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CONTENTS
Section
Page
I Results and Conclusions 1
II Recommendations 5
III Introduction 7
IV Research and Development Project 9
V Engineering Approach and Operational
Plan 11
VI Operational and Experimental Aspects
of the Project 29
VII Operation of the Treatment System
on a Production Basis 51
VIII Acknowledgements 53
IX References 55
X Appendices 57
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FIGURES
Page
1. Overall Schematic of the Wastewater and
Water Reuse Facility 14
2. Aerial View of Fiber Industries, Inc.,
Shelby, North Carolina 15
3. Schematic of Continuous Operation Chromate
Reduction System 16
4. Schematic of Plastic Media Trickling Filter
Showing Structural Members and Media Bundle
Arrangement 17
5. Photograph of Plastic Media Trickling Filter 18
6. Schematic of North Microscreen (Algae Screen) 19
7. Photograph of 500,000 gpd North Algae Screen
Installed Between Polishing Pond and Carbon
and Flocculant Treatment Unit 20
8. Schematic of Flocculant and Carbon Units 21
9. Exterior View of Permutit Carbon and Flocculant 22
10. The Automatic Valveless Gravity Final Filter
Installed Downstream of Settling Tank 23
11. Location of Sampling Points in Treatment Plant 39
12. Plastic Media Trickling Filter, Operational Mode
B & C - Sludge Recycle Hydraulic Loading
40
13. Plastic Media Trickling Filter, Operational Mode
A - No. Sludge Recycle Hydraulic Loading 41
14. Plastic Media Trickling Filter, Operational Mode
B & C - Sludge Recycle 42
15. Plastic Media Trickling Filter, Operational Mode
A - No Sludge Recycle 43
vn
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TABLES
No.
Page
1 Typical Hydraulic and Organic Loadings
for Plastic Media Trickling Filters 27
2 Chromate Reduction Unit Operational Data 33
3 Data from Microscreening and Chemical
Treatment Unit 35
4 Data from Microscreening and Chemical
Treatment Unit 37
5 Effectiveness of Polishing Ponds as A
Tertiary Treatment Unit 38
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SECTION I
RESULTS AND CONCLUSIONS
Many conclusions can be drawn from the evaluation of each of the
various research and development units installed in the treat-
ment plant as a part of this grant. These conclusions are pre-
sented on a unit by unit basis as they pertain to the grant.
Chromate Reduction Unit
1. It has been demonstrated that the removal of hexavalent chrom-
ium from cooling tower blowdown can be accomplished by chemical
reduction and precipitation utilizing sulfur dioxide in an
acidic media followed by neutralization and settling.
2. The biocides which are normally used in cooling water systems
and which may be contained in the effluent from the reduction
unit are accounted for as follows:
a. Sodium pentachlorophenate when used as a biocide in cool-
ing water will pass through the chromate reduction unit
and enter the waste water treatment plant. It has no
adverse effect on the plant and does not appear in the
effluent from the clarifier.
b. Methylene bis thiocyanate is similar to sodium penta-
chlorophenate in that it passes through the chromate system
and enters the waste treatment plant. It has no adverse
effect on the plant and does not appear in the clarifier
effluent.
c. 1, 3 dichloro -5, 5-dimethylhydantoin is riot stable with-
in the cooling system and dissipates within six hours of
introduction. It has not been detected in the cooling
tower blowdown. 3
d. N-alkyl dimethyl benzyl ammonium chloride is destroyed in
the reduction process and therefore is not a problem in
the waste treatment plant.
e. Sodium dimethyl thiocarbamate and disodium ethylene bis-
thiocarbamate are destroyed in the chromate reduction pro-
cess and therefore have no effect on the waste treatment
plant.
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Plastic Media Trickling Filter
3. Chemical and sanitary wastes generated in the production of
FORTREL Polyester can be treated using a tower packed with
plastic media. BOD5 reductions in the range of 40 percent
have been attained using a single tower and utilizing sludge
recycle from the clarifier.
4. The percent reduction in BOD5 appears to be constant at
approximately 40 percent over a loading range of 300 to 950
pounds BOD5 per 1000 cubic feet of media per day using a
sludge recycle mode. With no sludge recycle the percent
BODc reduction tends to be constant at 25 percent over a
loading range of 300 to 700 pounds per 100 cubic feet of
media per day.
5. The percent reduction of BOD^ at these loadings is not sig-
nificantly changed by variations in hydraulic loadings ranging
from 0.95 to 6.75 gallons per square foot per minute.
