(2) Seme as Level I
(3) Incinerator ash weights will vary with
content of original sludge
(2) Wasted sludge in kg/kkg of product
Category:
A
B
D
E
F
G
Dry
570
0
20
0
0
0
Wet
5700
0
2300
0
0
0
(1) Retained sludges range in solids content
from <1% to 10% depending on the
industry category.
(2) Wasted sludges range in solids content
from 2% to 10% depending on the
Industry category and the method of
sludge disposal used. Land spraying with
irrigation-type equipment requires low
solids content. Land spreading and land-
filling of solids requires high solids con-
tent. Also, depending on the wastewater
treatment involved, these solids may be
mostly organic (activated sludge with
residual dyes, heavy metals and chemi-
cals) or mixtures of these organics with
inorganics such as limes, alum, and
iron compounds.
(1) Same as Level I
(2
(2) Approved landfilling normally requires
sludge dewatering prior to disposal.
Solids after dewatering range from 10
to 25 percent.
(1) Same as Level I
(2) Same as Level II
(3) Incineration will normally require sludge
dewatering.
Ash from incineration will contain primarily
inorganic chemicals including potentially
hazardous heavy metals.
-------
Table 4-3. Levels of Technology for the Wastewater Treatment Sludges - continued
Factor
Level I
Level II
Level III
Factors Affecting
Hazard ousness
(1) Permeability of soil under retention
ponds
(2) Composition and amount of potentially
hazardous dyes and chemicals used in
plant
Ambient conditions for land spreading
or landfilling - pH level, permeability
of soil around landfills, and proximity
of surface and ground water
(1) Integrity of pond liners; i.e., cracking
of concrete liners or chemical attack
on plastic liners
(2) Proper management of approved landfill
(1) Same as Level II
(2) Same as Level II
(3) Incineration concentrates any potentially
hazardous inorganic component of original
sludges. Proper management of approved
landfill.
Reliability of
Technologies
Present technologies not reliable for
environmentally adequate disposal.
Good. Technologies are widely used and
demonstrated in this and other industries.
Same as Level II
^ Limitation of
JL, Technologies
Problems and
Comments
(1) Sludge retention in unlined ponds con
possibly result in percolation to ground
water supplies
(2) Land disposal of potentially hazardous
sludge by landfilling or land spreading
in uncontrolled facilities can lead to
leachate and runoff problems.
(1) Same approved pond liners may be
chemically attacked or inadvertantly
torn or cracked
(2) Approved landfill liners may also
deteriorate
Sludges are now considered by the industry
to be non-hazardous materials. Additional
work needs to be done to establish:
(a) the effect of an aerobic decomposition
of dyestuffs
(b) the environmental impact of land
spreading end landfilling of potentially
hazardous sludges from the textile
industry
(1) Costs to line aeration basins will be
high
(2) There are very few approved landfills
where most of the textile industry is
located
(1) Same as Level II
(2) Same as Level II
(3) Incineration — none.
!1) Same as Level II
2) Same as Level II
(3) The costs of environmentally adequate
incineration equipment are high. Fuel
costs are high and some fuels are not
available. Contract incineration may not
be available to textile plants.
-------
Table 4-3. Levels of Technology for the Wastewater Treatment Sludges - continued
Factor
Level I
Level II
Level II!
Compatibility with
Existing Facilities
Retention and disposal facilities already
exist
(1) Can line existing pond if necessary
(2) Good. Sludge dewatering is an add-on.
Approved landfills are separate
installations.
(1) Same as Level II
(2) Same as Level II
(3) Contract incinerators are separate i,>istal!a-
tions. On-site incineration is an add-on.
Non-Land
Environmental
Impact
Possible ground and surface water
contamination
None, provided adequate safeguards are
taken with pond liners and approved
landfills
(1) Same as Level II
(2) Same as Level II
(3) Air wastes from incineration. None with
environmentally adequate incinerator.
Energy
Requirements
10
o
(l)None
(2) Slight - pumping, handling and hauling (1) None
of land disposed sludges (2) Slight - handling and hauling of land-
filled sludges
(1) None
(2) Same as Level II
(3) Incineration — large fuel requirements
Monitoring and
Surveillance
Techniques
None employed
Surface and ground water monitoring for
leachate.
(1) Same as Level II
(2) Same as Level II
(3) Incineration - air pollution monitoring
required
Installation Time
for New
Facilities
No new facilities required
Pond liner - 6 months
Sludge dewatering - 12 months
Approved landfill - 12 months
Same as Level II, incineration - 12 months
-------
Table 4-4. Atypical Potentially Hazardous Textile Industry Wastes
Subcategory Waste Description
A . No atypical wastes
B Still bottoms from recovery of dry-
cleaning chlorinated solvents
D Hydrocarbon solvents and sludges
D Finishing sludges containing
adhesives, silicones, and solvents
E Acetone recovery still bottoms
E " Perchloroethylene still bottoms
Quantity (Dry) No. of Plants
(kg/1
-------
Toble 4-4. Atypical Potentially Hazardous Textile Industry Wastes - continued
Subcategory
F
Waste Description
Lint wet with non-fixed dye
Quantity
(kgAkg of Product)
12
(20 wet)
No. of Plants
(% of Plants)
3 of 1 1 plants
visited (27%)
Potential
Hazards Involved
Pollution of surface and
ground water
Comments on
Treatment/Disposal Technoloay
Presently landfilled^with
trash. Future environ-
mentally adequate treatment/
disposal technologies include
washing, approved landf illing,
or incineration.
Solvent and resin slurries from yarn
finishing operations
0.09
M
SJ
1 of 11 plants
visited (9%)
Air pollution, fires
Presently sealed in drums
and stored on-site. Future
environmentally adequate
treatment/disposal options
include reclaiming, approved
landfilling or incineration.
-------
Figure 4-1. TYPICAL MODEL OF LEVEL I TECHNOLOGY FOR
POTENTIALLY HAZARDOUS WASTE STREAMS IN
THE TEXTILES INDUSTRY
TEXTILE
PLANT
DYE AND f ^\
CHEMICAL / ^
CONTAINERS /COMPACTION
WITH \ PLANTS)
RESIDUAL DYES V I>LANI»'
AND CHEMICALS \. ./
GENERAL
•PURPOSE
LANDFILL
RAWWASTHWATER
E|W
PRIMARY
SCREENING
I
PRIMARY
SETTLING BASIN
(WOOL SCOURING
ONLY)
AERATED
BIOLOGICAL
TREATMENT
BASIN
CHLORIN-
ATION
(SOME
PLANTS)
UNDERFLOW
WASTED
SLUDGE.
-^•LANDFILL
OR LANDSPREAD
PLANT EFFLUENT
4-23
-------
Figure 4-2. TYPICAL MODEL OF LEVEL II TECHNOLOGY FOR POTENTIALLY
HAZARDOUS WASTE STREAMS IN THE TEXTILES INDUSTRY
TEXTILE
PLANT
DYE AND CHEMICAL
CONTAINERS WITH
RESIDUAL DYES .
AND CHEMICALS m^(
RAW WASTEJ WATER
' WASHING \
CLEANING /
TRESI DUAL DYES
CLEAN
CONTAINERS
TO LANDFILL
(NO LONGER
HAZARDOUS)
PRIMARY
SCREENING
CONCRETE-LINED
PRIMARY
SETTLING BASIN
(WOOL SCOURING
ONLY)
[^
REMOVED WATER
3
t
AERATED
BIOLOGICAL
TREATMENT
BASIN
RECYCLE
1 1
W v>
WASTED/ SLUDGE
SLUDGE V
APPROVED
LANDFILL
UNDERFLOW
CHLORIN
ATION
(SOME
PLANTS)
PLANT EFFLUENT
4-24
-------
Figure 4-3. TYPICAL MODEL OF LEVEL III TECHNOLOGIES FOR POTENTIALLY
HAZARDOUS WASTE STREAMS IN THE TEXTILES INDUSTRY
DYE AND CHEMICAL
CONTAINERS
WITH RESIDUAL
DYES AND
CHEMICALS
WASHING
AND
CLEANING
CLEAN
CONTAINERS
TO LANDFILL
(NO LONGER
POTENTIALLY
HAZARDOUS)
RESIDUAL
DYES AND
CHEMICALS
LINED PRIMARY
SETTLING BASIN
(WOOL SCOURING
ONLY)
LINED AERATED
BIOLOGICAL
TREATMENT
BASIN
CHLORIN
ATION
(SOME
PLANTS)
1,2 - ALTERNATE TECHNOLOGIES
PLANT EFFLUENT
4-25
-------
The percentages of plants shown in Table 4-2 using the Levels
I, II and III technologies were estimated from the plant visit data The
number of industry-wide plants using the technologies were derived by
applying these percentages to the total number of facilities in each
industry category.
Because dye and chemical containers can be decontaminated by
washing, there is no need for hazardous waste disposal technology. Only
good waste control practices are required prior to disposal of containers.
4.7.2 Wastewater Treatment Sludges
The data on treatment and disposal of wastewater treatment sludges
are sunmarized in Table 4-3. There are two ways that sludges generated
in textile dyeing and finishing plant wastewater treatment facilities can
pose a hazard to the environment. One is through landfilling, land spreadino
or land dumping of wasted sludge with potentially hazardous constituents
in places with no controls on leachate or runoff. The other way is through
use of an unlined, non-inpervious aeration basin where the sludge is being
generated and retained until removal becomes necessary.
Level I technologies for the handling and disposal of this sludge
consists of the retention of sludge in unlined aeration basins and the
disposal of wasted sludge in general purpose landfills or dumps or land
spreading on farmland. .
t level II technologies were found to be the use of lined aeration
Dasins to prevent the percolation of retained sludge and the disposal of
dewatered sludge in an approved landfill.
Level II technologies are also Level III. Additional Level III
technology is the incineration of dewatered sludge and approved landfilling
ot the residual ash. Incineration by a contractor would probably be
selected by the industry over installation of on-site incinerators because
of the high cost of environmentally adequate incinerators.
Of course, sludges are generated in only those facilities having
their own wastewater treatment systems. The percentages listed of those
plants in each industry category that retain sludges were obtained from
reference 10. These correspond to the per cent of each industry segment
with treatment systems. The number of plants in each category that retain
sludge was obtained by applying these percentages to the total number of
facilities in each category.
The percentage of plants with treatment systems that dispose of
sludge was determined fron the plant visit data. The industry-wide number
of plants wasting sludge was obtained by applying these percentages to the
total number of plants in each category that retain sludge (have treatment
systems).
4-26
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BPCTCA and BATEA stand for "best practicable technology currently
available" and "best available technology economically achievable" which
are used with reference to the wastewaber treatment technologies and
effluent standards to be achieved by 1977 and 1983, respectively.
4.7.3 Discussion of the Atypical Potentially Hazardous Wastes
The information on atypical potentially hazardous wastes is
summarized in Table 4-4. Most of these wastes are organic solvents.
Unlike the container and water treatment sludge wastes which are potentially
hazardous from a toxicity standpoint, these atypical wastes are potentially
hazardous primarily because of flammability. These wastes are sometimes
recognized by the textile industry as potentially hazardous and are disposed
of by environmentally adequate means such as reclaiming or incineration.
Other atypical wastes such as lint containing excess dye are
currently being landfilled, but can be treated and disposed of in environ-
mentally adequate fashion by washing, approved landfilling or incineration.
4.7.4 Other Treatment and Disposal Technology Options
4.7.4.1 Specialized Approved Landfills
General purpose approved landfills accept a wide variety of waste
materials. These may be either a public facility or privately-owned.
Another type of approved landfill is one designed and used by an individual
plant or company for only their wastes. Normally such facilities are
installed only when the waste volume is large or there is sufficient hazard
for the company to want to retain ultimate control of waste material. These
landfill areas have all the characteristics described for general purpose
approved landfills — impermeable barriers, monitoring, and leachate
control and treatment. They present a number of advantages over general
purpose landfills:
• handling and hauling charges are minimized;
• interactions with other wastes can be controlled or eliminated; and
• control of ultimate treatment/disposal conditions is maintained.
Some textile plants have sufficient wastewater treatment sludge to warrant
specialized approved landfill disposal, that is, disposal in a landfill
that handles only such material. However, this has not been found in use
in the textile industry.
4.7.4.2 Ocean Disposal
At least one textile company is known to have in the past used
ocean disposal for its wastewater treatment sludges. Presently, there
is no known ocean disposal practiced in the industry.
4-27
-------
4.7.4.3 Chemical Fixation of Wastes
Ihere are a number of processes for converting potentially
hazardous sludges into relatively innocuous solid materials by chemical
fixation. These processes involve reaction of cements, lute, mortars, plaster-
of-paris, and silicates and other readily available low-cost inorganic chem-
icals with sludge to produce a solid material with reduced leachability of
metals and other conponents such as oil and organics. The degree of fixation
depends on the chemicals used and the nature of the sludge. The applicability
of this treatment technology to textile sludges has not been demonstrated.
4.7.4.4 Encapsulation of Wastes
Land-destined hazardous wastes may be physically encapsulated
in iirpervious materials such as concrete, asphalt or plastics prior to dis-
posal: This technique is normally reserved for relatively small volumes
'of very hazardous materials and is not a practical application for the
potentially hazardous wastes of the textiles industry.
4-28
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5.0 POST ANALYSIS
5 . 1 Introduction
Although the types of wastes and the waste treatment and disposal
technologies for most textile industry categories are similar, the amounts
of wastes differ fron category to category. Costs of treatment and disposal
are determined by both the treatment and disposal technology used and the
amount of waste involved. Other factors influencing disposal costs are
the use of municipal sewage treatment systems and the indefinite retention
of sludges in the plant treatment system ponds. Sending the wastewater to a
municipal system, for example, not only transfers the generation and disposal
of the potentially hazardous sludges to the municipality, it also transfers
the sludge disposal costs as well, Intention of sludge in a plant's waste-
water treatment system may continue for 5 to 10 years or even longer without
the need of removal for disposal. Sludge disposal costs are zero during
this period. If and when seme sludge has to be disposed of, costs are then
incurred. These and other factors which significantly influence costs are
discussed as they apply in the individual industry category cost analysis
sections. J
5.2 Techniques and Assumptions Used
5.2.1 Sources of Post Information
Cost information contained in this report was assembled directly
fron industry, from waste treatment and disposal contractors, engineering
firms, equipment suppliers, government sources, and published literature.
Whenever possible, costs are based on actual installations , engineering
estimates for projected facilities as supplied by contributing companies ,
or fron waste treatment and disposal contractors' quoted prices. In the
absence of such information, costs estimates were developed insofar as
possible from plant^supplied costs for similar waste treatments and disposal
for other plants or industries.
Cross-checks were also made, whenever information was available, for
treatment and disposal costs from different sources, such as contract dis-
posal companies.
5.2.2 Cost References and Rationale
5.2.2.1 Interest Costs and Equity Financing Charges
^ r- jjwef3tmsnts involve the expenditure of money which must
be financed either on borrowed money or fron internal equity. Estimates
for this study were based on 10 per cent cost of capital, representing a
composite number for interest paid or return on investment required. This
value was established as reasonable by discussions with industry
5-1
-------
5.2.2.2 Time Index for Costs
All cost estimates are based on current prices and when necessary
were adjusted to this basis using the chemical engineering plant cost index.
The inflationary nature of the past years makes it particularly important
that this 1975 constant dollar basis be cited for any cost estimation
purposes. If desired, current costs may be converted to December 1973 values
(used in similar studies on different industries in the past) by multiplying
by a factor of 0.82.
5.2.2.3 Useful Service Life
The useful service life of treatment and disposal equipment varies
depending on the nature of the equipment and process involved, its usage
pattern, maintenance care and numerous other factors. Individual companies
have their own service life values based on actual experience and use these
values for internal amortization. A second source of such information,
based on other factors less relevant than company experience, is Internal
Revenue Service guidelines.
Based on discussions with industry and condensed IPS guideline
information, the following useful service life values were used:
Item Estimated Useful Service Life, Yrs.
(1) General Process Equipment 10
(2) Incineration, Distilling and Retorting
Equipment 5
(3) Ponds, Lined and Unlined 20
(4) Trucks, Bulldozers, Loaders and other such
materials handling and transporting
equipment 5
5.2.2.4 Capital Posts
Capital costs are defined, for the purposes of this report, as
all front-end loaded, out-of-pocket expenditures for the provision of
facilities. These costs include equipment, construction and installation,
buildings, services, engineering, special start-up costs and contractor
profits and contingencies.
When capital costs are known for a specific plant using a given
treatment and disposal technology, cost adjustment to the typical plant
size was made using exponential factors of size. The cost of process equipment
is scaled by an exponent of 0.6 and costs for treatment or disposal ponds
by an exponent of 1.0. This latter exponent was applied to any capital
item for which no appreciable economy of scale is appropriate.
5.2.2.5 Annualized Capital Costs
Almost all capital costs for treatment and disposal facilities
are front-end loaded; i.e., most if not all of the money is spent during
5-2
-------
the first year or two of the useful life. This present worth sum can be
converted to equivalent uniform annual disbursements by utilizing the
Capital Recovery Factor Method:
Uniform Annual Disbursement = P i d+i) nth power
(Lfi)nth power - 1
Where P = present value (capital expenditure)
i = interest rate, %/100,n = useful life in years
The capital recovery factor method is used for all annualized
capital costs in this report, which, in effect, would be similar to constant
annual payments on principal and interest where capital facilities are
paid for through a constant payment mortgage.
5.2.2.6 Treatment of Land Costs
Land-destined hazardous wastes require removal of land from
other economic use. The amount of land so tied up will depend on the
treatment/disposal method employed and the amount of wastes involved.
Although land is non-depreciable according to IPS regulations, there are
numerous instances where the market value of the land for land-destined
wastes has been significantly and permanently reduced, or actually become
unsuitable for future use due to the nature of the stored waste. Therefore,
where necessary, costs estimates have assumed land values and capital
recovery on the following basis:
(1) If land requirements for on-site treatment and disposal are not signi-
ficant, then no cost allowance was made.
(2) Where on-site land requirements are significant and the storage or
disposal of wastes does not affect the ultimate market value of the
land, cost estimates include only interest on invested money.
(3) For significant on-site land requirements where the ultimate market
value and/or availability of the land was seriously reduced, cost
estimates include both capital depreciation and interest on invested
money.
(4) Off-site treatment and disposal land requirements and costs for con-
tractors are not considered directly. It is assumed that land costs
are included in the contractor's fees along with other expenses and
profit.
In view of the extreme variability in land costs, no attempt was
made to set different land values for each plant, industry or location.
Instead, a value of $2,500/hectare ($l,000/acre) was assumed.
5-3
-------
5.2.2.7 Operating Expenses
Annual costs of operating the treatment and disposal facilities
include labor, supervision, materials, maintenance, taxes, and insurance.
The operating costs combined with annualized capital costs give the total
annual costs for treatment and disposal operations.
a. Labor and Supervision Costs
Based on discussion with textile industry plant management
personnel, the following labor costs were used:
Category $/hour
Process operators, plant laborers — 5.00
Truck driver, equipment operators — 5.00
Supervision — 7-50
The above figures include fringe benefits and plant overhead.
b. Taxes and Insurance
Taxes and insurance were taken as 3 percent of invested
capital.
c. Other Operating Costs
Operating costs for maintenance, materials, pcw&r and energy
are variable for each individual case.
5.2.2.8 Rationale for "Typical Plants"
All plant costs are estimated for "typical plants" rather than
for any actual plant. "Typical plants" are defined for the purpose of
these cost estimates as:
For dye and chemical container wastes — The arithmetic average
o£ production size for all plants in the specific industry
category.
o Wastewater treatment sludge wastes — The arithmetic average
of production size for those plants in each industry category
discharging wastes to surface water. These figures were obtained
by multiplying the total category production by 0.65 (the ATMI
estimates that plants comprising 65% of industry production dis-
charge to municipal systems) and then dividing by the total
nuriber of plants in the category having discharge to waterways
as determined fron reference 10.
5-4
-------
The vast majority of textile plants are located in the East, so this des-
cription was used throughout the report whenever typical location is
mentioned. Textile plant processing equipment age has little significance
as far as treatment and disposal technology and the associated costs are
concerned, and was not considered a factor in describing "typical plants".
It should be noted that the per ton costs to treat and dispose
of potentially hazardous wastes at any one given plant may be considerably
higher or lower than the typical plant because of individual circumstances.
5.2.2.9 Definition of Technology Levels
Costs were developed for the three levels of technology which
are repeated here:
Level I
Level II
Technology currently employed by typical facilities, i.e., broad
coverage present treatment and disposal practice in the industry
category.