6. Recycle rates up to 5:1 appear to have minor and insignificant
effect upon BODc percent reduction. At ratios ranging from
5:1 up to 9:1 there appears to be a five percent improvement
in the 6005 reduction. It must be concluded that increasing
recycling ratios in these ranges has no significant effect on
reduction.
7. Sludge recycle over the tower, together with sanitary and
chemical waste, results in a net BOD5 reduction increase of
a nominal 10 percent as compared to no sludge recycle under
the same conditions.
8. A comparison of the treatment of waste water from the manufac-
ture of polyester utilizing plastic media as a roughing filter
versus mechanical aeration indicates that costs of construction
for equivalent treatment capacities are equal. Therefore the
two systems must be compared and selected on a basis other than
cost.
9. Plastic media trickling filters will freeze and become inoper-
ative at ambient temperatures of 10°F. (waste influent tem-
perature 45°F.)
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Mlcroscreens and Chemical Treatment Unit
10. It has been observed that the microscreen (algae screen) per-
formed well in warm weather but tended to become clogged with
slime growth during periods corresponding to algae blooms in
the ponds. In winter the spray nozzles froze when the ambient
temperature dropped below freezing.
11. Polishing pond effluent waters can be chemically treated to
achieve water suitable for reuse as cooling tower make-up.
The cost for chemicals for such treatment is as low as $0.08,
per 1000 gallons of water treated. This is typical for the
many flocculants and carbons evaluated.
12. Clarifier effluent waters can be chemically treated to achieve
water suitable for reuse as cooling tower make-up. The cost
for chemicals for this treatment is $0.11 per 1000 gallons.
13. The BOD5 reduction and the COD reduction for the secondary
treatment system was in excess of 95% during the grant period.
14. Sludge disposal from the secondary treatment system as well as
spent powdered carbon from the tertiary system and screenings
from the microscreen were lagooned. This is considered to be
the ultimate disposal of the sludge. When the lagoon is full
another will be established and the present one will be covered
with dirt.
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SECTION II
RECOMMENDATIONS
The conclusions presented in this report are the basis on which these
recommendations are made. It should be noted that they are based on
ajinimum of one years full scale operation of the various treatment
further stud^ of the chromate
rMrt, er su^ o te chroma
reduction unit. The design and operation were satisfactory
and the unit is now in permanent use. The potential for
chromium pollution of the receiving stream from deliberate
cooling tower blowdown has been removed. A system of this
type is recommended for use at other installations havinq
similar cooling water blowdown problems.
2. It is recommended that the cooling water blowdown with heavy
metals removed and containing the type and concentration of
biocides evaluated in this study and normally used in such
treatment^ fants treated 1n activated sludge waste water
3. It is recommended that studies be instituted to develop an
oxidation-reduction potential (ORP) probe that will operate
under the conditions encountered with this cooling water for
longer periods of time without loss of sensitivity.
4. The use of a plastic media trickling filter for polyester waste
is recommended as a roughing filter ahead of an activated sludge
?JSnL!!aSer *reatment s^stem when additional treatment capacity
s needed and when space for construction of a treatment facility
s at a premium The use of the plastic media is not recommended
in areas where it will be placed in the open and where Sent
temperatures be ow freezing occur as the unit may freeze and
c^AT6^6- (WaSte water temperatures must be con-
effect } ^ °V6r rule the ambient
5. It is recommended that studies be undertaken to determine the
effects of commonly used biocides and dispersants in shock load
concentrations on activated sludge systems. This type infor-
mation would be valuable for overcoming the effects of spills
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6. The installation of a microscreen between a polishing pond
and a chemical treatment unit is recommended. This unit
serves the primary purpose of removing algae clumps and mats
and other macroscopic debris and by so doing protects the
chemical treatment system.
7. The reuse of chemically treated polishing pond effluent is
recommended over the reuse of chemically treated clarifier
effluent as cooling water makeup since the former is less
effected by treatment plant upsets and also has less phos-
phates and nitrates in the final treated water.
8. Studies centered around the reuse of polishing pond effluent
for recreational purposes is recommended. Such data is avail-
able for effluent from the treatment of municipal wastes, but
is lacking for industrial waste.
9. It is recommended that the treatment system be operated on a
production basis using chromate reduction, equalization,
roughing filter, mechanical aeration, clarification, polishing
ponds, algae screens, polymer addition and final filter at an
estimated cost of operation of 40^/1000 gallons.