Best technology currently employed. Identified technology at this
level must represent the soundest process from an environmental
and health standpoint, currently in use in at least one location
in the industry category. Installations must be commercial scale;
pilot plant and bench scale installations are not suitable.
Level III
Technology necessary to provide adequate health and environmental
protection"Level III may be more or less sophisticated or may
be identical with Level I or II Technology. At this level,
identified technology may include pilot or bench scale processes
providing the exact stage of development is identified. One
pertinent difference between Level III Technology and Levels I
and II Technology is that it is not necessary for any plant in
the industry category to be using Level III, Technology. Technology
transfers from other industries are also included. The defini-
tion of level III Technology as defined in this report represents
contractor judgment, and not that of the EPA. This level of
technology as defined for a particular potentially hazardous waste
stream is merely an attempt by the contractor to define an environ-
mentally acceptable technology. Thus, the technology level defined
should not be interpreted as a basis for future regulations. It
• is not based on cost-benefit, economic, or other analyses required
to appropriately define Level.III Technology.
5-5
-------
5.3 General Cost Basis for Treatment and Disposal Technologies
5.3.1 Waste Control Technology Cost Basis
Potentially hazardous dye and chemical residues are removed from
containers by washing at a number of plants. This decontamination procedure
makes the containers innocuous, after which they can be disposed of as
trash, reused, returned or sold. Costs for washing and cleaning are small
because of the use of existing plant personnel. It is estimated that
the annual costs for a typical plant in each category would be $250 (one
man-hour per week for 50 weeks).
5.3.2 Storage or Retention Lagoons Cost Basis
A typical plant in the textiles industry that has its own waste-
water treatment system will retain sludge in the aeration lagoon and dis-
pose of the excess as required. All plants with water treatment facilities
will retain some quantity of sludge but only the wool scouring and woven
fabric dyeing and finishing categories (A and D) typically waste sludge.
Almost all of the aeration lagoons in the textiles industry are unlined.
Lining with plastic sheet, clay or concrete to prevent leachate from reaching
ground water is a demonstrated technology in this and other industries.
Estimates of installed costs for various types of pond liners
follow:
Liner Material Additional Cost, $/sq.m.
thin clay liner (<2 in.) $2.50
sprayed asphalt $2.50
20 mil PVC $3-70
30 mil Hypalon $7.40
concrete $10.00
thick clay liner (2 ft.) $10.00
Two typical pond sizes were found in the textiles industry, 0.38
and 0.89 hectare, which correspond to 0.9 and 2.0 acres. The smaller size
is applicable to industry categories A, D, E, and F while the larger size
applies to categories B and G. The following estimates were made for the
costs involved in cleaning and preparing the typical sized ponds for instal-
lation of liners:
Pond Size
0.38 ha.0.89 ha.
Cleaning of existing pond
(@ $10/fo3 of removed sludge) $18,750 $44,500
Earthwork on existing pond
(@ $l/m3 of earth moving) 1/250 3,000
Totals $20,000 $47,500
5-6
-------
Pond costs were attributable to wastewater treatment costs and
therefore no cost is attributed to the retention of sludge in existing
unlined ponds. '
5.3.3 Land Dumping Post Basis
Land dumping costs are almost the same as landfilling costs
Normally, most of the cost is for handling and hauling. Analysis of the
collected plant data for off-site disposal of such solid wastes as trash
and dye and chemical containers, shows an average of about $13/kkg for
hauling and disposal. Disposal costs for the individual plants range from
$2 to $50 per kkg of trash disposed, The high average cost per kkg of
this type of waste is due to low bulk density (one metric ton may occupy
several cubic meters of volume). Contractors charge on a volume and trip
basis. ^
Land dumping of sludges has quite different costs than those
for container waste. Hauling costs are estimated to be approximately $2/kkg
of wet solids for the short (0-20 kilonsters) hauling distances involved.
Therefore, the land dumping cost for sludges is highly dependent on the
solids content when it is disposed of. Dewatering of sludge becomes an
attractive option to minimize the hauling costs.
5.3.4 Land Spreading Cost Basis
Costs for land spraying of 5 percent solids liquid sludge, based
on information from one plant, has been estimated as $25/kkg of dry solids.
This value is highly sensitive to the solids level of the sludge and the
percent of the tune that the system is actually in use. Both of these
factors may be expected to vary widely fron plant-to-plant.
Costs for land spreading of 20 percent solids dewatered sludge
are greater than for simple land dumping because of the spreading equipment
involved and is estimated as $20/kkg of dry solids handled.
5.3.5 Cost Basis of General Purpose Landfilling
The $l3/kkg cost given for land dumping was developed from
information collected on landfilling operations. Most of the plants
employ contractors who pick up the trash and containers, either compacted
or uncarpacted, and take them to a local public landfill. Although sane
public landfills charge a significant fee (up to $7Akg), most of than are
either free or charge a fee on the order of $l-2/kkg for landfilling
^fSS}8 (referenoe 32> • Our estimate of the average landfilling cost
is yl5/kkg.
treatment sludges, the average landfilling cost
** SlUdge C$2Akg dunpijlg °°st
5-7
-------
5.3.6 Cost Basis for General Purpose Approved Landfills
Operators of approved general purpose landfills charge fees of
$3 to $7 per metric ton (reference 32). Therefore the cost for dye and
chemical containers including the $13/kkg local hauling costs would be
as high as $20/kkg. The $7/kkg figure is more applicable to the textile
industry for wet sludge because the industry is located in a wet climate
area of the country necessitating more leachate and runoff controls. There-
fore the total cost for approved landfilling of wet sludge is $9/kkg
(includes $2/kkg local hauling cost).
Unlike general purpose landfills, approved landfills are not
usually found near a textile plant. In fact, approved landfills are
almost non-existent in the southeastern part of the U.S. where most of
the textile plants are located. Hauling costs are given in Figure 5-1,
and are added to landfilling costs for the distance.
5.3.7 Post Basis of Specialized Approved Landfills
i
Specialized approved landfills, constructed by the individual
plants or companies, are not known to exist today in the textiles industry.
They do exist in other industries (references 32 and 33). Even though the
disposal costs are higher than those estimated for general purpose approved
landfills, hauling costs reduce the difference. There is a possibility
that treatment of leachate or runoff from on-site approved landfills could
be accomplished by returning it to the plant wastewater treatment system,
eliminating some leachate treatment costs. This would depend on the
availability of land on or near the plant site.
5.3.8 Cost Basis for Incineration
The cost for incineration per metric ton of sludge is much higher
at the low volumes generated by the wastewater treatment systems of the
textiles industry than at the high volumes cannon with municipal wastewater
treatment systems (reference 32). On-site incineration of low volume,
lew solids sludges may be expected to cost $100 to $300 per metric ton of
dry solids (references 34 and 35). Off-site contract incineration of these
sludges will cost approximately $100 per metric ton of dry solids (reference
32) handling and hauling charges to the contractor's facilities. An average
cost of $150/fckg of dry solids is estimated for incineration by a contractor.
5.3.9 Wet Oxidation Cost Basis
Wet oxidation of sludge was tried by at least one plant in the
textiles industry and was found to be uneconomical because of the small
volume of sludge.
5-8
-------
Figure 5-1. REGIONAL TRANSPORTATION COSTS
100 r
NEW ENG.-NYC-WASH. RT.1
PACIFIC
CENTRAL
MID-ATLANTIC
ROCKY WIT.
NEW ENG.-MIDDLE WEST
SOUTHERN
SOUTHWEST
0 500 1,000 1,500
DISTANCE (KILOMETERS)
LONG DISTANCE HAULING (1973)
100
MOUNTAIN PACIFIC
NEW ENGLAND
CENTRAL
WESTERN
SOUTHERN
0 500 1,000 1,500
DISTANCE (KILOMETERS)
1972 RAIL
80
u
E
60
40
O
Q
20
LOAD:
MOM
10-20M
20-30M
40M
500 1,000 1,500
DISTANCE (KILOMETERS)
1973 MOTOR
5-9
-------
5.3.10 Ocean Disposal Cost Basis
textile plants apparently do not currently use ocean disposal.
One plant had used this disposal method in the past, but discontinued the
practice several years ago. Since most textile plants are not located
close to the ocean, long distance hauling costs should be added to the
following ocean disposal costs for wastewater treatment sludges:
Volume
liters/week
3,800
38,000
378,500
Cost/liter
1.5-2.1
0.8-1.0
0.6-0.85
Cost/kkg of Dry Solids
5% solids20% solids
$300-$400
$160-$200
$120-$170
$75-$105
$40-$50
$30-$42.50
These costs do not make ocean disposal an attractive option for most
textile plants.
5.3.11 Chemical Fixation Cost Basis
Costs for chemical fixation treatment range from 0.7$ to 1.6* per
liter of sludge (reference 32). At a density of 1 kg/liter and a sludge
solids content of 5 percent by weight, the cost is $140 to $320 per kkg
of dry solids. At 20 percent solids content, the cost is $35 to $80 per
kkg of dry solids.
5.3.12 Encapsulation Costs
Encapsulation in materials such as concrete, plastics or asphalt
cannot compete costwise with other environmentally adequate disposal
technologies for containers and wastewater treatment sludges. These tech-
niques are normally reserved for small volume highly toxic materials such
as radioactive wastes and pesticides.
5.3.13 Solvent Reclamation Cost
Aside from the cleaning and reuse of dye and chemical containers,
the only other reclaim of potentially hazardous wastes is some of the mis-
cellaneous solvent wastes. Costs for reclaiming solvents vary widely
according to the specific waste.
5.4 Costs for Levels I, II, and III Technologies
The two general classifications of potentially hazardous land-
destined wastes from the textiles industry are containers with residual dyes
and chemicals and wastewater treatment sludges.
5-10
-------
5.4.1 Container Waste Treatment and Disposal Posts by Industry Category
Industry categories A (Wool Scouring) and C (Greige Goods) do
not generate dye and chemical container wastes and therefore no treatment
or disposal costs are required.
Tables 5-1 through 5-5 give the three levels of container waste
treatment and disposal costs for industry categories B (Wool Fabric Eyeing
and Finishing), D (Woven Fabric Dyeing and Finishing), E (Knit Fabric
Dyeing and Finishing), F (Carpet Dyeing and Finishing) and G (Yarn and Stock
Dyeing and Finishing). In all industry categories, the typical plant size
is the average production rate of the category plants. Ihe three levels of
treatment and disposal are identical for typical plants in all industry
categories and are as follows:
Level I — Off-site landfill by contractor
Level II — Washing containers free of residual dyes and chemicals
prior to disposal
Level III — Same as Level II
Level I technology costs are based on a contractor fee of $15/kkg
of waste disposal and are summarized as follows:
Cost Factor Industry Range Industry Average
$Akg of product 0.005-0.046 0.028
$/kkg of wastestream no range 15
$/kkg of hazardous waste 1,820-7,270 3,524
Levels II and III technology costs are the sane and are based
on a typical plant using one man-hour per week for 50 weeks to clean con-
tainers prior to disposal and are summarized as follows:
Cost Factor Industry Range Industry Average
$/kkg of product 0.05-0.24 0.10
$/kkg of wastestream 17-170 84
$/kkg of hazardous waste 2,300-62,600 23,900
The high cost per metric ton of hazardous waste result from the very small
weight of the potentially hazardous constituents as compared to the total
weight of the waste stream.
5.4.2 Wastewater Treatment Sludge Treatment/Disposal Costs by Industry
Category
Industry category C (Greige Goods) does not generate wastewater
treatment sludges containing potentially hazardous constituents and therefore
no treatment and disposal costs are incurred. Plants having their own
wastewater treatment system in all other industry categories do or will incur
sludge treatment and disposal costs for at least one of the three technology
5-11
-------
Tab I
5-1
Category B Typical P!u;it Coils Kor Treatment and Dispotcl, 1975
""*"
Typical Pbnt-
Characteristics
Identifi cation of
V/aste Si-ream's)
Dye and Chemical
Containers
Tr&'pmsn t/Di sp~ra !
Costs/Levels
Investment Cost:
Land
Other
Tola! Fixed
Annual Costs
Copila! Costs
Oporai'ing
Maintenance
Enorr.y & Power
Confroct Services
Total Arinijcilized
Cosi/l.kq of product
CostAkg of potentially
hazardous waste
CostAkg of hazardous
constituents
Annual Production Location Mnnu^ar'njring
(1 975) £^1£!
Wool Fabric
2/800 kkg/yr. Eastern U. S. Dyeing and Finishing
Composition Physical Amount for
of Wastc-i Form Trealirie-it/Oisoosal
Fiber Drums and
Paper Bags with Solid
Residual Dyestuff
2.9 kg/B:g of Product
Total Containers
and Chemicals
°-°24 kg A kg of Product
Total
Hazardous Resid'uals
Dollars (1975)*
Level !
0
0
0
0
0
0
0
122
122
0.044
15
1,320
Level i!
0
0
0
0
0
0
0
122
122
0.044
15
1,820
Level III
0
0
0
250
0
0
o
250"
0.09
30.79
3,720
Description of Treatment/Disposal Technology:
Level I Off-site landfill by contractor
Level II Same as Level I
Level III Washing containers free of residual dyes and chemicals prior to disposal
* To convert costs to December, 1973 dollars, multiply by 0.82.
5-12
-------
Table 5-2 Category D Typical Plant Costs For Treatment and Disposal, 1975
Typical Plant
Characteristics
Identification of
Waste Si-ream (s)
Dye and Chemical
Containers
Annual PiocJucHcn_
(1975)
Location
2,800
kkg/yr.
Composition
of Waste
Fiber Drums and
Paper Bags with
Residual Dyes tuff
and Chemicals
Southeastern U.S.
Physical
Form
Solid
Manufac. 1 u r i n cj
Process
Woven Fabric
Dyeing and Finishing
Amount for
Treatmen t/Disposa I
1.24 kg/kkg of Product
Total Containers
0.006 _kg/l
-------
Table 5-3 Category E Typical Plant Costs For Treatment and Disposal, 1975
Typical Plant
Characteristics
Identification of
Waste Stream(s)
Dye and Chemi cal
Containers
Annual Production^
0975)
1,050 kkg/yr,
Location
Composition
of Waste
Fiber Drums and
Paper Bags with
Residual Dyestuff
and Cliem icals
Southeastern U.S.
Physical
Form
Solid
Manufacturing
jYocess
Knit Fabric
Dyeing and Finishing
Amount for
Trea tmen t/D i sposa I
L82 kg/kka of Product
Total Containers
0.0038 kg/kkg Of Product
Total
Hazardous Residuals
Treatment/Disposal
Costs/Levels
Investment Costs
Land
Other
Total Fixed
Annual Costs
Capital Costs
Operating
Maintenance
Energy & Power
Contract Services
Total Annnolized
Cost/kkg of product
Cost/kkg of potentially
hazardous waste
Cost/kka of hazardous
constituents ^_
Dollars (1975)*
Level 1
0
0
0
0
0
0
0
?9
£.7
29
0.028
15
7,270
Level II
0
0
0
0
250
0
0
o
f)Cf\
250
0.24
130
62,600
Level 1
same
as
Level
0.24
130
62,600
II
II
Description of Ticotment/ Disposal Tecnncuogy;
Level I Off-site landfill by contractor
Level II Washing containers free of residual dyes and chemicals prior to landfill ing
Level III Same as Level II
* To convert costs to December, 1973 dollars, multiply by 0.82.
S-14
-------
Tah
5-4 Category F Typical Plant Costs For Treatment and Dir.pc.sal, 1975
Typicc! Pldi-it
Characteristics
Identificavicn of
Waste Stroam(s)
Dye and Chemical
Containers
Treatment/Disposal
Annual Production
"(1975)
Location
-4/720 k!
-------
Table 5-5 Category G Typical Plant Coits For Treatment and Disposal, 1975
Annual Ptocluclion
Location
Manufactui ing
Typical Plant
Characteristics
Identification of
Waste Strearn(s)
(1975)
4f800 kkg/yr .
Composition
of Waste
Southeastern U.S.
Physical
Form
Process
Yarn and Stock
Dyeing and Finishing
Amount for
Treatment/Disposal
Dye and Chemical
Containers
Fiber Drums and
Paper Bags with
Residual Dyestuff
and Chemicals
Solid
3>Q7 kg/kkg of Product
Total Containers
0.022 kgAkg of Product
Total
Hazardous Residuals
Trea tmen f/Di sposa 1
Costs/Levels
Investment Costs
Land
Oiher
Total Rxed
Annual Costs
Capital Costs
Operating
Maintenance
Energy & Power
Contract Services
Total Am realized
Cesl/kkg of product
Cost/kkg of potential Isy
hazardous waste
CostAkg of hazardous
constituents
Dollars (1975)*
Level 1
n
\J
0
0
0
0
0
0
221
22}
0.046
15
2,100
Level II
0
0
0
250
0
0
0
250
0.05
17
2,300
Level III
same
as
Level II
0.05
17
2,300
Diise.ripfion of Ti eajfaicn t/ Dis-rx?reI_T?cr.nr>|g£;;/:
Level I Off-site landfill by contractor
Level II Washing containers free of residual dyes and chemicals prior
Level III Same as Level II
* To convert costs to December, 1973 dollars, multiply by 0.82
to landfill ing
5-16
-------
levels. It should be kept in mind that the costs developed for sludge waste-
streams apply only to the typical plants in each category with their own
wastewater treatanent systems. As previously indicated, the ATM has esti-
mated that plants comprising 65% of industry production are direct discharge
plants. However, the percentage of the number of plants in each category
that have direct discharge is much less than 65% as shown previously in
Table 4-3. r *
The location of typical plants in the various industry categories
are all in either the eastern or southeastern part of the U.S. where the
major part of the textiles industry is located. Process equipment age was
not considered in the typical plant selection because it has no bearing on
the amounts of sludge generated or wasted.
Costs were developed for typical plants in each industry category
considering both the retention of sludge in aeration lagoons and the wasting
of excess sludge from these lagoons. Categories A (Wool Scouring) and D
(Woven Fabric Dyeing and Finishing) are the only two that typically waste sludge.
Typical plants in the other industry categories have not yet found it neces-
sary to waste sludge because of a low rate of solids buildup in their waste-
water treatment systems. In all cases where sludges are retained in unlined
lagoons, there is no cost for retaining the sludge. The costs for the
aeration lagoons are attributed to wastewater treatment. However, costs for
lining of these ponds to prevent leachate fron reaching ground water were
attributed to hazardous waste control. The annual costs for pond lining
can be related to annual production as cost/kkg of product. They cannot
be related to the wastestream or any part of the wastestream because no
information is available for the generation rate of the sludges in wastewater
treatment ponds. The sludge may be generated and retained for periods of
5 to 10 years or more in sane cases before permanent disposal becomes
necessary.
5.4.2.1 Category A — Wool Scouring, Table 5-6
following **** ^^ ™* *** te «»
level I (i) Retention of sludge in unlined treatment ponds
(2) General land disposal of wasted sludge
level II (l) Retention of sludge in concrete lined treatment
ponds
(2) Same as Level I
Level III (1) same as Level II
(2) Disposal of wasted sludge in approved landfill
5-17
-------
Table 5-6 Category A Typical Plant Costs For Trc'dment and Disposal, 1975
Annual Production
"(1975)
Location
Manufacturing
Process
Typical Plant
Characteristics
Identification of
Waste Stream(s)
(1) Retained Wastewater
Treatment Sludge
(2) Wasted Wastewater
Treatment Sludge
5,600 kkg/yr.
Composition
of V/aste
Eastern U.S.
Physical
Form
Water, fibers, grease Liquid-solid
biological + chemical sludge
suspended solids with
adsorbed heavy metals
nnrl chlorinated organics
Containing:
Wool Scouring
*
Amount Wasted for
Treatment/Disposal
(wet)
5,700 kc/kkc; of Product
(dry)
570 _kg/lckg of Product
3.0 kgAkg of product
heavy metals
Treatment/Disposal
Costs/ Levels
Investment Costs
Land
Other
Total Fixed
Annual Costs
Capital Costs
Operating
Maintenance
Energy £ Power
Contract Services
Total Annual ized
Cosl/kkg of product
Cost/kkg of wet sludge
Cost/kkg of dry sludge**
(1)
0
0
0
0
0
0
0
0
0
0
0
0
Dollars
Level 1
(2)
0
20,000
20,000
5200
60,000
3,000
800
0
69,000
12.32
2.16
21.60
(1 975)***
Level II
(0
0
57,500
57,500
6750
0
4400
0
0
11,150
2.00
NA
NA
(2)
same
as
Level 1
12.32
2.16
21.60
0.00073
_ ..
l«i/kka of product
•c m or . urga n i cs
Level III
(1)
same
as
Level 11
2.00
NA
NA
(2)
0
0
0
0
144,000
144,000
25.71
4.51
45.10
Not applicable
DescrJ££ion^Treatment/ Disposal Technology;
Level I (1) Retention of sludge in unlined treatment ponds
(2) General land disposal of wasted sludge
Level II (1) Retention of sludge in concrete lined treatment ponds (0.38 ha.)