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SECTION III
INTRODUCTION
Background
The Fiber Industries, Incorporated, FORTREL Polyester plant at
Shelby, North Carolina, has been in operation since 1960. The
initial manufacturing plant was small and the sanitary and
industrial wastes were treated in an Imhoff Tank. As the FORTREL
Polyester plant grew, the waste water treatment facility expanded
and changed until in 1968 it consisted of a very large and modern
extended aeration activated sludge system and final polishing
lagoons.
In parallel with the growth of the FORTREL plant there was a
general awakening of interest in pollution abatement technology
throughout the country. Fiber Industries, Incorporated, recognizing
the potential for reusing effluent as cooling tower makeup, retained
Davis & Floyd Engineers, Inc. to perform a reuse feasibility study.
When this study indicated an apparent gap between desire and tech-
nology, application was made to the United States Department of the
Interior, Federal Water Quality Administration for a Research and
Development Grant. The proposed project was to include pre-treat-
ment of the cooling water to remove heavy metals, in-plant modifi-
cations and additions to the treatment plant to increase the treatment
capacity, and finally a post treatment system to polish the effluent
prior to selected reuse.
Fiber Industries, Incorporated was awarded Research and Development
Grant 12090 EUX by the Federal Water Quality Administration early in
1968. The project was basically a water reuse project utilizing the
existing activated sludge waste treatment plant onto which the various
grant units to be studied were superimposed.
The project was funded on April 4, 1968. Construction started early
in August. The first unit of the grant was placed in operation in
December 1968, and by February 1969 all units were in operation. The
plant was operated under the terms of the grant until June 4, 1970
at which time the operational phase was completed.
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SECTION IV
RESEARCH AND DEVELOPMENT PROJECT
APPROACH
Effluent from the existing waste water treatment facility, as
mentioned previously was of high quality. Specifically, the 8005
was generally less than 25 mg/1, the COD was less than 300 mg/1,
and the dissolved solids were in the range of 500 mg/1. Dissolved
oxygen and suspended solids content varied continuously as a
result of an ever changing quantity of algae growth in the polish-
ing lagoons. Thus, in order to reuse this water, facilities for
handling obvious quality deficiencies and/or waste treatment
problems which could arise had to be installed.
Suspended solids, primarily algae growths, and dissolved nutrient
materials had to be removed or reduced in quantity so that cooling
tower sludge and slime problems would not be unduly aggravated.
After consideration of various alternatives, microscreening followed
by powdered carbon-chemical coagulant-dual media filtration process-
ing was selected to pretreat effluent waters before their reuse in
the tower.
Dissolved solids in the effluent water were known to be much higher,
500 mg/1 as compared to 100 mg/1, than in the potable water normally
used for cooling tower makeup. It was expected, therefore, that
blowdown from the tower would be increased markedly. Increased
blowdown added two new requisites; namely, a facility for handling
tower system treatment chemicals; i.e., chromates and biocides and
a facility for handling increased biological loads from organic
contaminants; e.g., ethylene glycol.
A review of industrial practices revealed that chromates could be
effectively separated from an aqueous stream by chemically reducing
the hexavalent chromium to its trivalent form and then precipitating
the trivalent chromium as chromium hydroxide. A process using sulfur
dioxide as the reducing agent and sodium hydroxide as the precip-
itating alkali was chosen because of the greater ease of handling
and immediate availability of these chemicals.
A plastic media trickling filter was selected to supply the added
biological treatment capacity required to handle increased tower
blowdown. This sanction, which followed review of various poten-
tial treatment processes, was made primarily because promixing data
appearing in the literature indicated substantial cost savings over
other methods. Space and arrangement features also permitted
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relatively quick evaluation of this equipment's efficiency when used
as a roughing treatment preceding the existing activated sludge unit.
Scope and Objectives
The objectives of this research and development project were "to
treat synthetic fiber manufacturing waste and cooling water blow-
down by such methods as chemical reduction, sedimentation, plastic
media trickling filters, polishing ponds, algae microscreening,
carbon absorption and/or organic polymer flocculation, such that
the treated waters can be reused as a process water makeup stream".
In order to accomplish this, a general plan for the grant was
adopted as follows:
1. Install a chromium reduction system in the cooling tower blow-
down system which will remove hexavalent chromium from the waste
stream and evaluate the various biocides which are used to
control biological growth in cooling towers to determine if
they can be introduced into the waste treatment systems without
significantly reducing or changing the treatment capability
of the system.