(2) Same as Level I
Level III (1) Same as Level II
(2) Disposal of wasted sludge in approved landfill
*The amount of sludge retained cannot be based on the production rate. The estimated amount
retained by this typical plant is: 7,800 kg (wet), 780 kg (dry) containing 4.1 kg total heavy
metals and 0.001 kg total chlorinated organ let.
**Solids in sludge contain potentially hazardous constituents.
***To convert costs to December, 1973 dollars, multiply by 0.82.
5-18
-------
Level I costs were developed assuming:
a. an investment of $20,000 for a sludge truck amortized over
5 years.
b. a $2/kkg of liquid sludge disposal cost.
Level II costs were developed assuming:
a. an investment of $57,500 to line a 0.38 ha. treatment pond
with concrete amortized over 20 years.
b. a maintenance cost of $4400/year to clean the lined pond
every 5 years for inspection and repair of damage.
c. a $2Akg of liquid sludge disposal cost.
Level III costs were developed assuming:
a. same as Level II, a. and b. above.
b. a $45/kkg of dry solids sludge approved contractor landfill
disposal cost. This cost will be higher if the approved
landfill is not local (within 20 miles) to the plant.
The total costs for each level of technology are sunroarized below:
_ . „ Total Post
Cost Factor Level I Level II Level III
$Akg of product 12.32 14.32 27.21
$/kkg of waste stream 2.16 2.16 4.51
$/kkg of dry sludge 21.60 21.60 45.10
5.4.2.2 Category B — Wool Fabric Dyeing and Finishing, Table 5-7
^ , -, • Si6 ^i0^ Plant in this industry category was costed for the
following three levels of technology:
LeVSl X Si S?*81*1"1 of 8lua3B *» ^i^ treatment ponds
(2) The practice of wasting sludge was not found in
this category
Level II (1) same as Level I
(2) Same as Level II
Level III (1) Retention of sludge in 20 mil PVC lined treat-
ment ponds (0.89 ha.)
(2) Same as Level I
5-19
-------
Table 5-7 Category B Typical Plant Cosli For Treatment and Disposal, 1975
Annual Product ion
Location
Manufacturing
Process
Typical Plant
Characteristics
Identification of
Waste Si rt-am (s)
(1) Retained Wastewater
Treatment Sludge
(2) Wasted Wastewater
Treatment Sludge
5,200 _kl
-------
Levels I and II costs were developed assuming:
a. no cost for present sludge retention.
b. no cost for sludge disposal.
Level III costs were developed assuming:
a. an investment of $80,430 to line a 0.89 ha. treatoent pond
with 20 mil PVC amortized over 20 years.
b. a maintenance cost of $9,400/yr to clean the lined pond
every 5 years for inspection and repair of damage.
c. no cost for sludge disposal.
The total costs for each level of technology are surmBrized below.
Total Cost
Cost Factor
$/kkg of product
$/kkg of waste stream
$/kkg of dry sludge
5.4.2.3 Category C — Greige Goods
There are no potentially hazardous
category and therefore no costs are incurred.
Level I
0
0
0
Level II
0
0
0
Level III
3.62
not applicable
not applicable
*****
5.4.2.3 Category D - Woven Fabric Dyeing and Finishing, Table 5-8
The typical plant in this industry category was costed for thP
following three levels of technology: ^"^o^Y was costect tor the
Level I
Level II
(1) Retention of sludge in unlined treatment ponds
(2 General land disposal of wasted sludge
(1) Same as Level I
(2) Same as Level I
Level III (1) Retention of sludge in 20 mil PVC lined treat-
ment ponds (0.38 ha.)
(2) Disposal of wasted sludge in approved landfill
Levels I and II costs were developed assuming:
a. no cost for present sludge retention.
b. an investment of $20,000 for a sludge truck amortized over
5 years. -
c. a $2/kkg of liquid sludge disposal cost.
5-21
-------
Tabls 5-8 Category D Typical Plant Costs For Treatment and Disposal, 1975
Annual Production
Q975)
Location
Manufacturing
Process
Typical Plant
Characteristics
Identification of
Waste Strearr.(s)
0) Retained Wastewater
Treatment Sludge
(2) Wasted Wastewater
Treatment S|u,d
-------
Level III costs were developed assuming:
a. an investment of $33,900 to line a 0.38 ha. treatment
pond with 20 mil PVC amortized over 20 years.
b. a maintenance cost of $4,250/year to clean the lined pond
every 5 years for inspection and repair of damage.
c. an investment of $70,000 for sludge dewatering equipment
amortized over 10 years.
d. an annual ej?>ense of $16,500 to operate and maintain the
dewatering equipment.
e. a $45/kkg of dry solids sludge (dewatered to 20 percent
solids) approved landfill by a contractor disposal cost.
This cost will be higher if the approved landfill is not
local (within 20 miles) to the plant.
The total costs for each level of technology are summarized below.
Total Cost
Cost Factor Level I Level II Level in
$/kkg of product 5.54 5.54 7.35
$/kkg of waste stream 2.41 2.41 58.75
$/kkg of dry sludge 277 277 294
5.4.2.5 Category E — Knit Fabric Dyeing and Finishing, Table 5-9
The typical plant in this industry category was costed for the
following three levels of technology.
Level I (1) Retention of sludge in unlined treatment ponds
(2) The practice of wasting sludge is not typical
in this category
Level II (1) Retention of sludge in concrete lined treat-
ment ponds (0.38 ha.)
(2) Same as Level I
Level III (1) Same as Level II
(2) Same as Level I
Level I costs were developed assuming:
a. no cost for present sludge retention.
b. no cost for sludge disposal.
5-23
-------
Table 5-9 Category E Typical Plant Costs For Treatment and Disposal, 1975
AnnaI Prorl>.sction
Location
MaiiL'facturlng
Process
(1)
(2)
Typical Plant
Characteristics
Identification of
Waste Stream(y)
Retained Wastewater
Treatment Sludge
Wasted Wastewater
Treatment Sludge
4000 kkg/yr. Southeastern P.S.
Composition
of Waste
Physical
Form
Water, fibers, biological Liquid-solid
+ chemical suspended sludge
solids with adsorbed
heavy metals, chlorinated
organics + dyestuff
Knit Fabric
Dyeing and Finish ing
Amount* Wasted for
Trea tncn t/D i spos.? I
(wet)
0_ kgAka. of Product
Q__kgAkg of Product
1 rccnmen t/ u\ sposa 1
Costs/levels
Investment Costs
Land
Other
Total Fixed
Annual Costs
Capita! Costs
Operating
Maintenance
Energy & Power
Contract Services
Total Annualized
Cosi/kkg of precinct
Cost/kkg of wet sl.udge
Cost/kkg of dry sludge**
Level 1
(1) (2)
0 NA
0
0
0
0
0
0
0
0
0
0
0
Level II
(1) (2)
0 NA
5L500
57,500
6,750
4,400
0
11,150
2.79
NA
NA
Level III
(1) (2)
same NA
as
Level II
2.79
NA
NA
NA s "Not applicable
Description of TrcahrifinJ/ Disposal Technology
Level I (1) Retention of sludge in unlined treatment ponds
(2) The practice of wasting sludge is not typical in this category
Level II (1) Retention of sludge in concrete lined treatment ponds (0.38 ha.)
'(2) Same as Level I
Level III (1) Same as Level II
(2) Same as Level I
*The amount of sludge retained cannot be based on the production rate. The estimated amount
retained by this typical plant Is:
9,600 kg (wet),64 kg (dry) containing 0.32 kg total heavy metals,0.0041 kg total chlorinated
organics and 3.2 kg total dyestuff.
**Solids in sludge contain potentially hazardous constituents.
sts to December, 1973 dollars, multiply by 0.82.
*** To convert costs
5-24
-------
Levels II and III costs were developed assuming:
a. an investment of $57,500 to line a 0.38 ha. treatment
pond with concrete amortized over 20 years.
b. a maintenance cost of $4,400/year to clean the lined pond
every 5 years for inspection and repair of damage.
c. no cost for sludge disposal.
The total costs for each level of technology are surmarized below.
Total Cost
Post Factor Level I Level II Level III
$/kkg of product 0 2.79 2.79
$/kkg of waste stream 0 not not
applicable applicable
$/kkg of dry sludge 0 not not
applicable applicable
5.4.2.6 Category F — Carpet Dyeing and Finishing. Table 5-10
^««^•^Jb««••HI^M•^^•^^^HM^B
The typical plant in this industry category was costed for the
following three levels of technology:
Lsvel I (1) Retention of sludge an unlined treatment ponds
(2) The practice of wasting sludge is not typical
in this category
Level II (1) Same as Level I
(2) Same as Level I
Level III (1) Retention of sludge in 20 mil PVC lined treatment
ponds (0.38 ha.)
(2) Same as Level I
Levels I and II costs were developed assuming:
a. no cost for present sludge retention.
b. no cost for sludge disposal.
Level III costs were developed assuming:
a. an investment of $33,900 to line a 0.38 ha. treatment pond
with 20 mil PVC amortized over 20 years.
b. a maintenance cost of $4,250/year to clean the lined pond
every 5 years for inspection and repair of damage.
c. no cost for sludge disposal.
5-25
-------
Tcble 5-10 Category F Typical Plant Costs For Treatment and Disposal, 1975
Annual Production
(1975)
Local ion
Manufacturing
Process
Typical Plant
Charac'eristic
istics
Identification of
Waste Sheam(s)
(1) Retained Wastewater
Treatment Sludge
(2) Wasted Wastewater
Treatment Sludge
1 Q.OOO kkg/yr. Southeastern U.S
Carpet
Dyeing and Finishing
Composition Physical
of Wasi-e Form
Water, fibers, biological Liquid-solid
+ chemical suspended Sludge
solids with adsorbed
heavy metals, chlorinated
organ ics + dyestuff
Amount* Wasted for
Treatmen t/Disposa 1
(wet)
0 kg/!
-------
The total costs for each level of technology are summarized below.
Total Post
Cost Factor Level I Level II Level III
$/kkg of product 0 0 0.82
$/kkg of waste stream 0 0 not applicable
$/kkg of dry sludge 0 0 not applicable
5.4.2.7 Category G — Yarn and Stock Dyeing and Finishing, Table 5-11
The typical plant in this industry category was costed for the
following three levels of technology:
Level I (1) Retention of sludge in unlined treatment ponds
(2) The practice of wasting sludge is not typical
in this category
Level II (1) Same as Level I
(2) Same as Level I
Level III (1) Retention of sludge in 20 mil PVC lined treat-
ment ponds (0.89 ha.)
(2) Same as Level I
Levels I and II costs were developed assuming:
a. no cost for present sludge retention.
b. no cost for sludge disposal.
Level III costs were developed assuming:
a. an investment of $80,430 to line a 0.89 ha. treatment pond
with 20 mil PVC amortized over 20 years.
b. a maintenance cost of $9,400/year to clean the lined pond
every 5 years for inspection and repair of damage.
c. no cost for sludge disposal.
The total costs for each level of technology are suimiarized below:
Total Cost
Cost Factor Level I Level II Level III
$Akg of product 0 0 l.ll
$/kkg of waste stream 0 0 not applicable
$/kkg of dry sludge 0 0 not applicable
5-27
-------
Table 5-11. Category GTypical Plant Costs For Treatment and Disposal, 1975
Typical Plant
Characteristics
Identification of
Waste Stream(s)
(1) Retained Wastewater
Treatment SJqdge
(2) Wasted Wastewater
Treatment Sludge
Annual Production
(1975)
Location
17,000 kkg/yr. Southeastern U.5.
Composition
of Waste
Water, fibers, biological
+ chemical suspended
solids with adsorbed
heavy metals, chlorinated
organ ics and dyestuff
Physical
Form
Liquid-solid
sludge
Manufacturing
Process
Yarn and Stock
Dyeing and Finishing
Amount* Wasted for
Treatment/Disposal
(wet)
Q kg/kkg of Product
(dry)
0 kg/kkg of Product
Dollars (1975)'
Treatment/Disposal
Costs/Levels
Investment Costs
Land
Other
Total Fixed
Annual Costs
Capital Costs
Operating
Maintenance
Energy & Power
Contract Services
Total Annualized
Cost/kkg of product
Cosi/kkg of wet sludge
Cosl/kkq of dry sludge**
Level 1
(1) (2)
0 NA
0
0
0
0
0
TT
0
0
0
Level II
(1) W
same NA
as
Level 1
'
o
V
0
0
Level III
(1) (2)
0 NA
80,430
80,430
9,440
0
9,400
o
o
18,840
1.11
NA
NA
Description of ^Treatment/ Disposal Technology:
Level I (1) Retention of sludge in unlined treatment ponds
(2) The practice of wasting sludge is not typical in this category
Level II 0) Same as Level '
(2) Same as Level I
Level III (1) Retention of sludge in 20 mil PVC lined treatment ponds (0.89 ha.)
(2) Same as Level I ,, . .
"*The amount of sludge retained cannot be based on the production rate. The est.mated amount
20 OOolgCo/^'g (dry") containing 0.01 kg total heavy meta.s, 1.2 x lo'4 kg total ch.orinated
5-28
-------
5.5 Extrapolation of Technology Costs to the Industry Categories
Entire Industry
Table 5-12 summarizes the estimated treatment and disposal costs
for the whole of the industry categories and the entire textiles industry.
The costs relate only to that part of the industry category that presently
or will utilize the technologies cited. The following is an example of
the methodology used to extrapolate the costs for Category D, Woven Fabric
Dyeing and Finishing:
Level I
Total category cost = 1,801 x K0.019xa) 4- (5.54xb x c) 1
Level II
Total category cost = 1,801 x [(0.09xa) + (5.54xb x c)J
Level III
Total category cost = 1,801 x [(0.09xa) + (1.47xb) + (5.88xb x c)J
where 1,801 = total category production in kkg x 10
0.019, 5.44, 0.09, 1.47 and 5.88 = $Akg of product for each technology
taken from Tables 5-2 and 5-8
a = 1.0 = ratio of production in category that has container wastes
b = 0.65 = ratio of production in category with direct discharge
c = 0.56 = ratio of direct discharge production that wastes sludge
The estimated total annual costs for the entire industry at the
three levels of technology are $4,664,600, $6,532,800 and $11,704,000
respectively. The total industry rates in terms of $/kkg of product are
0.88, 1.24 and 2.21 respectively. The difference between what the industry
is presently spending and what is required for adequate health and environ-
mental protection is approximately $7,000,000. This amounts to only $1.32/kkg
of total production.
5.6 Comparison of Technology Costs with Sales Values for the Industry
Categories and the Entire Industry ~~ -
Table 5-13 summarizes the technology costs as a percent of sales
value for the various industry categories and the entire industry. The
sales values on the table were taken frcm 1972 Census of Manufacturers
reports and upgraded to 1975 values by assuming a 5% per year increase.
5-29
-------
u>
o
Table 5-12
Extrapolation of Technology Costs to the Industry
Categories and the Entire Textiles Industry
Annual Production
Annual Costs, 1975 Dollars*
Industry Category Thousand Metric Tons
A - Wool Scouring
B -Wool Fabric
Dyeing and Finishing
C - Greige Goods
D -Woven Fabric
Dyeing and Finishing
E - Knit Fabric
Dyeing and Finishing
F -Carpet
Dyeing and Finishing
G - Yarn and Stock
Dyeing and Finishing
TOTAL Industry
TOTAL Industry Rate $Akg
69
309
3,000
1,801
771
679
1,660
5,289*
of product
$/kkg of potentially hazardous
waste (dry weight)
$Akg
wastt
of potentially hazardous
g (wet weight)
Level 1
850,000
13,600
No potentially
3,700,000
21,600
3,400
76,000
4,664,600
0.88
$97.
$2.40
Level II
988,000
13,600
hazardous wastes
3,800,000
1,600,000
3,400
83,000
6,488,000
$1.23
$134
$3.35
Level III
1,910,000
754,000
- no technology costs
5,740,000
1,600,000
400,000
1,300,000
11,704,000
$2.21,
$242
$6.03
* To convert costs to December, 1973 dollars, multiply by 0.82
** Does not include Category C - Greige Goods
-------
Table 5-13
Comparison of Technology Costs With the Total Sales by
Industry Category and the Entire Textiles Industry
Industry Category
A -Wool Scouring
B -Wool Fabric
Dyeing and Finishing
C - Greige Goods
D - Woven Fabric
Dyeing and Finishing
E - Knit Fabric
Dyeing and Finishing
F - Carpet
Dyeing and Finishing
G - Yarn and Stock
Dyeing and Finishing
Weighted Average
For Entire Industry
Sales Value*
$Akg
3,000
1,650
No potentially hazardous
1,280
1,840
1,850
450
1,218
Technology Costs as Percent of Sales Value
Level 1
0.4
0.003
wastes - no technology
0.16
0.0015
0.0003
0.01
0.07
Level II
0.5
0.003
costs
0.16
0.11
0.0003
0.01
0.1
Level III
0.9
0.15
0.25
0.11
0.032
0.17
0.18
*1975 Dollars
-------
Values are less than 1% for all industry categories at all three
technology levels. The weighted average values for the entire industry
at the three levels of technology are 0.07%, 0.1% and 0.18% respectively.
For less than 0.2% of the sales value, the entire industry can provide
treatment/disposal technology for potentially hazardous land-destined
wastes that will give adequate health and envirormental protection.
5.7 Treatment/Disposal costs for Miscellaneous Atypical Potentially
Hazardous Textile? Industry Wastes
Table 5-14 • surtmarizes the current treatment/disposal costs for
the miscellaneous wastes listed in Table 4-4. These costs have not been
extrapolated for the entire industry because there is insufficient infor-
mation on the frequency of their occurrence. For some plants the costs of
treating and disposing of these wastes may be more significant than those
for either wastewater treatment sludges or dye and chemical containers.
5-32
-------
Table 5-14
Costs for Treatment/Disposal of
Miscellaneous Atypical Potentially
Hazardous Textile Industry Wastes
Waste Quantity
Suboategory* Description kg/kkg of oroduct
A
B
D
D
E
E
F
G
none
Still bottoms
from recovery
of chlorinated
solvents
Hydrocarbon
solvent and
sludges
Finishing sludges
containing
adhesives, silicones
and solvents
A cetone recovery
still bottoms
Perchloroethylene
still bottoms
Lint with wet
dye
Solvent and
resin slurries
none
5
50
333
63
10
12
0.09
* A - Wool Scouring
B - Wool Fabric D & F
D - Woven Fabric D & F
E- Knit Fabric D &F
F - Carpet D & F
G - Yarn and Stock D & F
Present
Treatment/Dispose I
landfill or dump
landfill
landfill
incineration
reclaimed by
contractor
landfill
landfilled
Present
Cost
$/year
100
5,000
1,500
7,150
no charge
10,800
100
5-33
-------
6.0 REFERENCES AND ADDITIONAL SOURCES OF INFORMATION
1. Standard and Poor's Industry Survey on the Textile Industry, June,
1975. p. 35-52.
2. United States Tariff Ocranission. Summaries of Trade and Tariff
Information, v.l. Schedule 3, Textile Fibers and Textile Products.
1C Publication 366. Washington, D.C., 1971.
3. United States International Trade Conmission. Synthetic Organic
Chemicals, United States Production and Sales, 1973. ITC Publication
728. Washington, D.C., 1975.
4. Clark's Directory of Southern Textile Mills. 1975 ed. dark
Publishing Company, Greenville, S.C. 459 p.
5. Davison's Textile Blue Book. 109 ed. 1975. Davison Publishing
Ccqpany, Ridgewood, N.J. 704 p. U.S. Bureau of the Census.
6. 1972 Census of Manufactures, Industry Series MC72(2)-22A, Weaving
Mills, SIC groups 221, 222, 223, and 224; MC72(P)-22B, Knit Goods,
SIC group 225; MC72(2)-22C, Dyeing and Finishing Textiles, Except
Wool Fabrics and Knit Goods, SIC group 226; MC72(2)-22D, Floor
Covering Mills, SIC group 227. U.S. Government Printing Office,
Washington, D.C., 1975.
7. Dun Market Indicator. Dun and Bradstreet. New York, New York., 1975.
8. U.S. EPA, Effluent Guidelines Division. Development Document for
Effluent Guidelines and Standards of Performance for Textile Mills.