2. Install a plastic media trickling filter in the treatment
plant influent stream and evaluate the following:
a. BOD5 and hydraulic loadings and recirculation rates for
the treatment of waste water from polyester fiber
manufacture.
b. The efficiency and economics of using plastic media as
compared to mechanical aeration for waste water treatment
as it pertains to this particular plant.
c. The efficiency of land usage for waste water treatment
systems utilizing plastic media as compared to mechanical
aeration for waste water treatment.
3. Install a final treatment system consisting of a micro-screen
(algae screen), and a powdered carbon and flocculant treatment
system_in the effluent stream to accomplish the following
objectives: 3
a. Demonstrate that a chemical fiber waste which has been pre-
treated in a waste treatment plant can be post-treated by
screening and/or activated carbon and/or flocculants and
reduce the color, BOD, COD and total solids to such a degree
that it can be used as process makeup water
10
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SECTION V
ENGINEERING APPROACH AND OPERATIONAL PLAN
Description of Treatment Plant Components
The wastewater treatment facility serving Fiber Industries, Inc.,
Shelby, North Carolina, is located on Company property and is for
the exclusive use of the plant. Both domestic and chemical ef-
fluent are treated. The design flow of the wastewater treatment
plant is 325,000 gallons per day at a BOD^ loading of 6000 pounds
per day. The chemical waste is composed of ehtylene glycol,
dimethyl terephthalate, long chain fatty acids such as oleic, 1ino-
lei c, 1 auric and their derivatives, quality control laboratory
waste, boiler blowdown, Dowtherm, methyl alcohol and cooling water
blowdown. The wastewater is routed to the treatment facility as
shown in Figures 1 and 2. The units in the system are described
as follows:
A. Chromate reduction unit (Grant Unit). The chromate reduction
unit is rated at 120 gpm at Cr04 concentrations up to 300 mg/1.
It is designed for continuous operation. The reduction tank
is designed for ten minutes retention; the neutralization tank
for twenty minutes retention. Both tanks are lined with poly-
vinyl chloride. The tanks and all the instrumentation for a
typical installation are shown in Figure 3. They are housed
in a 20' x 30' building, which is located immediately behind
the cooling tower.
B. Equalization basins. The chemical waste is routed through
three series connected equalization basins. These basins have
a total capacity of 190,000 gallons and are equipped with
mixers to prevent stratification and short circuiting. In
addition to the chemical process waste, cooling tower blowdown
is routed to this system after it passes through the chromate
reduction system. These basins serve to minimize the effects
of spills or intermittant waste loads containing high concen-
tration of organic materials.
C. Plastic Media Trickling Filter (Grant Unit). The plastic media
trickling filter is shown schematically in Figure 4. A photo-
graph of the unit is shown in Figure 5. The filter consists of
two tiers of media each ten feet thick and twenty-five feet in
diameter. Each tier is composed of five two-foot thick layers
of polyvinyl chloride media. The geometrical arrangement of
the media, each module measuring 2 ft. x 2 ft. x 4 ft., is
11
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critical both for strength and distribution and the arrange-
ment, as shown, is as required. There is a two foot air
space between the tiers. The tower is covered on the exterior
by galvanized siding except for a two foot air opening around
the bottom circumference. The tower is fitted with a four-
armed reaction type rotary distributor with variable flow
orifice nozzles. The tower rests on a sloped and curbed con-
crete pad which is connected to a sump which is equippad
with a recirculation pump. The pump used to circulate the
waste over the tower is variable speed and is rated up to
900 gpm @ 40 ft. TDH. The filter media used in the tower is
Koroseal Vinyl Core manufactured by the B. F. Goodrich Company.
A schematic and a photograph of this unit is shown in Figures
4 and 5.
U. Aeration basin. Following the plastic media tower is an
aeration basin equipped with three mechanical aerators; two
rated at 75 HP and one rated at 25 HP. The detention time in
the aeration basin is 30 hours based on 325,000 gpd flow and
100% recycle of the clarifier sludge. The Eimco Simcar
Aerators were tested in and are rated at 3.5 pounds of oxygen
per horsepower hour at standard conditions using water as a
test media.
E- Clarifier. The clarifier follows the aeration basin and is of
the peripheral flow type. Detention time is 3.6 hours at plant
design flow and a 100% sludge recirculation rate. Surface
overflow rate is 2125 gallons per day per square foot. Weir
overflow rate is 145 gallons per day per linear foot.
F. Polishing ponds. There are two series connected ponds having
a total detention time of 25 days at design flow. The sides of
these ponds have a 3:1 slope and are operated at a 5 ft. depth.
(These two ponds are stocked with catfish, bream and bass).
G. Micro screen or algae screen (Grant Unit). A portion of the
effluent from the polishing pond is routed through a rotary
drum microscreen to the flocculant and/or carbon treatment unit.