EPA 440/1-74/022, January, 1974. 205 p.
9. U.S. Bureau of the Budget. Standard Industrial Classification Manual,
1972. Washington, D.C., U.S. Governtent Printing Office. 649 p.
10. Textile Industry Technology and Costs of Wastewater Control. Prepared
by I^ckwood Greene for The National Conmission on Water Quality.
Contract No. WQ5AC021, June, 1975. 478 p.
11. U.S. Congress Proposed Hazardous Waste Management Act of 1973.
93d Congress, 1st session, Senate. S.1086, introduced Mar. 6, 1973.
House of Representatives. H.R. 4873, introduced Feb. 27, 1973.
U.S. EPA. Washington, D.C.
12. California State Department of Public Health, Jan., 1972. Tentative
Guidelines for Hazardous Waste Land Disposal Facilities.
13. Office of Solid Waste Management Programs. Report to Congress Disposal
of Hazardous Wastes. EPA Publication SW-115. Washington, U.S
Goverrment Printing Office, 1974. 110 p.
6-1
-------
14. American Dye Manufacturers Institute, Inc. Dyes and the Environment.
v.l. September, 1973. 439 p; v.2. September, 1974. 159 p.
15. Etzel, J.E., and C.P.L. Grady, Jr. Effects of Dyes on the Anaerobic
Digestion of Primary Sewage Sludge. In Dyes and the Environment.
Chap. 7.v.l. American Dye Manufacturers Institute, Inc., Sept., 1973.
75 p.
16. Lamb, J.C. and L.W. Little. Acute Toxicity of 46 Selected Dyes to the
Fathead Minnow, Pimephales promelas. In Dyes and the Environment.
Chap. 5.v.l. American Dye Manufacturers Institute, Inc., Sept., 1974.
115 p.
17. Little, L.W. and M.A. Chillingworth. Effect of 56 Selected Dyes on
Growth of the Green Alba, Selenastrum capricomutum. In Dyes and
the Environment. Chap. 2.v.2. American Dye Manufacturers Institute,
Inc., Sept., 1974. 21 p.
18. Little, L.W., W.B. Durkin, J.C. Lamb, and M.A. Chillingworth. Effect
. of Biological Treatment on Toxicity of Dyes to Fish. In Dyes and
the Environment. Chap. 3. v.2. American Dye Manufacturers Institute,
Inc., Sept., 1974. 21 p.
19. Hunter, J.B. Report on the Effect of Dyes on Aerobic Systems. In
Dyes and the Environment. Chap. 6. v.l. American Dye Manufacturers
Institute, Inc., Sept,, 1974. 139 p.
20. Poweli, S.D. Biodegradation of Anthraquinone Disperse Dyes. Masters
Thesis, Georgia Institute of Technology, September,; 1969. 42 p.
21. Anderson, J.H. Biodegradation of Vinyl Sulfone Reactive Dyes. Masters
Thesis, Georgia Institute of Technology, December, 1969. 40 p.
22. Pratt, Jr., H.D. A Study of Some Azo Disperse Dyes in Waste Disposal
Systems. Masters Thesis, Georgia Institute of Technology, September,
1968. 36 p.
23. The Contribution of Dyes to the Metal Content of Textile Mill Effluents.
In Dyes and the Environment, v.l. American Dye Manufacturers
Institute, Inc., September, 1973. 14 p.
24. Soria, J.R.R. Biodegradability of Sane Dye Carriers. Masters Thesis,
Georgia Institute of Technology, March, 1970. 63 p.
25 Code of Federal Regulations, Transportation. Parts 100 to 199.
*' Revised as of October, 1973. U.S. Government Printing Office.
Washington, 1973. Section 173.118. p. 114.
6-2
-------
26. New Orleans Area Water Supply Study, Draft Analytical Report, 1974
with April 1975 updates. Surveillance and Analysis Division, Region
VI, U.S. EPA. Dallas, Texas.
27. Office of Toxic Substances. Identification of Organic Compounds in
Effluents from Industrial Sources. Prepared by Versar, Inc.,
Washington, D.C., April, 1975. 172 p.
28. U.S. EPA, Cincinnati, Ohio. Organic Compounds Identified in Drinking
Water in Cincinnati, Ohio. 1972 and 1974. Unpublished data.
29. U.S. Department of Health, Education and Welfare. Occupational
Exposure to Cotton Dust. Washington, D.C., 1974. 159 p.
30. Personal ocmnunication. D. Guinan, Versar, Inc. to John M. Peters, M.D.,
Associate Professor of Occupational Medicine, School of Public Health,
Harvard University, Boston, Massachusetts.
31. Personal cotmunication. D. Guinan, Versar, Inc. to Harold R. Imbus,
M.D., Medical Director, Burlington Industries, Greensboro, N.C.
32. Personal ccnmunication. E. Abrams, Versar, Inc. to Kim Ives, Office
of Solid Waste Management, State of Georgia, Environmental Protection
Division.
33. Eldredge, R.W. Ultimate Disposal of Residual Liquids and Solids
Fran Pollution Abatement Efforts. Roy F. West on, Inc. Presented at
16th Annual Meeting AlChE, Delaware Valley Section, University of
Delaware, Newark, March 18, 1971. 6 p.
34. Georgia Department of Natural Resources, EPD. Rules and Regulations
for Solid Waste Management. Atlanta, Ga., October, 1974. Chaps.
391-3-4. p. 501-518.
35. Process Design Manual for Sludge Treatment and Disposal. U.S. Environ-
mental Protection Agency Technology Transfer Series, October, 1974.
EPA 625/1-74-006.
36. Lindsay, A. and S. Morekas. Union Carbide Corporation - Industrial
Waste Treatment and Ultimate Disposal - Institute, West Virginia.
Trip Report. U.S. Environmental Protection Agency, Office of Solid
Waste Management Programs, January 7, 1975.
37. Assessment of Industrial Hazardous Waste Practices, Inorganic Chemical
Industry. Draft Final Report, Contract No. 68-01-2246. Prepared by
Versar, Inc. for U.S. Environmental Protection Agency, Office of
Solid Waste Management Programs, March, 1975. 457 p.
38. Personal ccmnunication. L. Parker, Versar, Inc. to Mr. J.T. Graves,
Door-Oliver, Inc., Stamford, Connecticut.
6-3
-------
ADDITIONAL SOURCES OF INFORMATION
A Review of Water Impellent Finishes and Coatings. Textile Tech-
nology Monograph Series, Monograph #105. American Association
for Textile Technology, Inc., December, 1970. 10 p.
Office of Research and Monitoring. A Study of the Photodegradation
of Comercial Dyes. Environmental Protection Technology Series,
EPA-R2-73-058 March, 1973. 94 p.
Book of Papers 1974 National Technical Conference. American Asso-
ciation of Textile Chemists and Colorists, 1974.
Office of Research and Development. Chemical/Physical and Biological
Treatment of Wool Processing Wastes. EPA-660/2-73-036, January, 1974.
Cherimisinoff, Paul N. Disposal of Hazardous Wastes: Treat or Truck.
Pollution Engineering, May, 1975. p. 52-53.
Office of Research and Monitoring. Dyestuff Color Removal by Ionizing
Radiation and Chemical Oxidation. Environmental Protection Technology
Series, EPA-R2-73-048, March, 1973. 118 p.
Office of Planning and Evaluation. Economic Analysis of Proposed
Effluent Guidelines, Textile Industry. EPA-230A-73-028, March, 1974.
Fiber Facts: 1969-1970. FMC Corporation, American Viscose Division.
Philadelphia, Pennsylvania, 1969.
Garrison, A.W. and D.W. Hill. Organic Pollutants from Mill Persist
in Downstream Waters. Southeast Water Laboratory, EPA. Athens,
Georgia, 1971.
Hart, F.T., Q. Helfgott, and R.G. Bedard. An Evaluation of Persistency
for Waterborne Organics. Presented at 30th Annual Purdue Industrial
Waste Conference, Purdue University, Lafayette, Indiana, May 6-8,
1975. 16 p.
South Carolina Department of Health and Environmental Control.
Industrial Solid Waste Disposal Regulation for Minimum Standards and
Permit Application Guidelines for the State of South Carolina,
March 8, 1972. 16 p.
In-Plant Control of Pollution: Upgrading Textile Operations to Reduce
Pollution. EPA Technology Transfer Publication, EPA-625/3-74-004,
Parts 1 and 11, October, 1974.
International Textile Bulletin. World Edition, Dyeing, Printing,
Finishing, March, 1972.
6-4
-------
Leatherland, L.C. The Treatment of Textile Wastes. Presented at 24th
Purdue Industrial Waste Conference, Purdue University, Lafayette,
Indiana, May 6-8, 1969.
Man-Made Fiber and Textile Dictionary. 3rd ed. Celanese Corporation,
December, 1974.
Man-Made Fiber Fact Bock. Man-Made Fiber Producers Association, Inc.
Washington, D.C., 1974.
Page, G.C. and R.M. Bethea. The Collection of Lint Fly by Wet Im-
pingement. Journal of the Air Pollution Control Association. v.22(5),
May, 1972. p. 372-373.
Perspectives for Textile Management. No. 20. Kurt Salmon Associates,
Inc., July, 1974. 12 p.
Porter, J.J., D.W. Lyons, and W.F. Nolan. Water Uses and Wastes in
the Textile Industry. Environmental Science and Technology. v.6(l),
January, 1972. p. 36-41.
Press, J.J. ed. Man-made Textile Encyclopedia. New York Textile Book
Publishers, Inc., Interscience Publishers, Inc., 1959.
Proceedings: 14th Textile Chemistry and Processing Conference,
Agricultrual Research Service, U.S. Department of Agriculture,
February, 1975.
Products/75. Journal of the American Association of Textile Chemists
and Colorists. v.6(10A), October, 1974. 436 p.
Water Quality Office. State of the Art of Textile Waste Treatment.
Water Pollution Control Research Series 12090ECS02/71. U.S. Government
Printing Office, Washington, February, 1971. 348 p.
Summary Annual Report, EPA Grant No. R802964-01. Identification of
Organic Compounds in Textile Plant Effluents. Dr. A.W. Garrison,
Project Officer. Southeast Environmental Research Laboratory, EPA.
Athens, Georgia, February 28, 1975. 6 p.
Technical Bulletin. NSWMA. v.7(7), August, 1975. 4 p.
The Textile Industry and the Environment; Proceedings; American
Association of Textile Chemists and Colorists, Environmantal Sciences
Technology Cotitdttee. Atlanta, Georgia. Mar. 31 - Apr. 1, 1971.
Wilhelmi, A.R. and R.O.B. Ely. The Treatment of Toxic Industrial
Wastewaters by a Two-Step Process. Presented at 30th Annual Purdue
Industrial Waste Conference, Purdue University, Lafayette, Indiana,
May 8, 1975. 25 p.
6-5
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7.0 ACKNCMJEDGEMENTS
The preparation of this report was accomplished through the efforts
of the staff of General Technologies Division, Versar Inc., Springfield,
Virginia, under the direction of Mr. Edwin F. Abrams, Program Manager.
Mr. Matthew A. Straus, Project Officer, Timothy Fields, Jr., Acting
Program Manager, and William Sanjour, Branch Chief, Hazardous Waste
Division, through their assistance, leadership, advice and careful review
of the draft report have made an invaluable contribution to the preparation
of this report.
Appreciation is extended to the following trade associations for assis-
tance and cooperation in this program:
American Textile Manufacturers Institute
Carpet and Rug Institute
Northern Textile Association
Appreciation's also extended to the many textile companies, state
and federal agencies who gave us invaluable assistance and cooperation
in this program. Also, our appreciation is extended to the individuals
of the technical staff of General Technologies Division of Versar Inc.,
for their assistance during this program. Specifically our thanks to:
Dr. Robert G. Shaver, Vice President
Mrs. D. K. Guinan, Environmental Chemist
Mr. D. L. Derkics, Environmental Scientist
Mr. S. Powers, Environmental Scientist
Dr. L. Parker, Senior Chemical Engineer
Mr. M. C. Calhoun, Field Engineer
Dr. M. Khattak, Analytical Chemist
Mr. F. Fortess, Consultant
Mr. H. Henderson, Consultant
Acknowledgement and appreciation is also given to the secretarial staff
of General Technologies Division of Versar Inc. for their efforts in the
typing of drafts/ necessary revisions, and final preparation of this document.
7-1
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APPENDIX A
GLOSSARY
Accelerant - A chemical used to speed up chemical or other processes. For
example, accelerants are used in dyeing triacetate and polyester fabrics.
Acid Dyes - See Dyes.
Actinic Resistance - Ability to retain strength and resist deterioration on
exposure to sunlight.
Activated Carbon - Charcoal, mostly of vegetable origin, of high absorptive
capacity.It is used for decolorizing liquids and other adsorption
purifications. Usually made by carbonization and chemical activation.
Aesthetics - In textiles, properties perceived by touch and sight, such as
the hand, color, luster, drape, and texture of fabrics and garments.
After treatment - A term which is normally used in relation to processes
carried out after dyeing or printing to iitprove fastness properties
and/or to produce normal shades.
Ageing - 1. Ihe deterioration of textile or other materials caused by the
gradual oxidation in storage and/or exposure to light. 2. The oxida-
tion stage of alkali-cellulose in the manufacture of viscose rayon
from bleached wood pulp. 3. Originally a process in which printed
fabric was exposed to a hot, moist atmosphere. Presently, the term is
applied to the treatment of printed fabric in moist steam in the absence
of air. Ageing is also used for the development of certain colors in
dyeing, e.g., aniline black.
Ager - A steam chamber used for the ageing of printed or padded material.
Aniline Dyes - See dyes.
Animal Fibers - Fibers of animal origin such as wool, alpaca, camel hair,
and silk.
Anthraquinone Dyes - See Dyes.
Azo Dyes - See Dyes.
Azoic Dyes - See Dyes, Naphthol Dyes.
Backcoating - The application of latex or adhesive to the back of a carpet
to anchor the tufts, usually followed immediately by the addition of
a secondary backing material such as woven jute or nonwoven polypro-
pylene.
A-l
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Backing - 1. A general term for any system of yarn which interlaces on the
back of a textile material. 2. A knit or woven fabric or plastic foam
bonded to a face fabric. 3. A knit or woven fabric bonded to a vinyl
or other plastic sheet material. 4. See Carpet Backing.
Backwinding - 1. Rewinding yarn from one type of package to another.
2. Winding yarn as it is deknit.
Balling Up - A yarn defect in which loose of frayed fibers form into a ball
and are then woven into the fabric.
Basic Dyes - See Dyes.
BCF Yarns - BuUced continuous filament yarns for carpet trade, mostly nylon
but occasionally polypropylene.
Beam - A cylinder of wood or metal, usually with a circular flange on each
end, on which warp yarns are wound for slashing, weaving, and warp
knitting.
Beam Dyeing Machine - A high-temperature dyeing machine _ forJyeing warp
yarns or fabrics which have been wound onto a special beam, the barrel
of which is evenly perforated with holes. The dye liquor is forced
through the yarn or fabric from inside to outside.
Beaming - The operation of winding warp yarns onto a beam in preparation for
slashing, weaving, or warp knitting.
Beck - A vessel for dyeing fabric in rope form, consisting primarily of a
tank and a reel to advance the fabric.
Bleaching - Any of several processes to remove the natural and artificial
Imparities in fabrics to obtain clear whites for finished fabric or in
preparation for dyeing and finishing.
Bleeding - Loss of color by a fabric or yarn when immersed in water, a solvent,
5Ta similar liquid medium, as a result of improper dyeing or the use
of dyes of poor quality. Fabrics that bleed cause staining of white
or light shade fabrics in contact with them while wet.
Blending - Ihe combining of staple fibers of different physical characteris-
tics to assure a uniform distribution of these fibers throughout the
yarn.
Bonded Fabric - A fabric containing two or more layers of cloth joined
together with resin, rubber, foam, or adhesive to form one ply.
Rrushina - A finishing process in which rotating brushes raise a nap on
knit or woven fabrics. Brushing is used on sweaters, scarves, knit
underwear, wool broadcloths, etc.
A-2
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Calendering - A mechanical finishing process for fabrics to produce special
effects, such as high luster, glazing, moire, and embossed effects.
In this operation, the fabric is passed between heated rolls under
pressure.
Carbonizing - A chemical process for eliminating cellulosic material from
wool or other animal fibers. The material is reacted with sulfuric
acid or hydrogen chloride gas followed by heating. When the material
is dry the carbonized cellulose material is dust-like and can be
removed.
Carding - A process in the manufacture of spun yarns whereby the staple
is opened, cleaned, aligned, and formed into a continuous, untwisted
strand called a sliver.
Carpet Backing - A primary backing through which the carpet tufts are inserted
is always required for tufted carpets. The backing is usually made of
woven jute or formed (nonwoven) man-made fiber fabrics. A secondary
backing, again made of jute or man-made fibers, is normally added at the
latex backcoating stage. Carpet backings are an important end use for
formed fabrics.
Carpets - Heavy functional and ornamental floor coverings consisting of pile
yarns or fibers and a backing system. They may be tufted or woven.
Also see Tufted Carpet.
Carrier - 1. A product added to a dyebath to promote the dyeing of hydro-
phobic man-made fibers and characterized by the affinity for, and
ability to swell, the fiber. 2. A moving holder for a package of yarn
used on a braiding machine. 3. A term sometimes used to describe
the tube or bobbin on which yarn is wound.
Cationic Dyes - See Dyes, Basic Dyes.
Cellulose Material - Material composed of or derived from cellulose (e.g.,
cotton, rayon, acetate and triacetate).
Chain Dyeing - See Dyeing.
Cheese - A cylindrical package of yarn wound on a flangeless tube.
Chelating Agent - A compound that will inactivate a metallic ion by making
it an integral part of an inner ring structure. The metal is
attached by coordinate links to two or more nonmetal atoms in the
same molecule.
Circular-Knit Fabric - A tubular weft-knit fabric made on a circular-knit-
" ting machine.
A-3
-------
Coated Fabric - A fabric to which a substance such as lacquer, plastic, resin,
- rubber, or varnish has been applied in finnly § adhering layers to provide
certain properties, such as water impermeability.
Combing - A step subsequent to carding in cotton and worsted system processing
- which straightens the fibers and extracts neps, foreign natter, and
short fibers. Garbing produces a stronger, more even, more compact,
finer, smoother yarn.
Coning - The transfer of yarn fron skeins or bobbins or other types of packages
to cones.
Converted Fabric - A finished fabric as distinguished from greige fabric.
Converter - An individual or organization which buys greige fabrics and sells
- thiS as a finished product to cutters, wholesalers, retailers, and others.
The converter arranges for the finishing of the fabric, namely bleach-
ing, mercerizing, dyeing, printing, etc., to the buyers' specifications.
Crimp - The difference in distance between two points on an unstretched fiber
^^and the same two points when the fiber is straightened under specified
tension.
Crocking - The removal of dye from a fabric as a result of insufficient dye
- penetration or fixation. This is caused by the use of improper dyes
o^Sing^ethods, or insufficient washing and treatment after the dyeing
operation.
Cross Dyeing - See Dyeing.
Cut Pile - A pile surface obtained by cutting the loops of yarn in a tufted
or woven carpet.
Decatizing (Decating) - A finishing process in which t****?^*-
- on a perforated roller, either has hot water circulated through
°wet decatizing) , or has steam blown through it (dry decatizing) . The
process is aimed chief ly at improving the hand and removing wrinkles.
Denier - A weight-per-unit-length measure of any linear material. °f2fially'
- It is the nurtber of unit weights of 0.05 grams P» /f^S*3^®**'
This is numerically equal to the weight in grams of 9,000 meters of the
material.
Dereaistering (crimp) - The process of disordering or disaligning the crijnp
in a tow band to produce bulk.
Developed Dyes - See Dyes.
Developing - A stage in dyeing or printing in which leuco compounds, dyes
ordye intermediates are converted to the final, stable state or shade.
A-4
-------
Dip Dyeing - See Dyeing.
Direct Dyes - See Dyes.
Direct Printing - See Printing.
Discharge Printing - See Printing.
Disperse Dyes - See Dyes.
Doctor Blade - A metal knife which cleans or scrapes the excess dye frcm
engraved printing rollers, leaving dye paste only in the valleys of
engraved areas. Also used to describe other blades which are used
to apply materials evenly to rollers or fabrics.
Dope-Dyed - See Dyeing, Mass-Colored.
Double-Knit Fabric - A circular-knit fabric with a double thickness pro-
duced by using a double stitch on machines employing two sets of
needles (dial and cylinder).