This screening unit has a rated maximum flow of 500,000 gpd.
It is equipped with a 40 micron (120 x 400 mesh) stainless steel
screen. The backwash is routed to the sludge pond. (Figures
6 and 7.)
H. Flocculant and/or carbon unit (Grant Unit). This unit is oper-
ated jointly with Item F above and is a packaged unit designed
by Permutit. It consists of a dry carbon feeder, a liquid
12
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chemical addition system consisting of two 30 inch diameter
x 42 inches high mixing tanks to which is connected double
feed pumps. These systems feed into a contact tank which is
followed by a clarifier. The contact tank measures 6 ft. in
diameter by 9 ft. high and is equipped with a mixer. The
clarifier, a Permutit Permu-Jet measures 20 ft. in diameter
and 12 ft. deep. A Permutit 10 ft. diameter 12 ft. high
valveless filter packed with sand and anthracite serves as
a final filter. The system is shown on the schematic in
Figure 8. Photographs of the unit appear as Figures 9 and
10.
I. Sludge pond. The earthern sludge pond measures 250' x 500'
and operates at a 5' depth. The sides of this pond have a
3:1 slope.
J- Digester. The aerobic digester basin has a capacity of
67,000 cubic feet ans is equipped with a 75 HP and a 25 HP
mechanical aerator. The oxygen transfer per horsepower hour
is comparable to that for the aerators in the aeration basin
as described previously.
13
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AEROBIC DIGESTER
AERATION BftSIN
linn ijiH i li in I mi n i ii i£i li iiiiii [i nfl
EQUALIZER BASINS
HOLDING LAGOON CHROMATE REDUCTION
TREATMENT TANK
I TREATMENT CHEMICAL
STORAGE a SOLUTIONS
POLISHING PONDS
CARBON
SLUD« POND CLARIFLOCCULATOR
COOLING TOWKR
OUTFALL
(OUMMG «-USE
NOTE:
GRANT UNITS SHOWN WITHIN
BLOCKED AREAS.
OVERALL SCHEMATIC
of the
WASTEWATEft and WATER REUSE FACILITY
at
FIBER INDUSTRIES. INC, SHELBY N C
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FIGURE 2
Aerial view of Fiber Industries, Inc., Shelby, North Carolina
shown in the foreground is at the rear of the plant.
The Treatment facility
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L
T
SCHEMATIC of CONTINUOUS OPERATION
CHROMATE REDUCTION SYSTEM
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\
FIGURE 4
SCHEMATIC of PLASTIC MEDIA
TRICKLING FILTER
Mtorag
STRUCTURAL MEMBERS and MEDIA
BUNDLE ARRANGEMENT
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FIGURE 5
Photograph of plastic media trickling filter. Variable speed
shown on the left. Samples of plastic media tower packing is
the foreground.
pump is
shown in
18
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SCHEMATIC
of
NORTH' MICROSCREEN
(ALGAE SCREEN)
-------
no
FIGURE 7
Photograph of 500,000 GPD North algae screen installed between polishing pond and carbon and
flocculant treatment unit.
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POWDERED
CARBON FEEDER
BY WALLACE 8
TIERNAN
MODEL OF 60
FROM ALGAE SCREEN
CHEMCIAL FEED TANKS
BY PERMUTIT
TO REUSE
CONTACT TANK
10' DIA, VALVELESS
GRAVITY FILTER
BY PERMUTIT
20' DIA. PERMUJET
FIGURE 8
SCHEMATIC
of
FLOCCULAHT «nd CARBON UNITS
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ro
ro
FIGURE 9
Exterior view of Permutit carbon and flocculant treatment unit.
feed unit, the liquid additive mixing tanks and feed pump. The
of the photograph.
The building houses the dry carbon
settling tank appears to the right
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FIGURE 10
The automatic valveless gravity final filter is installed down-
stream of the settling tank. Filtered water is pumped to the
plant cooling tower for use as makeup water.
23
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PRIOR ART
Micro-Screening
Screening devices of various types have been in use for many years
in removing suspended materials from water. These uses include
the removal of paunch from meat processing waste, solids removal
from domestic sewage, lint removal from textile and woolen mill
waste. In recent years, screening devices commonly called "algae
screens" or "micro-screens" have also been used for the removal
of fine suspended materials as a first step in the treatment of
water for potable or process use. This type use has been rather
extensive in the paper industry where large volumes of "raw water"
are required.
A micro-screen is generally a device in which a wire mesh covers a
rotating cylinder and through which the liquid to be filtered flow.
The residue is deposited on the screen as the liquid passes through.
The residue is removed from the screen and deposited in a trough as
it rotates past spray nozzles which backwash the screen. Size and
amount of suspended material removed depends upon screen size and
pattern of weave. Obviously, a finer screen has a better removal
capability; however, the finer screens are known to be "blind" and
become inoperative (15).
Chemical Treatment
The removal of soluble organic and finely dispersed insoluble organic
and inorganic materials by flocculation or by the use of activated
carbon has received a great deal of attention in recent years. Crook
and Poll is (14) have extensively investigated the use of polyelectro-
lytes, both cationic and anionic, for use in the removal of such
materials from water. They have found that by the use of a polyamine
bisulfate salt and similar polymers having molecular weights of 3 x
105, significant quantities of soluble organic and insoluble organic
materials from domestic and industrial waste can be removed. This
has been proven in field tests by this group. This technique has
been applied directly to the treatment of waste water by the Federal
Water Quality Administration at Lebanon, Ohio (15) with very promising
results. Much of this work was directed towards the use of polymers
for pretreatment of wastewater prior to normal secondary treatment.
Carbon on the other hand was used by this group for the most part
to reduce the BOD5, COD, color and other parameters as a form of post
treatment after secondary treatment. There has been very little work
accomplished in the area of post treatment of the waste water using
these two methods after the waste has been reduced in 8005 by 95
24
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percent or more in a biological treatment system. The water obtained
from the 95 percent treatment process is naturally of a much higher
quality than that from only secondary treatment and any significant
improvement in its quality would be of major interest for those
interested in water reuse.
Chromate Reduction
A variety of reducing agents are employed for the reduction of hexa-
valent chromium (1, 2). Listed below in their order of importance
are the most common agents:
1. Sulfur Dioxide (S02) (Used in 12090 EUX)
2. Sodium Bisulfite (NaHS03)
3. Sodium Sulfite (Na2S03)
4. Sodium Metabisulfite
5. Ferrous Sulfate (FeSO/j)
Of these, sulfur dioxide, ferrous sulfate, and sodium metabisulfite
are the most generally used. Typical reactions are illustrated below.
1. 2Cr03 + 3S02-*-Cr2 (S04)3 (Used in 12090 EUX)
2. 4Cr03 + 6NaHS03 + 3H2S04~»-3Na2S04 + 2Cr2 (S04)3 + 6H20
3. 2Cr03 + 3Na2S03 + 3H2S04 -*-3Na2S04 + Cr2 (S04) + 3H20
4. 4Cr03 + 3Na2S205 + 3H2S04->-3Na2S04 + 2Cr2 (S04)3 + 3H2
5. 2Cr03 + 6FeS04 .7H20 + 6H2S04-*-3Fe2 (S04)3 +Cr2 (S04)3 + 48H20
All of the above reactions occur in acidic media, some necessitating
the addition of an acid such as sulfuric to insure a rapid reaction
rate and minimum quantities of reducing agent. All of the procedures
convert hexavalent chromate to trivalent chromium and must therefore
be followed by a supplementary step to remove trivalent chromium from
solution. This is accomplished by elevating the pH of the waste stream
to 8.0 - 9.0 and precipitating the chromium as chromic hydroxide.
Lime is most often utilized for this purpose. Sodium hydroxide or any
other available alkali may be preferred in smaller installations be- .
cause of the greater ease of handling and its immediate availability.
The precipitation reaction is as follows:
Cr2 (S04) Cr2 (S04)3 + 3Ca(OH)2-»-2Cr(OH)3 + 3CaS04
25
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Adequate time must be provided for the settling of the chromic hy-
droxide precipitate to assure its removal.
Ferrous sulfate is one of the early chemicals used and is still
applicable today for smaller systems or where improved settling
rates are especially desirable. The ferrous ion formed in the re-
duction reaction precipitates in the alkaline solution forming
ferric hydroxide which serves as a coagulant to assist in bringing
down the slow settling chromic hydroxide. Generally, ferrous sulfate
would be supplemented by one of the other reducing agents in larger
systems due to economic considerations.
PI asti c Hedi a Trickl i n g Fi Her
Trickling filters in themselves are not new, in fact, they have
been used quite extensively for the treatment of wastewater for
many years. Early designs consisted of merely discharging waste
over a pile of rocks. Micro-organisms in the form of a slime layer
developed on the rock pile and the waste in some manner and to some
degree was treated.