Drafting - See Drawing 1.
Drape - A term to describe the way a fabric falls while it hangs.
Drawing - 1. The process of attenuating or increasing the length per unit
weight of laps, slivers, slubbings, or rovings. 2. The hot or cold
stretching of continuous filament yarn or tow to align and arrange
the crystalline structure of the molecules in order to achieve improved
tensile properties.
Drying Cylinders - Any of a number of heated revolving cylinders for drying
fabric or yarn. They are arranged either vertically or horizontally
in sets, with the number varying according to the material to be
dried. They are often internally heated with steam and Teflon-coated
to prevent sticking.
Dyeing - A process of coloring fibers, yarn, or fabrics with either natural
or synthetic dyes. Some of the major dyeing processes are described
below:
a. Batik - A resist-dyeing process in which portions of a fabric
are coated with wax, and during the dyeing process, only the
uncovered areas take the dye. The process can be repeated so
that several colors are used. Batik dyeing is often imitated in
machine printing.
b. Chain Dyeing - A method of dyeing yarns and fabrics of low tensile
strength by tying them end-to-end and running them through the
dyebath in a continuous process.
A-5
-------
•• -
the different fibers.
d. Dip Dyeing - A general term used for the dyeing of hosiery and other
knit goods to differentiate with yarn dyeing. In this sense, it is
synonymous with piece dyeing.
e. High-Temperature Dyeing - A dyeing operation in which the aqueous
dyebathsVe maintained at temperatures greater than 100 C by use
of pressurized equipment. Used for many man-made fibers.
f. ingrain - A term used to describe yarn or stock which is dyed in two
cTm^ shades prior to knitting or weaving to create blended color
effects in fabrics.
a Mass-Colored - A term to describe a man-made fiber (yarn, staple, or
g* S SiS has been colored by the introduction of pigments or insoluble
Ss £Ertnf polymer melt or spinning solution prior to extrusion.
Usually, the colors are fast to most destructive agents.
h. Muff-Dyeing - A form of yarn dyeing in which the cone has been removed.
i. Package Dyeing - See Dyeing, Yarn Dyeing.
j. Pad Dyeing - A form of dyeing whereby a dye solution is applied by
means of a padder or mangle.
k. Piece Dyeing - Ohe dyeing of fabrics "in the piece", i.e., g^ic
form after weaving or knitting as opposed to dyeing in the form of
yarn or stock.
1. Pressure Dyeing - Dyeing by means of forced c
through packages of fiber, yarn, or fabric under
pressure (100-200 psi).
m. Printing - See Printing.
n.
Reserve Dyeing - 1. A method of dyeing in which one component of a
to be colored but which are not substantive to the fiber to be
reserved. 2. A method of treating yarn or fabric so that intne
Subsequent dyeing operation the treated portion will not be dyed.
o. Skein Dyeing - ?he dyeing of yarn in tiie form of skeins, or hanks.
p Solvent Dyeing - A dyeing method based on the solubility of the dye
P' £ some Squid other than water, although water may be present in
the dyebath.
A-6
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ace Dyeing - A yarn-dyeing process in which each strand is dyed
with more than one color at irregular intervals. Space dyeing
produces an effect of unorganized design in subsequent fabric form.
The two primary methods are knit-de-knit and warp printing.
r. Spun Dyed - See Dyeing, Mass-Colored.
s• Stock Dyeing - The dyeing of fibers in staple form.
t. Thermal Fixation - A process for dyeing polyester, where the color
is diffused into the fiber by means of dry heat.
u- Union Dyeing - A method of dyeing a fabric containing two or more
fibers or yarns to the same shade so as to achieve the appearance
of a solid colored fabric.
v. Yam Dyeing - The dyeing of yarn before the fabric is woven or knit.
Yam can be dyed in the form of skeins, muffs, packages, cheeses,
cakes, chain-warps, and beams.
Dyeing Auxiliaries - Various substances which can be added to the dyebath
to aid dyeing. They may be necessary to transfer the dye from the
bath to the fiber or they may provide improvements in leveling, penetra-
tion, etc. Also called dyeing assistants.
Dyes - Substances which add color to textiles by adsorption into the fiber.
Dyes differ in their resistance to sunlight, perspiration, washing,
gas, alkalies, and other agents; their affinity for different fibers;
their reaction to cleaning agents and methods; and their solubility
and method of application. Dyes are commercial preparations containing
only approximately 50 per cent pure dyestuff, with the rest being some
inert filler such as sugar and surfactants. Various classes and types
are listed below:
a. Acid Dyes - A class of dyes used on wool and other animal fibers.
Acid dyes are seldom used on cotton or linen since this process
requires a mordant. Acid dyes are widely used on nylon when high
washfastness is required. In some cases, even higher washfastness
can be obtained by after-treatment with fixatives. Acid dyes are
comparatively small dye molecules with one or more sulfonic acid
groups attached to the organic substrates.
b. Aniline Dyes - Dyes derived chemically from aniline or other coal
tar derivatives. Aniline dyes are used mainly on cotton.
c- Anthraquinone Dyes - Dyes which have anthraquinone as their base and
the carbonyl group ^C = 0 as the chromophore. Anthraquinone-
based dyes are found in most of the synthetic dye classes.
A-7
-------
d Azo Dyes - Dyes characterized by the presence of the azo group
the chrorophore. Azo dyes are found in mny of the
synthetic dye classes. Azo dyes are used mainly on cotton and
rayon fabrics.
e. Azoic Dyes - See Dyes, Naphthol Dyes.
Dves - A class of positive-ion-carrying dyes known for their
^t hues. Basic dyes are composed of large-molecule, water-
which have a direct affinity for wool and silk and can
ub wc a
appliS to Stton with a ircrdant. 'The fastness of basic.dyes on
se fiberfis very poor. Basic dyes are also used on basic-
lTaSlics, ^acrylics, and polyesters, on which they exhibit
reasonably good fastness.
g. Cationic Dyes - See Dyes, Basic Dyes.
h Developed Dyes - Dyes which are formed by the use of a developer.
1*
jjt:Vfc:xul-*2=<;p>
The substrate is first dyed in a neutral solution Wltna oye_uat»e,
s^js?ss--s s"--Jr^iSSS1"'
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and lightfastness. Developed dyes are used on both cotton and
rayon fibers.
i Direct Dyes - A class of dyestuf f s which are applied di^^lyh^eg ^n
'
ass s
direct colors").
*
most man-made fibers.
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desired.
s rJK-iSSS srsr
used on nylon, silk and wool.
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m. Naphthol Dyes - A type of azo compound formed on the fiber by first
treating the fiber with a phenolic compound. The fiber is then
immersed in a second solution containing a diazonium salt which
reacts with the phenolic compound to produce a colored azo compound.
Since the phenolic compound is dissolved in a caustic solution, these
dyes are mainly used for cellulose fibers, however, other fibers
can be dyed by modifying the process. (Also see Developed Dyes).
n. Premetallized Dyes - Acid dyes which are treated with coordinating
metals such as chromium. This type of dye has much better wet-
fastness, than regular acid dyes. Premetallized dyes are used on
nylon, silk and wool.
o. Sulfur Dyes - A class of water-insoluble dyes which are applied
in a soluble, reduced form from a sodium sulfide solution which are
then reoxidized to the insoluble form on the fiber. Sulfur dyes
are mainly used on cotton for economical dark shades of moderate
to good fastness to washing and light. They generally give very
poor fastness to chlorine.
p. Vat Dyes - A class of water-soluble dyes which are applied to the
fiber in a reduced, soluble form (leuco compound) and then reoxidized
to the original insoluble form. Vat dyes are among the most
resistant dyes to both washing and sunlight. They are widely used
on cotton, linen, rayon and other vegetable fibers.
Dye Sites - Functional groups within a fiber which provide sites for chemical
bonding with the dye molecule. Dye sites may be either in the polymer
chain or in chemical additives included in the fiber.
Dyestuff - The chemical component of dyes that imparts the color to a fabric;
usually a complex, organic compound.
Exhaustion - During wet processing, the ratio at any time between the amount
of dye or substance taken up by the substrate and the amount originally
available.
Extract Printing - See Printing, Discharge Printing.
Fastness - Resistance to facing; i.e., the property of a dye to retain its
color when the dyed (or printed) textile material is exposed to con-
ditions or agents such as light, perspiration, atmospheric gases, or
washing that can remove or destroy the color. A dye may be reasonably
fast to one agent and only moderately fast to another. Degree of fast-
ness of color is tested by standard procedures. Textile materials often
must meet certain fastness specifications for a particular use.
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Feel - See Hand.
Fell - The end of a piece of fabric which is woven last.
Fiber-Reactive Dyes - See Dyes.
Filament - A fiber of indefinite or extreme length such as found naturally
IrTsilk. Man-made fibers are extruded into filaments which are
converted into filament yarn, staple, or tow.
Filling - In a woven fabric, the yarn running from selvage to selvage at
right angles to the warp. Each crosswise length is called a pick.
In the weaving process, the filling yarn is carried by the shuttle or
other type of yarn carrier.
Finish - 1. A substance or mixture of substances which are added to textile
materials to impart desired properties. 2. A process, physical or
chemical, applied to textile materials to produce a desired effect.
3. A property, such as smoothness, drape, luster,water repellency,
flame retardancy or crease resistance which is produced by 1 and/or
2 above. 4. The state of a textile material as it leaves a process.
(Also see Finishing).
Finishing - All the processes through which the fabric is passed after bleach-
Ing7 dyeing, or printing in preparation for the market or use. Finish-
ing includes such operations as heat-setting, napping, embossing, press-
ing, calendering, and the application of chemicals which change the
character of the fabric. The term finishing is also sometimes used to
refer collectively to all processing operations above, including
bleaching, dyeing, printing, etc.
Fixation - The process of setting a dye after the dyeing or printing
operation, usually by steaming or other heat treatment.
Flock - The material obtained by reducing textile fibers to fragments by
cutting or grinding. There are two main types: precision cut flock,
where all fiber lengths are approximately equal, and random cut flock,
where the fibers are ground or chopped to produce a broad range of
lengths.
Flocking - A method of cloth ornamentation in which adhesive is printed or
Seated on a fabric, and finely chopped fliers are applied all over by
means of dusting, air-blasting, or electrostatic attraction. In flock
printing, the fibers adhere only to the printed or coated areas and
are removed from the unprinted areas by mechanical action.
Fly - The short, waste fibers that are released into the air in textile
processing operations such as picking, carding, spinning, and
weaving.
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Formed Fabric - An assembly of textile fibers which are held together by
the mechanical interlocking in a random web or mat, by flosing the
fibers or by bonding with a cementing medium such as starch, glue,
casein, rubber latex, or one of the cellulose derivatives or syn-
thetic resins. Formed fabrics are used for expendable items, such
as hospital sheets, napkins, diapers and wiping cloths, as the base
material for the coated fabrics, and in a variety of other applications.
Fulling - A finishing process used in the manufacture of woolen and worsted
fabrics. The cloth is subjected to moisture, heat, friction, chemicals,
and pressure which cause it to mat and shrink appreciably in both the
warp and filling directions, resulting in a denser, more compact fabric.
Garnetting - A process for reducing various textile waste materials to fiber
by passing them through a machine called a garnett, which is similar to
a card.
Gilling - See Pin Drafting.
Gray Fabric - See Greige Fabric.
Grease Wool - Wool shorn from the sheep, unsecured and in its natural state.
Greige Fabric - A fabric just off the loom or knitting machine, i.e., in an
unfinished state.
Grey Fabric - See Greige Fabric.
Hand - The qualities of a fabric, e.g., softness, firmness, elasticity,
fineness, resilience, and other qualities perceived by touch.
Hank - A skein of yarn.
Heat-Setting - Ihe process of imparting dimensional stability and often other
desirable properties such as wrinkle resistance and improved heat resist-
ance to man-made fibers, yarns, and fabrics by means of either moist or
dry heat.
Heat-Transfer Printing - See Printing.
Heddle - A cord around steel wire, or thin flat strips with a loop or eye
near the center through which one or more warp threads pass on the loom
so that its movement .may be controlled in weaving. Ihe heddles are
held at both ends by the harness frame. They control the weave pattern
and shed as the harnesses are raised and lowered during the weaving.
High Temperature Dyeing - See Dyeing.
Hue - The attribute of colors that permits them to be classed as red,
yellow, green, blue, or an intermediate between any contiguous pair
of these colors.
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Hvdrophdbic - Lacking affinity for, or the ability to absorb water.
J-Box - A J-shaped holding device used in continuous operations to provide
varying amounts of intermediate material storage such as in wet
processing of fabrics and in tow production. The material is fed at
the top and is plaited down to fill the long arm before being with-
drawn from the short arm.
Jet Dyeing Machine - A high-temperature piece-dyeing machine which circulates
^Slye liquor through a Venturi jet, thus imparting a driving force
to move the fabric. The fabric, in rope form, is sewn together to
form a loop.
Ji2 - A dyeing machine in which the fabric in open-width form is transferred
repeatedly from one roller to another, passing each time through a
batch of relatively small volume. Jigs are used for scouring, dyeing,
bleaching and finishing.
jute - A bast fiber used for sacking, burlap, and tmne, and as a backing
material for tufted carpets.
Kier - A large metal tank, capable of being heated uniformly and used for
wet processing.
Kier Boiling - The process of boiling cellulosic materials in alkaline
liquors in a kier at or above atanospheric pressure.
Knitting - A method of constructing fabric by interlocking a series of
loops of one or more yarns. The two major classes of knitting are
warp knitting and weft knitting:
a. Warp Knitting - A type of knitting in which the yarns generally
runlengthwiie in the fabric. The yarns are Prepared as warps
on the beams with one or more yarns for each needle. Examples
of this type of knitting are milanese, raschel, and tricot
knitting.
1. Milanese Knitting - A type of run-resistant warp knitting with
a diagonal rib effect using several sets of yarns.
2. Raschel Knitting - A versatile type of warp knitting made in
plain and jacqulrd patterns; the latter can be made^with
intricate eyelet and lacy patterns and is often used for
underwear fabrics. Raschel fabrics are coarser than other
warp knit fabrics, but a wide range of fabrics can be made.
Raschel knitting machines have one or tsro sets of latch
needles and up to thirty sets of guides.
3 Tricot Knitting - A run-resistant type of warp knitting in
' which either single or double sets of yarn are used.
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B. Vfeft Knitting - A cannon type of knitting, in which one continuous
thread runs crosswise in the fabric making all of the loops in
one course. Vfeft knitting types are circular and flat knitting:
1. Circular Knitting - The fabric is produced on the knitting
machine in the form of a tube, the threads running continuously
around the fabric.
2. Flat Knitting - The fabric is produced on the knitting machine
in flat form, the threads alternating back and forth across the
fabric. The fabric can be given shape in the knitting process
by increasing or decreasing the loops. Full-fashioned garments
are made on a flat knitting machine.
Kusters Dyeing Range - Continuous dye range for carpets. The unit wets the
carpet, applies dyes and auxiliary chemicals by means of a doctor blade,
fixes the dyes in a festoon steamer, and washes and dries the carpet in
one pass through the range. An optional auxiliary unit may be installed
to randomly drip selected dyes onto the background shade for special
styling effects. This process is called TAK dyeing.
Lap - A continuous, considerably compressed sheet of fiber tufts which is
rolled under pressure into a cylindrical package, usually weighing
40 to 50 pounds.
Latex - A milky rubber raw material used as a backing for carpets.
Leveling - Migration of dye molecules leading to uniform distribution of dye
In a dyed material. Leveling may be a property of the dye or it may
require chemical assistance.
Lightfastness - The degree of resistance of dyed textile materials to the
~~color-destroying influence of sunlight.
Long Staple - A long fiber. In reference to cotton, long staple indicates
a fiber length of not less than 1 1/8 inches. In reference to wool,
the term indicates fiber 3 to 4 inches long suitable for combing.
Loom - A machine for weaving fabric by interlacing a series of vertical,
1 parallel threads (the warp) with a series of horizontal, parallel
threads (the filling). The warp yarns from a beam pass through the
heddles and reed, and the filling is shot through the "shed" of
warp threads by means of a shuttle or other device and is settled
in place by the reed and lay. The woven fabric is then wound on a
cloth beam. The principal elements of the loom are the shedding,
picking, and beating-up devices. In shedding, a path is formed for
•die filling by raising some warp threads while others are left down.
Picking consists essentially of projecting the filling yarn from one
side of the loom to the other. Beating-up forces the pick, which has
just been left in the shed, up to the fell of the fabric. This is
accomplished by the reed which is brought forward with some force by
the lay.
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Loop Pile - Carpet construction in which the tufts are formed into loop
from the supply yarn.
Lubricant - An oil or emulsion finish applied to the fibers to prevent damage
during textile processing or to the knitting yarns to make them more
pliable.
Man-made Fiber - A class name for the various genera of fibers (including fila-
ments) produced from fiber-forming substances which may be: (1) polymers
synthesized from chemical compounds, e.g., acrylic, nylon, polyethylene,
polyurethane, and polyvinyl fibers; (2) modified or transformed natural
polymers, e.g., alginic and cellulose-based fibers such as acetates
and rayons; or (3) mineral, e.g., glass. The term man-made usually
refers to all chemically produced fibers to distinguish them fron the
truly natural fibers such as cotton, wool, silk, flax, etc.
Mercerization - A treatment for cotton yarn or fabric to increase its luster
and affinity for dyes. The material is immersed under tension in a
cold sodium hydroxide (caustic soda) solution in warp, skein form, or
in the piece, and is later neutralized in acid. Ihe process causes a
permanent swelling of the fiber and thus increases its luster.
Metallized Dyes - See Dyes.
Moire ~ A wavy or watery effect on a textile fabric, especially a corded
fabric of silk, rayon or one of the man-made fibers.
Mordant - A chemical used in some textile fibers to provide affinity for
dyes.
Muft ~ A loose skein of textured yarn prepared for dyeing or bulking.
Muff Dyeing - See Dyeing.
Naphthol Dyes - See Dyes.
Napping - A finishing process 'that raises the surface fibers of a fabric by
means of passage over rapidly revolving cylinders covered with metal
points or teasel burrs. Outing, flannel, and wool broadcloth derive
their downy appearance from this finishing process. Napping is also
used for certain knit goods, blankets, and other fabrics with a raised
surface.
i
Narrow Fabric - Any nonelastic woven fabric, 12 inches or less in width,
having a selvage on either side, except for ribbon or seam binding.
Natural Fiber - A class nama for the various genera of fibers (including
filaments) of (1) animal, (2) mineral, or (3) vegetable origin. For
example: (1) silk and1 wool, (2) asbestos, and (3) cotton, flax, jute,
and ramie.
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Nep - A small knot of entangled fibers that usually will not straighten to
a parallel position during carding or drafting.
Noil - A short fiber which is rejected in the combing process of yarn
manufacture.
Opening - 1. A preliminary operation in the processing of staple fiber.
Opening separates the compressed masses of staple into loose tufts and
removes the heavier impurities. 2. An operation in the processing of
tow that substantially increases the bulk of the tow by separating
the filaments and deregistering the crimp.
Optical Brightener - A colorless compound which, when applied to the fabric,
absorbs the ultraviolet rays in light and emits them in the visible
spectrum.
Package Dyeing - See Dyeing, Yarn Dyeing.
Padding - The application of a liquor or paste to textiles either by passing
the material through a bath and subsequently through squeeze rollers,
or by passing it between squeeze rollers, the bottom one of which carries
the liquor or paste.
Paddle Dyeing Machine - A machine used for dyeing garments, hosiery, and
other small pieces which are packaged loosely in mesh bags. The unit
consists of an open tank and revolving paddles that circulate the
bags in the dyebath.
Pad Dyeing - See Dyeing.
Permanent Press - A term describing a garment which has been treated so that
it retains its smooth appearance, shape and creases or pleats in
laundering. In such garments, no ironing is required, particularly if
the garment is tumble dried. Permanent press finishing is accomplished
by several methods; two of the most common are: (1) A fabric containing
both a thermoplastic fiber and cotton or rayon, may be treated with a
special resin which, when cured, imparts the permanent shape to the
cotton or rayon component of the fabric. The resin-treated fabric nay
be precured (i.e., cured in finishing and subsequently pressed in
garment form at a higher temperature to achieve the permanent shape)
or postcured (not cured until the finished garment has been sewn and
pressed into shape). In both cases, the thermoplastic fiber in the
garment is set in the final heat treatment. This fiber, when heat-set,
also contributes to the permanence of the garment shape, but the thermo-
plastic component of the blend is needed for strength since the cotton
or rayon component is somewhat degraded by the permanent-press treat-
ment. (2) Garments made from a fabric containing a sufficient amount
of a thermoplastic fiber, such as polyester, nylon, or acrylic, pressed
with sufficient pressure and time to achieve a permanent garment shape.