Many refinements have been made as experience has been gained and
the standard trickling filter of today consists of a distribution
system which sprays waste over a uniform bed of rock or slag or some
other inorganic media. The bed is fitted with a ventilation system,
tile underdrain and possibly recirculation pumps. These traditional
systems are limited in both hydraulic and organic loading due to the
limited surface area of the media and free space between units of
the media.
Recently, progress has been made in the use of synthetic materials
as media in trickling filters. Process systems have been developed
wherein a polyvinyl chloride honeycomb has been formed and used as
the media. Such a system is referred to as a plastic media trickling
filter, and it has distinct advantages over the conventional filter.
Some of the major advantages are as follows:
1. The plastic media provides more surface area per cubic foot
than traditional inorganic media.
2. The plastic media possesses approximately 97 percent void
space as compared with 45 percent for slag and rock.
3. Plastic media requires less land area because of its vertical
construction.
4. Plastic media requires less structural support.
26
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5. No elaborate or expensive tile underdrain system is
necessary.
6. A preformed media of uniform and controlled quality is
assured as compared to the randomness of rock or slag.
Various literature references in the past few years have contained
loading data for plastic media filters and the subsequent BOD re-
duction. Some typical data on this work is as follows:
TABLE 1
TYPICAL HYDRAULIC AND ORGANIC LOADINGS
FOR PLASTIC MEDIA TRICKLING FILTERS (11, 12, 13)
Type of Organic Loading Percent BOD
Waste #/day/1000 c.f. Reduction
Domestic 92 72
Domestic 370 57
Textile 65 60
106 58
Pulp & Paper 600 43
Frozen Foods
Processing 600 .53
Fruit & Vegetable
Processing 102 80
Brewery Wastes 126 80
Unusual and sometimes unexpected results have been obtained by the
use of these filters. In an attempt to explain some of the phenomena
many persons have presented their observations. Chipperfield's
(12, 13) work and his extensive review of other work suggests that
since "there is a constant percentage removal of BODs from solution
with increasing load that the biological filtration process at high
loadings is similar to the absorption process, and thus, in a given
unit, the only limitation to the amount of BOD removed per unit volume
of filter would be the availability of the treatment bios to the
substrate". With Chipperfield's work as background it would appear
that under a given set of loading conditions a situation would
develop wherein the bios become the limiting factor. If more bios
could be introduced then the amount of BOD removal could be increased.
Such a situation could be produced if mobile biota, activated sludge
for example, could be introduced into the system to supplement the
stationary bios present on the trickling filter structure. This can
be accomplished by placing the filter ahead of an activated sludge
27
-------
system and recycling sludge directly to the trickling filter. The
effluent from the tower would then discharge into the aeration basin
and then to the clarifier. Such an arrangement was a part of this
project and will be discussed in the experimental section.
Chipperfield also states that at loadings of 260-370 pounds per 1000
cubic feet per day, removals lie between 40 and 65% depending on the
waste. It was also stated by Chipperfield that recycle in sufficient
amount to maintain the minimum wetting rate for the filter was opti-
mum since excess recirculation above this rate may cause some decrease
in percentage BOD removal.
28
-------
SECTION VI
OPERATIONAL AND EXPERIMENTAL ASPECTS OF THE PROJECT
OPERATION
Chromate Reduction Unit
The chromate reduction system was designed to receive effluent
from the cooling tower at rates of up to 120 gpm. The influent to
the unit contains up to 30 mg/1 chromium (VI) as chromate and the
effluent from the unit contains chromium (III). Internally the
system has two tanks in which reactions occur. The first tank is
the reduction tank and it is equipped with an oxidation reduction
potential electrode (ORP electrode) and a pH electrode. The
electrical signal generated by the ORP electrode is directed to a
potentiometer type recorder equipped with pneumatic control. The
output from this controller is fed to a pneumatically positioned
flow regulator valve within a sulfonator which in turn automatically
proportions the feed rate of SO? to the system in accordance with
the demands of the ORP electrode. This feed rate is, therefore, a
function of the unreduced chromium (VI) in the system since the ORP
cell measures the potential difference in the chromium (VI) and
chromium (III) in the system. The pH system operates similarly but
in this case controls an acid feed pump. The second tank or neu-
tralization tank is series connected to the first and is equipped
with a pH system which operates an alkali pump in a similar manner.
Based on the day to day demands for cooling tower operation and blow-
down, the operating personnel preset the rate of flow and the ORP
and pH set points. In addition, they replace the chemical drums
and gas cylinders as necessary.