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Photographic Printing - See Printing.
Picking - 1. A process which continues the opening and cleaning of staple and
forms a continuous fiber sheet (or lap), which is delivered to the card.
2. The operation of passing the filling through the warp shed during
weaving.
Piece Dyeing - See Dyeing.
Pigment Printing - See Printing.
Pile - 1. A fabric effect formed by introducing tufts, loops, or other erect
yarns on all or part of the fabric surface. Types of pile are warp,
filling, and knotted pile, or loops produced by weaving an extra set of
yarns over wires which are then drawn out of the fabric. Plain wires
leave uncut loops; wires with a razor-like blade produce a cut pile
surface. Pile fabric may also be made by producing a double-cloth
structure woven face to face, with an extra set of yarn interlacing with
each cloth alternately. The two fabrics are cut apart by a traversing
knife, producing two fabrics with a cut pile face. Pile should not be
confused with nap. Corduroys are another type of pile fabric, where
long filling floats on the surface are slit, causing the pile to stand
erect. 2. In carpets, pile refers to the face yarn, as opposed to
backing or support yarn. Pile carpets are produced by either tufting
or weaving. (Also see Cut Pile and Loop Pile).
Pin Drafting - Any system of drafting in which the orientation of the fibers
relative to one another in the sliver is controlled by pins.
Plying - Twisting together two or more single yarns or ply yams to form,
respectively, ply yarn or cord.
Pressure Dyeing - See Dyeing.
Printing - A process for producing a pattern on yarns, warp, fabric, or
carpet by any of a large nuntoer of printing methods. The color or
other treating material usually in the form of a paste, is deposited
onto the fabric which is then usually treated with steam, heat, or
chemicals for fixation. Various types of printing are described
below. (Also see Dyeing).
1. Methods of Producing Printed Fabrics;
a. Block Printing - The printing of fabric by hand, using carved
wooden or linoleum blocks, as distinguished from printing by
screens or rollers.
b. Blotch Printing - A process wherein the background color of a
design is printed rather than dyed.
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c. Burn-Out Printing - A method of printing to obtain a raised design
on a sheer ground. The design is applied with a special chemical
onto the fabric woven with different pairs of threads of different
fibers. One of the fibers is then destroyed locally by chemical
action. Bum-out printing is often used on velvet. The product
of this operation is known as a burnt-out print.
d. Direct Printing - A process wherein the colors for the desired
designs are applied directly to the white or dyed cloth, as dis-
tinguished from discharge printing and resist printing.
e. Discharge Printing - In "white" discharge printing, the fabric is
piece dyed, then printed with a paste containing a chemical which
reduces the dye and hence removes the color where the white designs
are desired. "Colored" discharge printing is similar except that a
color is added to the discharge paste in order to replace the dis-
charged color with another shade.
f • Duplex Printing - A method of printing a pattern on the face and
the back of a fabric with equal clarity.
g. Etching - See Burn-Out Printing.
h. Extract Printing - See Discharge Printing.
i- Heat-Transfer Printing - A method of printing fabric of polyester
or other thermo-plastic fibers with disperse dyes. The design is
transferred from preprinted paper onto the fabric by contact heat.
Having no affinity for paper,the dyes are absorbed by the fabric.
The method is capable of producing well-defined clear prints.
j. Photographic Printing - A method of printing from photoengraved
rollers. The resultant design looks like a photograph. The
designs may also be photographed on a silk screen which is used
in screen printing.
k. Pigment Printing - Printing by the use of pigments instead of dyes.
The pigments do not penetrate the fiber but are affixed to the
surface of^ the fabric by means of synthetic resins which are cured
after application to make them insoluble. The pigments are insoluble,
and application is in the form of water-in-oil or oil-in-water
emulsions of pigment pastes and resins. The colors produced are
bright and generally fast except to crocking.
1. Resist Printing - A printing method in which the design is produced:
(1) by applying a resist agent in the desired design, then dyeing
the fabric, in which case the design remains white although the
rest of the fabric is dyed, or (2) by including a resist agent and
a dye in the paste which is applied for the design, in which case
the color of the design is not affected by subsequent dyeing of
the fabric background.
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m. Roller Printing - The application of designs to fabric, using a
machine containing a series of engraved metal rollers positioned
around a large padded cylinder. Print paste is fed to the rollers
and a doctor blade scrapes the paste from the unengraved portion
of the roller. Each roller supplies one color to the finished
design, and as the fabric passes between the roller and the padded
cylinder, each color in the design is applied. Most machines are
equipped with eight rollers, but some have sixteen.
n. Rotary Screen Printing - A combination of roller and screen
printing in which a perforated cylindrical screen is used to apply
the color. Color is forced from the interior of the screen onto
cloth.
o. Screen Printing - A method of printing similar to using a stencil.
The areas of the screen through which the coloring matter is not to
pass are filled with a waterproof material. Ihe printing paste
which contains the dye is then forced through the untreated portions
of the screen onto the fabric below.
p. Warp Printing - The printing of a design on the sheet of warp
yarns before weaving. The filling is either white or a neutral
color, and a grayed effect is produced in the areas of the design.
2. Methods of Producing Printed Carpets;
a. Mitter Printing Machine - A rotary carpet printing machine with
up to eight stainless~iteel mesh screens, and with cylindrical
squeegees of moderately large diameter in each rotary screen. The
unit has a steaming zone for dye fixation.
b. Stalwart Printing Machine - A carpet printing machine in which the
color is applied to the carpet with a neoprene sponge laminated to
the pattern. The pattern is cut in a rubber base attached to a
wooden roll. It is very similar to relief printing. Used primarily
for overprinting randan patterns on dyed carpets. Suitable for
shags and plush carpets as well as level loop and needle tuft types.
c. Zirtmer Flatbed Printing Machine (Peter Zinmer) - A carpet printing
machine which uses flat screens and dual, metal-roll squeegees.
The squeegees are operated by electromagnets to control the applied
pressure. The unit also has a steamer for dye fixation. The
Zinmer flatbed machine is normally used for carpets of low to
medium pile heights. Very precise designs are possible but speeds
are slower than with rotary screen printers.
d. zitnrer Rotary Printing Machine (Johannes Zinroer) - A three-step
rotary carpet printing machine consisting of (1) rotary screens
with small-diameter steel-roll squeegees inside, with pressure
adjusted electromagnetically for initial dyestuff application,
(2) infrared heating units to fix the dyes on the tuft tips, and
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(3) application of low-viscosity print paste, followed by
steaming for complete penetration of dyes into tufts.
e. Ziitmer Rotary Printing Machine (Peter Zinroer) - A rotary carpet
printing machine in which each rotary screen has a slotted
squeegee inside to feed the print pastes through the screens to
the carpet. Pressure of the print paste is adjusted by hydro-
static head adjustments.
Print Paste - The mixture of gum or thickener, dye and appropriate chemicals
used in printing fabrics. Viscosity varies according to the types of
printing equipment, the type of cloth, the degree of penetration
desired, etc.
Quilling - The process of winding filling yarns, for weaving, onto filling
bobbins, or quills, in preparation for use in the shuttle.
Raw Fiber - A textile fiber in its natural state, such as silk "in the gum"
and cotton as it comes from the bale.
Reed - A comb-like device on a loom which spaces the warp yarns and also beats
each succeeding filling thread against that already woven. The reed
usually consists of a top and bottom rib of wood into which metal strips
or wires are set. The space between two adjacent wires is called a dent
and the warp is drawn through the dents. The fineness of the reed is
calculated by the number of dents per inch.
Refractory - A term used in connection with organic compounds indicating
that they are non-biodegradable or resistant to biological treatment
and degradation.
Reserve Dyeing - See Dyeing, Reserve Dyeing.
Resin+Treated - Usually, a term descriptive of a textile material which has
received an external resin application for stiffening or an internal
fiber treatment (especially of cellulosics) to give wrinkle resistance
or wash-and-wear characteristics.
Resist Dyeing - See Dyeing, Reserve Dyeing.
Resist Printing - See Printing.
Retained Sludge - That sludge that is generated by aerated biological
degradation of textile wastewaters. The rate of sludge generation is
very slow in certain areas of the textiles industry (e.g., knit fabric
dyeing and finishing) and there is no need to dispose of the small amounts
of sludge. This sludge is accumulated over several years and stored in the
wastewater treatment pond.
Retarder - A chemical which, when added to the dyebath, decreases the rate
of dyeing but does not affect the final exhaustion.
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Roller Printing - See Printing.
Hope - Fabric in process without weft tension, thus having the appearance of
a thick rope.
Rotary Screen Printing - See Printing.
Roving - 1. In spun yarn production, an intermediate state between the sliver
and the yarn. Roving is a condensed sliver which has been drafted,
twisted, doubled, and redoubled. The product of the first roving
operation is sometimes called slubbing. 2. The operation which produced
roving (see 1).
Sanforizing - A mechanical process to preshrink the fabric.
Scouring - An operation to remove the sizing and tint used on the warp yarn in
weaving and, in general, to clean the fabric prior to dyeing.
Screen Printing - See Printing.
Selvage or Selvedge - The narrow edge of the woven fabric that runs parallel
to the warp. It is made with stronger yarns in a tighter construction
than the body of the fabric to prevent raveling. A fast selvage encloses
all or part of the picks, and a selvage is not fast when the filling
threads are cut at the fabric edge after every pick.
Shadow Printing - See Printing, Warp Printing.
Shearing - A dry finishing operation in which the projecting fibers are
mechanically cut or triitmed from the face of the fabric. Woolen and
worsted fabrics are almost always sheared. Shearing is also widely
employed on other fabrics, especially on napped and pile fabrics where
the amount varies according to the desired height of the nap or pile.
For flat-finished fabrics such as gabardine, a very close shearing is
given.
Shuttle - A boat-shaped device, usually made of wood with a metal tip, that
carried the filling yarns through the shed in the weaving process. It
is the most common weft-insertion device. The shuttle holds a quill,
or pirn, on which the filling yam is wound. It is equipped with an
eyelet at one end to control the rate. The filling yarn is furnished
during the weaving operation.
Singeing - The process of burning off protruding fibers from yarn or fabric
bypassing it over a flama or a heated copper plate. Singeing gives
the fabric a smooth surface and is necessary for fabrics which are to
be printed and for those fabrics where smooth finishes are desired.
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Single Knit Fabrics - A fabric constructed with one needle bed and one set of
needles, also called plain knit.
Sizing - 1. A generic term for compounds which are applied to the warp yarn
to bind the fiber together and stiffen the yarn to provide abrasion
resistance during weaving. Starch, gelatin, oil, wax, and man-made
polymers such as polyvinyl alcohol, polystyrene, polyacrylic acid, and
polyacetates are employed. 2. The process of applying sizing compounds.
(Also see Slashing). 3. The process of weighing sample lengths of
yarn to determine the count.
Skein - A continuous strand of yarn or cord in the form of a collapsed coil.
It may be of any specified length and is usually obtained by winding a
definite number of turns on a reel under prescribed conditions.
Skein Dyeing - See Dyeing.
Slashing - A process of sizing warp yarns on a slasher. (Also see Sizing, 1).
Sliver - A continuous strand of loosely assembled fibers without twist. The
sliver is delivered by the card, the conber, or the drawing frame.
Ihe production of sliver is the first step in the textile operation
that brings staple fiber into a form that can be drawn (or reduced
in bulk) and eventually twisted into a spun yarn.
Slubber - A machine used in textile processes prior to spinning which reduces
the sliver and inserts the first twist.
Slubbing - The product of the slubber, it is the intermediate stage between
sliver and roving.
Solution-Dyeing - See Dyeing, Mass-Colored.
Solvent Dyeing - See Dyeing.
Space Dyeing - See Dyeing.
Spin-Drawing - The reduction of roving during spinning by a roller drafting
mechanism similar to that used on the roving frame.
Staple - Natural fibers or cut lengths from filaments. Ihe staple length
of natural fibers varies from less than 1 inch as with some cotton
fibers to several feet for some hard fibers like linen. Man-made
staple fibers are cut to a definite length, from 8 inches down to
about 1 1/2 inches (occasionally down to 1 inch), so that they can be
processed on cotton, woolen, or worsted yarn spinning systems. The
term staple (fiber) is used in the textiles industry to distinguish
natural or cut length man-made fibers from filament.
A-21
-------
Stock Dyeing - See Dyeing.
Stripping - 1. A chemical process for removing color from dyed cloth by the
use of various chemicals. Stripping is done when the color is unsatis-
factory and the fabric is to be redyed. 2. The physical process of
removing fiber that is embedded in the clothing of a card.
Suint - The dried perspiration of sheep, deposited in the wool, yielding
potash.
Sulfur Dyes - See Dyes.
TAK Dyeing - See Kusters Dyeing Range.
Tenter Frame - A machine that dries the fabric to a specified width under
tension. The machine consists essentially of a pair of endless chains
on horizontal tracks. The fabric is held firmly at the edges by pins or
clips on the two chains, which diverge as they advance through the
heated chamber, adjusting the fabric to the desired width.
Thermal Fixation - See Dyeing.
Thread - 1. A slender, strong strand or cord, especially one designed for
sewing or other needle work. Most threads are made by plying and twistinc
yarns. A wide variety of thread types are in use today, e.g., spun
cotton and spun polyester, core-spun cotton with a polyester filament
core, polyester or nylon filaments (often bonded), and monofilament
threads. 2. A general term for yams used in weaving and knitting,
as in "thread count" and "warp threads".
Top - 1. A wool sliver which has been combed to straighten the fibers and
remove short fibers; an intermediate stage in the production of worsted
yarn. 2. A similar untwisted strand of man-made staple delivered by the
comb or made directly from tow.
Top Dyeing - 1. The process of covering already dyed fiber with an additional
dye, not necessarily of the same color or class, to obtain the desired
shade. 2. The dyeing of top in package form.
Tow - A large strand of continuous man-made fiber filaments without definite
twist collected in loose, rope-like form, usually held together by
crinp.
Tubular Fabric - A fabric woven or knit in a tubular form with no seams,
such as seamless pillowcases, most knit underwear fabrics, and
seamless hosiery.
A-22
-------
Tufted Carpet - Carpet produced by a tufting machine instead of a loon.
It is an outgrowth of hand-tufted bedspreads. Today, broadloom tufting
machines produce over 90 per cent of all domestic carpeting. Tufting
machines are essentially multineedle sewing machines which push the
pile yarns through a primary backing fabric and hold them in place to
form loops as the needles are withdrawn. The loops are then either
released for loop-pile carpets or cut for cut-pile carpets. The pile
yarns may be either predyed or uncolored in which case, the greige
carpet is then piece-dyed or printed. In either case, a latex or other
binding agent is applied to the backstitch to lock the tufts in place
and to secure the secondary backing fabric. Formerly, all carpets were
woven, either by hand or machine. The vastly greater productivity of
tufting has revolutionized the carpet industry and has made soft floor
coverings available to the mass market for the first time.
Vat Dyes - See Dyes.
Warping - The operation of winding the warp yarn onto a beam in preparation
for weaving or warp knitting. Also called beaming.
Warp-Knit Fabric - A fabric that is knit with the yarns running lengthwise,
e.g., tricot, milanese, and raschel.
Warp Printing - See Printing.
Warp Sizing - See Slashing.
Washfastness - The resistance of a dyed fabric to loss of color or change
in properties during home or cotmercial laundering.
Wasted Sludge - Excess sludge generated in a textile mill wastewater treat-
ment system that must be removed from the system and disposed of.
Weaving - The method or process of interlacing two yarns of similar materials
so that they cross each other at right angles to produce a woven fabric.
The warp yarns, or ends, run lengthwise in the fabric, and the filling
threads (weft), or picks, run from side to side. Weaving may be done
on a power or hand loom or by several hand methods.
Winding - The transfer of a yam or thread from one type of package to
another (e.g., from cakes to cones).
Wool - The term is usually used for the fleece of sheep, but according to the
Textile Fiber Products Identification Act, wool is defined for purposes
of labeling as: "The fiber from the fleece of the sheep or lamb or hair
of the Angora or Cashmere goat (and may include the so-called specialty
fibers from the hair of the camel, alpaca, llama, and vicuna) which
has never been reclaimed from any woven or felted wool product."
A-23
-------
Wool is vised in a variety of blends in which it is combined with nearly
all natural or man-made fibers. Wool fibers have scales which tend
to interlock with each other, binding the fibers together. This pro-
cess is called felting. In blends, particularly those with man-made
fibers, wool is used to improve the feel or appearance of finished
products. Man-made fibers are sometimes blended with wool to enable
the spinning of very fine or loosely twisted yarns with increased tensile
strength or to produce ease-of-care properties. Wool can be treated to
control shrinkage, to provide resistance to damage by moths, to impart
stain resistance, and to set permanent creases in fabrics.
Woolen System - The fundamental system of making yarns for woolen fabrics.
In yarns spun on the woolen system, the fibers are not parallel but are
crossed in what appears to be a haphazard arrangement. After blending,
fibers produced on the woolen system are evenly distributed in carding
on two, three, or even four cards. From here, the split web, called
roving, goes to the spinning frame. In addition to wool, man-made fibers,
cotton, wastes, and noils can be processed on the woolen system. In
general, the fibers used are shorter and more highly crimped than those
used on the worsted system and are of the type which can be fulled.
Worsted System - A system of textile processing for manufacturing spun yarns
from staple fibers usually over 3 inches in length. The main operations
are carding, combing, drafting, and spinning. There are three basic
systems of worsted yarn spinning: the Bradford (or English system),
the French (Alsation or Continental system), and the American system.
Woven Fabric - A fabric composed of two sets of yarns, warp and filling,
formed by weaving, which is the interlacing of these sets of yarns to
form a fabric. There may be two or more warps and fillings in a fabric,
depending on the complexity of the pattern. The manner in which the two
sets of yarns are interlaced determines the weave. By using various
combinations of the three basic weaves (i.e., plain, twill, and satin),
it is possible to produce an almost unlimited variety of fabrics. Other
effects may be obtained by varying the type of yarns, filament or spun,
fiber types, twist levels, etc.
Yarn - A generic term for a continuous strand of textile fibers, filaments,
or material in a form suitable for knitting, weaving, or otherwise
intertwining to form a textile fabric. Yarn occurs in the following
forms: (1) a number of fibers twisted together (spun yarn), (2) a
number of filaments laid together without twist (a zero-tolst yarn),
(3) a number of filaments laid together with a degree of twist, (4) a
single filament with or without twist (a monofilament), or (5) a narrow
strip of material, such as paper, plastic film, or metal foil, with
or without twist, intended for use in a fabric.
Yarn Dyeing - See Dyeing.
A-24
-------
APPENDIX B
DIRECTORY OF TREATMENT AMD DISPOSAL CONTRACTORS
ENCOUNTERED IN THE TEXTILES INDUSTRY
Category A - Wbol Scouring
Containers - None
Sludge - None
Category B - Vfool Fabric Dyeing and Finishing
Containers - L.R.J. Enterprise
109 Dwayne Drive
Dublin, Georgia
Sludges - None
Category D - Woven Fabric Dyeing and Finishing
Containers - Herman Gamer
Lexington, North Carolina
Truman Dogget
Summerfield, N.C.
Murden Sanitation Service
Orangeburg, S.C.
Kenyan Bros.
Kenyan, R. I.
Benjamin Luchka
Waod River Junction, R.I.
City of Lancaster
Lancaster, S.C.
Spartan Waste Control, Inc.
Greenville, S.C.
Opelika Scrap Material
Qpelika, Alabama
Container & Disposal Co.
Asheville, N.C.
Sanitary Container Service
Greensboro, N.C.
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
B-l
-------
Category D (continued)
Containers -
(cont.)
Puritan Industrial
Maintenance
Spartansburg, S.C.
Buzhardt Trash Service
Greenwood, S.C.
Waynesboro Nursery
Waynesboro, Va.
Steve Cash
Waynesboro, Va.
Sludges -
Category E - Knit Fabric Dyeing and Finishing
Containers -
Chattanooga Disposal Co.
Chattanooga, Term.
Murden Sanitation
Pine Hill Ccmnunity
Orangeburg, S.C.
Sperry Truck Co.
Glens Falls, N.Y.
Greenwood Disposal Co.
Lowell, Mass.
B & E Garbage Service
Mullins, S.C.
John T. Rice & Sons
Clinton, S.C.
Otis Wells
Newberry, S.C.
City of Fannville
Farmville, N.C.
Container Service &
Disposal Co.
Asheville, N.C.
City of Longview + Plant
Longview, N.C.
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
Farm Spreading
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
-------
Category E (continued^
Containers - Sanitation Services, Inc. General Purpose Landfill
(cont.)
Sludges -
Lumber-ton, N.C.
Johnson Waste
Spartanburg, S.C.
Binzac Waste Renoval
Greenville, S.C.
Garbage Disposal Service
of Rutherford County
Forest City, N.C.
Grand Central Sanitation
Pen Argyl, Pa.
Pollution Abatement
Services
Oswego, N.Y.
G.R.O.W.S. Subs, of
Warner's Landfill
Morrsiville, Pa.
Category F - Carpet Dyeing and Finishing
Thrifty Best Rubbish
Fresno, Calif.
Containers -
Suburban Waste &
Garbage Co.
Pockingham, N.C.
Browning and Ferris'
Chattanooga Waste
Disposal Service
Chattanooga, Tenn.
LaGrange Disposal Co.
LaGrange, Georgia
Simon & Sons
LaGrange, Georgia
Sanitation Service System
Atmore, Alabama
Foothill Disposal
Mountain View, Calif.
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
Solvent Recovery
State Approved Landfill
with leachate controls
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
B-3
-------
Category F - continued
Sludges - None
Category G - Yarn and Stock Dyeing and Finishing
Containers - Tobacco Valley Sanitation
Windsor, Conn.
Waste Basket, Inc.
Marion, N.C.
Elliott Container Service
Augusta, Georgia
City of Greenville
Greenville, S.C.
LaGrange Disposal Co.
LaGrange, Georgia
Waste Handling System,Inc.
Forest City, N.C.
Wilkes County Sanitation
Department
Wilkes County, Georgia
Hall-ing Refuse Co.
Albany, Georgia
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
General Purpose Landfill
Sludges - None
B-4
-------
APPENDIX C
SAMPLING TECHNIQUES AND ANALYTICAL METHODS
Sample Collection
Sludge sanples from textile mill wastewater treatment facilities
were collected from the clarifier underflow returning to the aeration pond.
Four-hour composite sanples for both heavy metal and chlorinated organic
analyses were taken. These consisted of four, one-hour sanples, thoroughly
mixed. Sampling was repeated once a week for four consecutive weeks.
Sanples that were analyzed for heavy metals were put in poly-
ethylene bottles and acidified with nitric acid to a pH of 2.0. Sanples
that were analyzed for chlorinated organics were specially handled in
sterilized glass containers to make certain no contamination occurred.
Complete characterization of the textile sludge was complicated
by the nature of the sludge as well as time and money constraints. There-
fore, a relatively simple analytical method was chosen and used. The
sludges were determined to have a solids content of 2 per cent Or less
and thus, the atomic absorption method for determining total trace metals,
as outlined in detail below.
Procedure for Determination of Total Trace Metals
A one-pint sample of the textile sludge was acidified at the time
of collection with 50 per cent nitric acid to a pH of 2. At the laboratory,
a 100 ml portion of the well mixed sample was transferred to a Griffin
beaker and 5 ml of concentrated redistilled nitric acid was added. The
beaker was then placed on a hot plate and the sample evaporated to dryness.
This procedure must be done cautiously to avoid boiling. The beaker was
then allowed to cool and another 3 ml of concentrated redistilled nitric
acid was added. The beaker was covered with a watch glass and returned to
the hot plate. The temperature of the hot plate must be increased so that
a gentle reflux action occurs. The cycle of heating and adding additional
acid was continued as necessary until the digestion process was complete
(generally indicated by a light colored residue). Distilled 50 per cent
hydrochloric acid was then added and the beaker warmed again to dissolve
the residue. The beaker walls and watch glass was then washed down with
distilled water, and the sample filtered to remove silicates and other
insoluble material that could clog the atomizer. The sample volume was
then adjusted to 100 ml with distilled water.
The concentrations of the metals except mercury and arsenic
were measured using air/acetylene and nitrous oxide/acetylene flames.
The samples were aspirated directly into the flame and the absorbence
recorded.
C-l
-------
For mercury and arsenic other analytical methods must be used
and these are detailed below.
Hg' (Mercury)
A 50 ml portion of the digested sample was transferred into a
round bottom flask, and diluted to 100 ml with distilled water. The
concentration of mercury in the sample was then measured by the flameless
atomic absorption method.
As (Arsenic)
A 25 ml portion of the digested sample was transferred into an
arsine generating flask. The concentration of arsenic was then determined
either by the silver diethyldithiocarbamate method or by atomic absorption.
Determination of Arsenic by the Silver Diethyldithiocarbamate Method
Apparatus:, 1. Arsine generator
2. Spectrophotometer |
Reagents: 1. Concentrated hydrochloric acid
2. 15 per cent potassium iodide solution
3. 20 per cent stannous chloride solution in concentrated
hydrochloric acid
4. 5 per cent silver diethyldithiocarbamate solution in
pyridine (fumes, use and discard in hood)
5. Free zinc, 20-30 mesh
6. Stock solution, 1 rng/ml
7. 10 per cent lead acetate solution
Procedure
The sample and 30-40 ml of water was placed in a clean generator
bottle, with the following reagents added stepwise: 5 ml of concentrated
hydrochloric acid; 2 ml of 15 per cent potassium iodide solution; and 8
drops of 20 per cent stannous chloride solution. This was allowed to mix
for 15-20 minutes, while the scrubber and absorber were prepared and
assembled.
The glass wool in the scrubber was impregnated with lead acetate
solution, and then 4 ml of the silver diethyldithiocarbamate solution was
placed in the absorber tube. One to two grams of zinc were put into a
generator tube attached to the generator bottle containing the mixture of
sample with reagents. The scntober and absorber assembly was then connected.
Thirty minutes were allowed for the reaction to go to completion. The
absorption at 535 nanometer was recorded and the concentration of arsenic
determined.
02
-------
Trace Metals in the Suspended Solids of Textile Sludges
(Suspended or/Insoluble Trace Metals) —
Trace amounts of suspended (insoluble) metals in the textile
sludge may be determined from the non-acidified samples which were also
tested for organics. A representative volume of the non-acidified sample
was centrifuged. Centrifugation was necessary because these samples
cause blockage to a 0.45 micron membrane filter. The supernatant liquid
was removed and the semi-solid settled materials were dewatered under
suction and finally air dried in an open dish.
A known weight of the solid (from 0.5 to 2 g) was placed in a
Griffin beaker (250 ml), with 5 ml of concentrated nitric acid. The beaker
was covered with a watch glass and heated gently. The temperature of the
hot plate was increased to digest the material. When the acid had evaporated,
the beaker and the watch glass were allowed to cool. Another 5 ml of
concentrated nitric acid was then added to the beaker and covered and again
heated until digestion was complete. Five ml of distilled 50 per cent
hydrochloric acid was then added to the dry residue and the beaker was
warmed gently to dissolve the material. The watch glass and beaker walls
were rinsed with distilled water to dissolve the material. The sample was
then filtered to remove the insoluble material such as silicates and
phosphates. The sample volume was adjusted and ready for analysis. Con-
centrations determined an this way were reported as ppm in suspended
solids.
Determination of Solid Contents of Textile Sludges
Fifty ml volumes of the unpreserved samples were transferred to
weighed evaporating dishes. The water was evaporated on a steam bath.
After complete evaporation, the residues were put in an oven maintained
at 100-105° C and dried to a constant weight.
Determination of Suspended Solids of Textile Sludges
Suspended solids in the textile sludge was determined by filtration
of a known volume of sludge through weighed glass fiber disks. The solids
retained by the disks were dried at 100-103° C to constant weights.
t
A glass fiber disk was placed in a membrane funnel and washed
with distilled water under a vacuum. The filter disk was dried in an
oven 100-105° C for 30 minutes and allowed to cool. The disk was weighed
and placed in the funnel. A selected volume of sludge was then filtered
under suction and washed with distilled water. The filter disk was then
removed and dried at 100-105° C for one hour. After allowing it to cool
to room temperature, the filter and solids were weighed on an analytical
balance.
C-3
-------
Procedure for Determination of Chlorinated Organics
The samples for organic analysis were carefully handled to avoid
contamination, placed in sterile containers and returned to the "boratcay,
where the samples were blended and the pH adjusted to 6.5 - 7.5 with 50 per
cent sulfuric acid. An aliquot of the sample was transferred into a two-
liter separatory funnel and diluted to one liter. Sixty (60 ml of 15 per
cent methylene dhlorine in hexane was then added to the sample and ^e
mixture was shaken vigorously for too minutes. The mixed solvent was
allowed to separate from the sample and the water drawn into a one-liter
Erlenmeyer flaS. The organic layer was then passed through a column
containing 3 to 4 inches of anhydrous sodium sulfate and collected in a
flask. The water phase was returned to the separatory funnel and a second
and third extraction were carried out in the same way. The extract was
then concentrated on a hot water bath.
The sample was then ready to be injected into the gas chromatograph
unless a need for additional sample cleanup was indicated.
Interferences in the form of distinct peaks or high background
rs?trssi^s^«
knowledge of the sample help indicate whether cleanup was required.
When interferences are indicated, the following procedures were
taken:
Acetonitrile partition was used to isolate fats and oils from the
sample extracts. Ihe previously concentrated extract was transferred to
a separatory funnel with enough hexane to bring the final volume to 15 mi.
araSs^rpSsS S^SSL?^S«O>
-------
ethyl ether in petroleum ether; the third with 200 ml of 50 per cent ethyl
ether-petroleum ether; and the fourth with 200 ml of 100 per cent ethyl
ether. The eluates were then concentrated on a hot water bath and were
ready for gas chromatographic analysis.
The concentration of the organics was determined using the
absolute calibration method:
micrograrns/liter =
A = micrograms of standard per standard peak area
B = sample aliquot peak area
Vi = volume of extract injected (microliters)
Vt = volume of total extract (microliters)
Vs = volume of water extracted (milliliters)
Detailed Sampling Results
The detailed analytical results of the sampling are tabulated on
the following pages.
05
-------
REPORT OF TRACE METALS
PROJECT NO. 469
PLANT WOOL SCQURINf? pLANT A-2
LOCATION
(Unit = PPM)
Sample No.
Aluminum
*Arsenic
Barium
*Cadmium
*Chromium
*Cobalt
*_Copper
Iron (total)
*Lead
Magnesium
Manganese
*Mercury
Mo ybdenum
Nickel
Potassium
Sodium
Strontium
*Zinc
TSS
TS
1
543.1 1
<0.01
5.4
0.12
1.8
0.52
1.85
641 _i
3.86
720
26.0
< 0.001
<0.2
1.6
1.469
75.0
3.08
13.04
97,870
100,700
2
388.6
<0.01
3.4
0.10
1.16
0.30
1.4
3.52
2.48
429
17.3
< 0.001
<0.2
0.94
1.034
65.0
1.92
10.7
3
545.4
<0.01
3.5
0.12
1.56
0.37
1.66
496
2.75
617
22.1
< 0.001
<0.2
1.23
1.303
-
71.0
2.42
9.13
4
430
<0.01
11.5
0.14
3.2
0.50
2.3
450
2.35
475
17.5
< 0.001
<0.2
l."28
1.200
-
60.0
1.3
10.0
5
489
-------
PROJECT NO.
Analysis for Chlorinated Hydrocarbons
469
PLANT and LOCATION: WOOL SCOURING PLANT A-2
DESCRIPTION OF SAMPLE: Clarifier Underflow
Liquid Phase
SAMPLE NO.
1
2
3
4
AVERAGE
No. of
Compounds
18
12
17
12
15
ppm
0.0062
0.0256
0.0069
0.0078
0.0116
No. of
Compounds
23
5
14
7
12
ppm
0.866
0.273
3.13
0.83
1.27
REMARKS:
C-7
-------
REPORT OF TRACE METALS
PROJECT NO. 469
PLANT WOOL FABRIC D &*F PLANT B-7
LOCATION .
(Unit = PPM)
Sample No.
Aluminum
*Arsenic
Barium
*Cadmium
*Chromium
*Cobalt
*Copper
~i — "T rc
Iron (total;
*Lead
Magnesium
Manganese
* Mercury
Molybdenum
Nicke
Potassium
Sodium
Strontium
*Zinc
TSS
TS
1
23.0
-------
Analysis for Chlorinated Hydrocarbons
PROJECT NO.
469
PLANT and LOCATION: WOOL FABRIC D & F PLANT B-7
DESCRIPTION OF SAMPLE:
Liquid Phase
Suspended Phase
SAMPLE NO.
1
2
3
4
AVERAGE
No. of
Compounds
12
11
11
9
11
ppm
0.1142
0.055
0.048
0.220
0.1093
No. of
Compounds
ppm
REMARKS:
There were insufficient suspended solids to measure quantity
in solid phase.
09
-------
REPORT OF TRACE METALS
PROJECT NO. 469
PLANT WOVEN FABRIC D & F PLANT D-8
LOCATI ON '
(Unit = PPM)
Sample No.
Aluminum
*Arsenic
Barium
*Cadmium
*Chromium
"Cobalt
*Copper
Iron (total)
*Lead
Magnesium
Manganese
*Mercury
Molybdenum
Nickel
Potassium
Sodium
Strontium
*Zinc
TSS
TS
1
10.3
<0.01
<0.1
0.01
0.72
<0.05
1.91
3.87
0.13
42.10
1.26
< 0.001
<0.2
0.12
40.63
_
424.6
0.22
14.50
5,530
8,100
2
12.25
<0.01
<0.1
0.04
0.60
<0.05
2.17
6.66
<0.1
30.5
1.16
0.002
<0.2
0.14
40.52
-
395.0
0.10
19.20
3
14.9
<0.01
0.17
0.02
0.80
<0.05
2.38
11.25
0.13
26.9
1.15
0.001
<0.2
0.21
40.30
-
338.8
0.20
18.75
4
14.5
<0.01
0.11
0.04
0.76
<0.05
2.10
7.93
0.28
19.0
1.26
< 0.001
<0.2
0.08
56.00
-
625.0
0.17
15.0
5
13.0
<0.01
<0.12
0.03
0.72
<0.05
2.14
7.43
<0.16
29.6
1.20
< 0.001
<0.2
0.14
44.40
446
0.17
16.9
6
1.600
<1
<15
3.7
89
<6
264
917
<20
3.650
148
<0.1
<25
17
5,480
55^000
21
2,090
Note: 5-Ayeraqe ppm liquid and solids
6-Averoge ppm total solids (mg/g
TSS - total suspended solids
TS - total solids
.C-10
-------
Analysis for Chlorinated Hydrocarbons
PROJECT NO. 469
PLANT and LOCATION: WOVEN FABRIC D & F PLANT D-8
DESCRIPTION OF SAMPLE:
Phase
SAMPLE NO.
1
2
3
4
AVERAGE
No. of
Compounds
8
6
9
7
7.5
ppm
0.400
0.369
0.715
0.520
0.501
No. of
Compounds
18
12
9
10
12.3
ppm
47.7
56.0
17.8
33.5
38.8
REMARKS:
C-ll
-------
REPORT OF TRACE METALS
PROJECT NO. 469
PLANT WOVEN FABRIC D '& F PLANT D-17
LOCATION
(Unit --= PPM)
Sample No.
Aluminum
*Arsenic
Barium
*Cadmium
*Chromium
*Cobalt
*Copper
Iron (total)
*Lead
Magnesium
Manganese
*Mercury
Molybdenum
Nickel
Potassium
Sodium
Strontium
*Zinc
TSS
TS
1
191.25
<0.01
2.10
0.22
84.13
0.16
4.36
312.5
0.43
50.0
7.36
0.003
<0.2
1.75
44.42
-
383.5
<0.03
141.81
13,430
20,430
2
375.0
0.04
0.92
0.24
58.4
<0.05
4.62
195.5
1.28
39.0
6.40
0.006
<0.2
1.92
47.0
-
567.5
0.03
158.0
3
333.3
<0.01
2.20
0.19
95.4
0.07
4.63
393.7
1.80
22.4
6.29
0.002
<0.2
1.91
37.3
-
581.3
0.03
179.2
4
150.0
<0.01
1.70
0.23
86.0
0.08
2.10
207.0
1.43
25.0
5.85
0.003
<0.2
1.60
50.4
-
875.0
0.10
159.0
5
262
<0.02
1.73
0.22
81.0
<0.09
3.93
277
1.24
34.0
6.5
0.004
<0.2
1.8
45.0 _j
602
<0.05
159.0
6
12,800
<0.98
85
10.8
3,969
<4.4
192.6
13.600
61
1,660
318
0.196
<9.8
88.2
2,205
29,500
<2.45
7,791
Note: 5-Ayerage ppm liquid and solids
6-Averoge ppm total solids (mg/g
TSS - total suspended solids
TS - total solids
C-12
-------
Analysis for Chlorinated Hydrocarbons
PROJECT NO.
469
PLANT and LOCATION: WOVEN FABRIC D & F PLANT D-17
DESCRIPTION OF SAMPLE:
Liquid Phase
SAMPLE NO.
1
2
3
4
AVERAGE
No. of
Compounds
7
9
7
5
7
ppm
0.0630
0.0800
0.0554
0.1070
0.0764
No. of
Compounds
20
17
23
17
19
ppm
29.0
13.0
12.8
55.9
27.7
REMARKS:
C-13
-------
REPORT OF TRACE METALS
PROJECT NO, 469
PLANT WOVEN FABRIC D &F PLANT D-18
LOCATION
(Unit = PPM)
Sample No.
Aluminum
"Arsenic
Barium
*Cadmium
*Chromium
*Cobalt
*Copper
Iron (total)
*Lead
Magnesium
Manganese
*Mercury
Molybdenum
Nickel
Potassium
Sodium
Strontium
*Zinc
TSS
TS
1
26.6
<0.01
0.40
0.04
6.90
0.72
10.1
26.6
0.28
13.1
0.34
0.003
<0.2
0.13
10.7
477.0
<0.03
13.40
8,100
9,500
2
44.0
<0.01
0.46
0.02
14.00
1/32
15.0
65.9
<0,1
12.45
0.44
0.011
<0.2
0.35
14.9
580.2
<0.03
8.32
3
55.7
<0.01
0.68
0.03
10.75
0.96
8.5
51.6
0.13
12.9
0.38
0.001
<0.2
0.47
11.4
700.9
<0.03
6.67
4
43.3
<0.01
0.44
0.04
9.00
1.17
8.75
45.7
0.1
12.6
0.62
0.002
<0.2
0.30
16.8
437.0
<0.03
6.50
5
42.4
<0.01
0.50
0.033
10.20
1.04
10.6.
47.0
<0.15
12.76
0.45
0.006
<0.2
0.31
13,50
549
<0,0?
8.72
6
4.460
<1
53
3.5
1,070
109
1,120
4.950
<16
1,340
47
0.6
<21
33
1.420
,57,800
<3
918
Note: 5-Ayerage ppm liquid and solids
6-Average ppm total solids (mg/g
TSS - total suspended solids
TS - total solids
C-14
-------
PROJECT NO.
Analysis for Chlorinated Hydrocarbons
469
PLANT and LOCATION; WOVEN FABRIC D & F PLANT D-18
DESCRIPTION OF SAMPLE:
Liquid Phase
Suspended Phase
SAMPLE NO.
1
2
3
4 !
AVERAGE
No. of
Compounds
9
17
10
12
12
ppm
0.1551
0.100
0.1778
0.1453
0.1445
No. of
Compounds
16
19
12
12
15
ppm
13.86
19.56
14.00
15.50
15.70
REMARKS:
C-15
-------
REPORT OF TRACE METALS
PROJECT NO. 469
PLANT WOVEN FABRIC D & F PLANT D-9
LOCATION
(Unit = PPM)
Sample No.
Aluminum
*Arsenic
Barium
*Cadmium
*Chromium
"Cobalt
*Copper
Iron (total)
•Lead
Magnesium
Manganese
*Mercury
Molybdenum
Nickel
Potassium
Sodium
Strontium
*Zinc
TSS
TS
1
28.8
<0.01
0.40
<0.01
3.78
<0.05
6.65
28.4
<0.1
57.8
0.20
0.002
<0.2
<0.05
46.1
_
654.0
0.03
0.21
4,200
7,230
2
21.0
<0.01
<0.10
<0.01
3.60
<0.05
5.15
26.6
<0.1
48.0
0.58
0.009
<0.2
0.07
41.5
_
580.2
0.03
5.55
3
15.9
<0.01
0.17
<0.01
2.49
<0.05
4.35
18.75
<0.1
29.6
0.49
0.002
<0.2
0.13
36.5
_
661.0
0.03
1.17
4
19.0
<0.01
0.22
<0.01
3.46
<0.05
6.43
23.30
0.2
30.4
1.14
0.002
<0.2
0.13
59.6
_
844.0
0.10
2.25
5
21.2
<0.01
<0.22
<0.01
3.33
<0.05
5.64
24.3
<0.12
41.4
0.60
0.005
<0.2
<0.09
45.9
685
0.05
2.30
6
2,930
<1.4
<30
<1.4
460
<6.9
806
3.360
<16
5,730
83
0.7
<28
<12
6,350
94,700
6.9
318
Note: 5-Average ppm liquid and solids'
6-Average ppm total solids (mg/g
TSS - total suspended solids
TS - total solids
C-16
-------
PROJECT NO.
Analysis for Chlorinated Hydrocarbons
469
PLANT and LOCATION: WOVEN FABRIC D & F PLANT D-9
DESCRIPTION OF SAMPLE:
Liquid Phase
Phase
SAMPLE NO.
1
2
3
4
AVERAGE
No. of
Compounds
8
4
8
5
6
ppm
0.4472
0.1140
0.1440
0.230
0.2340
No. of
Compounds
21
12
11
13
14
ppm
0,336
0.34
2.38
2.25
1.33
REMARKS:
017
-------
REPORT OF TRACE METALS
PROJECT NO. 469
PLANT WOVEN FABRIC D & F PLANT D-15
LOCATION
(Unit = PPM)
Sample No.
Aluminum
*Arsenic
Barium
"Cadmium
*Chromium
•Cobalt
*Copper
Iron (total)
'Lead
Magnesium
Manganese
*Mercury
Molybdenum
Nickel
Potassium
Sodium
Strontium
*Zinc
TSS
TS
1
15.4
<0.01
<0.1
0.03
5.49
<0.05
13.99
15.16
0.99
28.5
0.62
0.003
<0.2
0.13
34.0
-
330.7
0.83
7.98
12,780
17,650
2
28.75
<0.01
0.15
0.06
10.5
<0.05
26.25
48.1
1.0
40.5
0.86
0.006
<0.2
0.32
51.2
-
333.3
0.82
17.6
3
28.80
<0.01
0.42
0.04
6.16
<0.05
21.5
31.6
1.16
27.6
0.77
0.002
<0.2
0.26
43.4
-
308.9
0.68
10.10
4
27.50
<0.01
0.16
0.06
5.4
<0.05
18.6
26.8
1.60
24.0
0.74
< 0.001
<0.2
0.18
45.0
-
400.0
1.00
15.00
5
25.1
<0.01
<0.21
0.048
6.9
<0.05
20
30.4
1.2
30.2
0.75
< 0.003
<0<2
0.22
43.4
343
0.83
12.7
6
1,420
<0.6
<12
2.7
390
<2.8
1,130
1,720
68-
1,710
42
<0.17
<11
12
2,460
19,400
47
720
Note: 5-Average ppm liquid and solids
6-Average ppm total solids (mg/g
TSS - total suspended solids
TS - total solids
C-18
-------
Analysis for Chlorinated Hydrocarbons
PROJECT NO.
469
PLANT and LOCATION: WOVEN FABRIC D & F PLANT D-15
DESCRIPTION OF SAMPLE:
Liquid Phase
Suspended Phase
SAMPLE NO.
1
2
3
4
AVERAGE
No. of
Compounds
9
5
12 ;
10
8
ppm
0.0015
0.0014
0.0014
0.0014
0.0014
i
No. of
Compounds
16
7
16
13
13
ppm
1.8
2.4
8.3
4.5
4.3
REMARKS:
.C-19
-------
REPORT OF TRACE METALS
PROJECT NO, 469
PLANT KNIT FABRIC D & F PLANT E-3
LOCATION
(Unit = PPM)
Sample No.
Aluminum
*Arsenic
Barium
"Cadmium
"Chromium
"Cobalt
^Copper
Iron (total)
"Lead
Magnesium
Manganese
*Mercury
Molybdenum
Nickel
Potass ium
Sodium
Strontium
*Zinc
TSS
TS
1
12.5
<0.01
<0.1
<0.01
1.49
<0.05
4.66
15.83
<0.1
34.9
0.52
0.002
<0.2
0.06
28.5
-
537.5
0.06
1.59
11,120
13,500
2
22.5
0.04
<0.1
<0.01
0.28
<0.05
0.07
25.1
<0.1
7.25
0.06
0.003
<0.2
<0.05
11.57
-
46.2
0.03
0.33
3
15.9
<0.01
<0.1
<0.01
0.26
<0.05
0.1
17.5
<0.1
3.67
0.06
0.001
<0.2
<0.05
36.5
—
53.1
0.03
0.35
4
36.0
<0.01
0.55
<0.01
0.42
<0.05
0.13
32.8
<0.1
6.3
0.05
0.002
<0.2
<0.05
8.8
_
55.0
0.07
4.24
5
22.0
<0.02
<0.2
<0.01
0.62
<0.05
1.2
23.0
<0.1
13.0
0.17
0.002
<0.2
<0.05
21.0
173
0.05
1.63
6
1,630
<1.5
<15
<0.7
46
<3.7
89
1,700
<7
963
12.6
0.15
<15
<3.7
1,560
12,800
3.7
120
Note: 5-Average ppm liquid and solids
6-Average ppm total solids (mg/g"
TSS - total suspended solids
TS - total solids
C-20
-------
PROJECT NO.
Analysis for Chlorinated Hydrocarbons
469
PLANT and LOCATION: KNIT FABRIC D & F PLANT E-3
DESCRIPTION OF SAMPLE:
Liquid Phase
Suspended Phase
SAMPLE NO.
1
2
3
4
AVERAGE
No. of
Compounds
7
5
9
8
7
ppm
0.059
0.040
0.0274
0.0356
0.0405
No. of
Compounds
19
9
8
17
13
ppm
0.55
0.27
4.40
3.45
2.20
REMARKS:
C-21
-------
REPORT OF TRACE METALS
PROJECT NO. 469
PLANT KNIT FABRIC D & F PLANT E-16
LOCATION
(Unit = PPM)
Sample No.
Aluminum
*Arsenic
Barium
*Cadmium
*Chromium
•Lobalt
•Lopper
Iron (total)
"Lead
Magnesium
Manganese
*Mercury
Molybdenum
Nickel
Potassium
Sodium
Strontium
*Zinc
TSS
TS
1
4.60
<0.01
<0.1
<0.01
0.02
<0.05
0.11
4.82
<0.1
1.81
0.17
< 0.001
<0.2
<0.05
2.40
_
59.0
<0.03
2.81
221
800
2
2.25
<0.01
<0.1
<0.01
0.01
<0.05
0.20
5.03
<0.1
1.15
0.06
0.002
<0.2
<0.05
2.63
_
79.1
<0.03
0.49
3
10.40
<0.01
<0.1
<0.01
0.04
<0.05
0.03
12.19
<0.1
1.40
0.11
0.001
<0.2
<0.05
3.10
_
83.0
<0.03
0.47
4
4.00
<0.01
<0.1
<0.01
<0.01
<0.05
0.03
4.40
<0.1
0.86
0.05
<0.001.
<0.2
<0.05
4.80
_
59.0
<0.03
0.26
5
5.3
<0.01
<0.1
<0.01
<0.02
<0.05
0.09
6.61
<0.1
1.30
0.09
< 0.00 If
<0.2
<0.05
3.23
70.0
<0.03
1.00
6
6,625
<12
<125
<12
<2.5
<62
112
8.260
<125
1.625
112
<1.9
<250
<62
4.040
87.500
<38
1,250
Note: 5-Average ppm liquid and solids
6-Average ppm total solids (mg/g
TSS - total suspended solids
TS - total solids
C-22
-------
Analysis for Chlorinated Hydrocarbons
PROJECT NO.
469
PLANT and LOCATION: KNIT FABRIC D & F PLANT E-16
DESCRIPTION OF SAMPLE:
Suspended Phase
SAMPLE NO.
1
2
3
4
AVERAGE
No. of
Compounds
9
5
7
8
7
ppm
0.624
0.132
0.345
0.433
0.384
No. of
Compounds
19
10
27
15
18
ppm
90.4
83.3
423.5
126.5
180.9
REMARKS:
C-23
-------
REPORT OF TRACE METALS
PROJECT NO. 469
PLANT KNIT FABRIC D & F'PLANT E-14
LOCATION
(Unit = PPM)
Sample No.
Aluminum
*Arsenic
Barium
*Cadmium
*Chromium
*Cobalt
*Copper
Iron (total)
'Lead
Magnesium
Manganese
*Mercury
Molybdenum
Nickel
Potassium
Sodium
Strontium
*Zinc
TSS
TS
1
13.5
<0.01
<0.10
<0.01
0.78
<0.85
9.78
10.75
0.13
15.47
0.30
0.004
<0.2
0.12
30.52
_
452.0
0.06
1.34
9,230
11,750
2
12.5
<0.01
0.15
0.01
0.64
<0.05
15.0
27.40
0.42
14.45
0.30
0.012
<0.2
0.18
37.30
_
728.3
0.03
4.72
3
23.0
<0.01
0.51
<0.01
0.61
<0.05
10.5
19.70
0.26
11.00
0.29
0.005
<0.2
0.13
32.00
_
690.3
0.07
4.50
4
11.75
<0.01
0.11
0.01
0.32
<0.05
13.1
15.52
0.28
8.40
0.48
0.003
<0.2
0.04
39.00
—
1,063.0
0.07
2.40
5
15.2
<0.01
0.22
<0.01
0.59
<0.05
12.1
18.30
0.27
12.33
0.34
0.008
<0.2
0.12
34.70
733
0.06
3.24
6
1,293
<0.85
18.7
<0.85
50.2
<4.2
1.030
1.557
23
1.049
29
0.7
<17
10.2
29.53
62,400
5.1
276
Note: 5-Average ppm liquid and solids
o-Ayerage ppm total solids (mg/g
TSS - total suspended solids
TS - total solids
C-24
-------
Analysis for Chlorinated Hydrocarbons
PROJECT NO.
469
PUNT and LOCATION: KNIT FABRIC D & F PLANT E-14
DESCRIPTION OF SAMPLE: .
Liquid Phase
Suspended Phase
SAMPLE NO.
1
2
3
4
AVERAGE
No. of
Compounds
8
10
U
12
11
ppm
0.990
0.199
0.800
0.520
0.620
No. of
Compounds
16
20
17
18
18
ppm
14.9
10.3
6.15
8.3
9.9
REMARKS:
0-25
-------
REPORT OF TRACE METALS
PROJECT NO. 469
PLANT CARPET D & F PLANT F-10
LOCATION
(Unit = PPM)
Sample No.
Aluminum
"Arsenic
Barium
'Cadmium
'Chromium
*Cobalt
"Copper
Iron (total)
*Lead
Magnesium
Manganese
"Mercury
Molybdenum
Nickel
Potassium
Sodium
Strontium
*Zinc
TSS
TS
1
2.3
<0.01
<0.1
<0.01
0.08
0.04
0.15
2.02
<0.1
0.80
0.06
< 0.001
-------
PROJECT NO.
Analysis for Chlorinated Hydrocarbons
469
PLANT and LOCATION: 'CARPET D & F PLANT F-10
DESCRIPTION OF SAMPLE:
Liquid Phase
Suspended Phase
SAMPLE NO.
1
2
3
4
AVERAGE
No. of
Compounds
14
13
6
7
10
ppm
0.0946
0.0484
0.3520
0.2480
0.1858
No. of
Compounds
-
M
12
11
11.5
ppm
-
-
66.8
35.6
51.2
REMARKS:
C-27
-------
REPORT OF TRACE METALS
PROJECT NO. 469
PLANT CARPET D & F PLANT F-3
LOCATION
(Unit = PPM)
Sample No.
Aluminum
*Arsenic
Barium
"Cadmium
*Chromium
*Cobalt
*Copper
Iron (total)
"Lead
Magnesium
Manganese
Molybdenum
Nickel '
Potassium
Strontium
*Z,inc
TSS
TS
1
2.63
<0.01
<0.1
<0.01
0.35
<0.05
0.04
1.05
<0.1
3.00
0.07
<0.001
<0.2
<0.05
2.10
-
45.4
0.03
0.17
160
1,380
2
1.75
<0.01
<0.1
<0.01
0.08
<0.05
0.02
0.40
<0.1
2.20
0.02
< 0.001
<0.2
<0.05
2.10
-
51.5
0.03
1.00
3
3.00
<0.01
<0.1
<0.01
0.143
<0.05
<0.01
1.72
<0.1
3.35
0.45
< 0.001
<0.2
<0.05
2.00
-
56.4
0.03
0.18
4
2 25
<0.01
<0.1
<0.01
0.10
<0.05
0.03
0.48
<0.1
2.80
0.03
< 0.001
<0.2
<0.05
2.00
_
71.0
0.07
0.04
5
2.40
<0.01
<0.1
<0.01
0.17
<0.05
<0.03
0.91
<0.1
2.84
0.14
< 0.001
<0.2
<0.05
2.05
56.1
0.04
0.35
6
17.40
<7
<70
<7
123
<36
<22
660
<70
2,060
101
<0.7
<145
<36
1,490
41,000
29
254
Note: 5-Average ppm liquid and solids
6-Average ppm totnl solids (mp/g
TSS - total suspended solids
TS - total solids
C-28
-------
Analysis for Chlorinated Hydrocarbons
PROJECT NO.
469
PLANT and LOCATION: CARPET D & F PLANT F-3
DESCRIPTION OF SAMPLE:
Liquid Phase
Suspended Phase
SAMPLE NO.
1
2
3
4
AVERAGE
No. of
Compounds
12
7
8
9
9
ppm
0.00020
0.00025
0.00041
0.00032
0.0003
No. of
Compounds
14
-
23
20
19
ppm
0.735
-
1.425
0.940
1.03
REMARKS:
C-29
-------
REPORT OF TRACE METALS
PROJECT NO. 469
PLANT YARN AND STOCtf D &F PLANT G-10
LOCATION
(Unit = PPM)
Sample No.
Aluminum
*Arsenic
Barium
*Cadmium
"Chromium
*Cobalt
''Copper
Iron (total)
*Lead
Magnesium
Manganese
*Mercury
Molybdenum
Nickel
Potassium
Sodium
Strontium
*Zinc
TSS
TS
1
0.75
<0.01
<0.1
<0.01
0.10
<0.05
0.15
0.67
<0.1
0.94
0.01
< 0.001
<0.2
<0.05
3.78
-
356.1
<0.03
0.77
182
2,100
2
<0.50
<0.01
<0.1
<0.01
0.04
<0.05
0.10
0.96
<0.1
0.80
0.02
0.001
<0.2
<0.05
4.38
-
407.4
0.03
0.89
3
<0.50
<0.01
•<0.1
<0.01
0.04
<0.05
0.20
1.22
<0.1
0.90
0.01
<0.001
<0.2
<0.05
3.80
-
408.6
<0.03
0.58
4
1.25
<0.01
<0.1
<0.01
0.16
<0.05
0.43
2.24
<0.1
0.74
0.02
< 0.001
<0.2
<0.05
5.60
-
687.0
0.03
2.50
5
<0.75
<0.01
<0.1
<0.01
0.08
<0.05
0.22
1.27
<0.1
0.85
0.02
< 0.001
<0.2
<0.05
4.40
465
<0.03
1.20
6
<357
<5
<50
<5
38
<24
105
605
<50
405
10
<0.5
<100
<24
2,100
221.000
14
571
Note: 5-Averoge ppm liquid and solids
6-Average ppm total solids (mg/g
TSS - total suspended solids
TS - total solids
030
-------
PROJECT NO.
Analysis for Chlorinated Hydrocarbons
469
PLANT and LOCATION: YARN AND STOCK D & F PLANT G-10
DESCRIPTION OF SAMPLE:
Liquid Phase
Suspended Phase
SAMPLE NO.
1
2
3
4
AVERAGE
No. of
Compounds
6
6
9
7
7
ppm
0.0090
0.0063
0.0042
0.0035
0.0058
•
i
No. of
Compounds
17
17
20
18
18
ppm
3.69
2.50
3.63
3.45
3.32
REMARKS:
. 031
-------
REPORT OF TRACE METALS
PROJECT NO. 469
PLANT YARN AND STOCK D&F PLANT G-3
LOCATION
(Unit = PPM)
Sample No.
Aluminum
"Arsenic
Barium
'Cadmium
Chromium
"Cobalt
-Copper
Iron (total)
*Lead
Magnesium
Manganese
*Mercury
Molybdenum
Nickel
Potassium
Sodium
Strontium
*Zinc
TSS
TS
1
1.14
<0.01
<0.1
<0.01
0.02
<0.05
0.28
1.78
<0.1
12.50
0.08
0.001
<0.2
<0.05
4.64
-
277 JQ
0.14
6.00
129
1,230
2
3.50
<0.01
<0.1
0.01
0.06
<0.05
0.75
5.03
<0.1
8.40
0.18
0.002
<0.2
<0.05
12.28
-
666.6
0.03
5.28
3
4.76
<0.01
<0.1
0.01
0.04
<0.05
0.60
5.16
<0.1
7.35
0.22
< 0.001
<0.2
<0.05
7.62
-
564.7
0.07
0.52
4
1.75
<0.01
<0.1
<0.01
Q.Q1
<0.05
Q.43
1.38
<0.1
5.06
0.10
0.001
<0.2
<0.05
12.00
-
937
0.07
0.21
5
2.80
<0.01
<0.1
-------
Analysis for Chlorinated Hydrocarbons
PROJECT NO.
469
PLANT and LOCATION: YARN AND STOCK D & F PLANT G-3
DESCRIPTION OF SAMPLE:
Liquid Phase
Suspended Phase
SAMPLE NO.
1
2
3
4
AVERAGE
No. of
Compounds
8
10'
5
7
7.5
ppm
0.0093
0.0350
0.0980
0.0850
0.0568
No. of
Compounds
22
-
10
12
14.7
ppm
61.6
-
92.3
76.5
76.8
REMARKS:
C-33
-------
APPENDIX D
PARTIAL LISTING OF THE CHEMICALS MDST USED
IN THE TEXTILE INDUSTRY
Chemical Type
acids
alkalies
bleaches
adhesives and polymers
cross-linking agents
carbonizing agents for wool
conditioners
catalysts
detergents, soaps, dispersing
agents
dye assistants, carriers,
accelerants
Examples
acetic, formic, hydrochloric, sulfuric
and oxalic
nono-, di-, and trLethanolamines,
sodium carbonate, sodium hydroxide and
sodium roetasilicate
sodium hypochlorite, hydrogen peroxide,
sodium perborate, sodium chlorite and
peracetic
polyvinyl acetate, polyacrylates and
methacrylates, polyvinyl alcohols, polyvinyl
chloride, copolymers of acrylonitrile,
butadiene, styrene, polyurethanes,
modified starch ethers and natural rubber
latices
urea f ontaldehydes, formaldehyde, cyclic
ethylene urea formaldehyde and methylol
carbctnates
aluminum chloride and sulfuric acid
ethylene glycol, propylene glycol and
glycerine
diamnonium phosphate, magnesium chloride,
calcium chloride, zinc nitrate and zinc
chloride
alkyl aryl sulfonates, alkane sulfates,
sodium and amine soaps, alkyl phosphate
salts, sodium polyphosphates, polyethylene
oxide and polypropylene oxide condensates,
sodium and potassium soaps - oleate, stearate
trichlorobenzene, butyl benzcate, ortho
phenylphenol, biphenyl, methyl salicylate,
alkylated naphthalenes and mixed chlorinated
aromatics
D-l
-------
Chanical Type Examples
flame retardants polyvinyl chloride and tin oxide, chlorinated
paraffins and waxes and tin oxide, THPC-
tetrakishydroxymethyl phosphonium chloride,
tris debrorpropyl phosphate, anrooniun
sulfamate, ammonium bronide, amtDniim
phosphate, thiourea, copolyitErs of vinyli-
dene chloride, tetrabrono bis phenol and
copolymers of acrylonitrile and vinyl
chloride
chemical finishes polyethylene and polypropylene-softeners,
polymeric hand builders, cfuaternary am-
monium long chain aliphatics-softeners,
silicon fluids-lubricants, siloxane polymers-
water repellants and polyperf luoro chemicals-
water and oil repellants
solvents trichlorcethane, perchloroethylene, dioxane,
butyl carbital, butyl cellosolve and
stoddard solvent-petroleum distillate
U01419
*UA GOVERNMENT PRINTING OFFICE: 1976 340-848/7Z
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