During the grant period a number of minor operational difficulties
were encountered. They are as follows:
1. Flow fluctuations. The chromate reduction system is fed from
the cooling tower riser. This riser is subject to the pressure
fluctuations and this in turn results in flow fluctuations to
the chromate reduction unit. This was a minor problem and was
resolved by the installation of a feed pump.
29
-------
2. Electrode poisoning. After about eight weeks of operation, it
was found that the ORP system was slowly becoming insensative.
The cause was investigated and it was concluded that Dowtherm,
which had been inadvertantly spilled into the cooling system,
was coating the dip type electrodes. This problem continues
to occur and ORP electrodes must be changed every three to four
months as a result.
PIastic Medja Trickling Fi 1 ter
The plastic media trickling filter was designed and constructed in
such a manner as to allow a 10 ft. deep tier of media to be readily
removed or a 10 ft. tier of media to be readily added. The 10,000
cubic foot unit as constructed had a 25 ft. diameter and was hex-
agonal in shape. It was fitted with a standard rotary distributor.
The recirculation pump was installed in the sump and a capacity
ranging up to 900 gpm. Valving and piping arrangements to the tower
were designed so that sanitary and chemical waste could be fed to
the tower and treatment of these wastes could be observed as a slime
layer built up on the tower. An alternate method of operation was
provided where in return sludge could be blended with this waste
and the blend pumped across the tower for observation. Operational
problems associated with this unit are as follows:
1. Freezing. At ambient temperatures below 10°F the wastewater
freezes when it is sprayed out of the rotary distributor.
During the early part of 1970 the unit was shut down no less
than sixty days due to freezing. Once the interior of the tower
within the media is frozen, it takes approximately ten days of
above freezing temperatures (during daylight hours) to thaw.
Placing the tower within a heated building or warehouse would
alleviate this problem, but it may be economically unattractive.
It should be noted that the surface of the aerator basin con-
taining the mechanical aerators freezes under the same ambient
conditions with the resulting overloading and shutting down of
the aerators. However, the aeration basin thaws in about one-
tenth of the time required for the plastic media tower. No
structural damage to the media or to the twoer structure occurred
during the freeze. The mechanical effect of the freeze thaw cycle
on the media should be closely observed in the future, however,
in order to gain knowledge in this area.
2. Rotary Distributor Orifice Plugging. When the rotary distribu-
tor was first placed in operation, the comminutor in the sani-
tary sewer at the head of the plant was out of order. It was
thought that the solids materials might tend to plug the
orifices of the distributor. Such was not the case. No plugging
was noted.
30
-------
Microscreeping and Chemical Treatment Unit Operation
Influent to this system comes from the polishing ponds. The water
first passes through the microscreen into a piping system fitted
with an in-line mixer and then into a contact tank. From the con-
tact tank the water continues on through a clarifier to a final
filter and then is pumped back to the cooling tower for use. Back-
wash from the microscreen, waste sludge from the clarifier and back-
wash from the final filter are pumped to the treatment plant sludge
pond. The operator regulates the rate of flow by utilizing a valve
and rotometer. Chemicals either powdered or liquid are introduced
into the water prior to the contact tank. Sludge wasting from the
clarifier is accomplished on a daily basis as necessary by the
operator. Backwashing of the final filter is automatic and is con-
trolled by pressure drop across the final filter.
Equipment problems encountered during the study are as follows:
1. The backwash spray nozzles on the microscreen became frozen
during below freezing ambient conditions. This problem can
be resolved by placing the filter in a protected area.
2. The rotor assembly in the clarifier is impulse driven by pumped
recirculated water. As the sludge blanket built up in the
clarifier, there was a tendency for the rotor to stall. This
in turn caused a major sludge build-up and the entire clarifier
system became inoperative. A permanent resolution for this
problem is the installation of a direct motor drive on the
rotor assembly of the clarifier since the impulse drive does
not appear to be sufficient.
3. During summer operation slime growth developed on the screens
of the microscreen and impaired flow thereby necessitating
cleaning. This became rather common and time consuming and was
at its peak during algae bloom periods in the polishing ponds.
This was deliberately allowed to happen in order to observe its
effect on the operation of the filter. The microscreen is fitted
with a steam tap so that the backwash nozzles can be utilized
for steam cleaning of the screen under such conditions; therefore,
a permanent fix is contained on the unit itself.
31
-------
EXPERIMENTAL
The basic concept in this demonstration project was to install the
grant units in the existing treatment plant in such a manner that all
of the wastes, including cooling tower blowdown, would be routed to
the treatment plant, treated to a high degree and discharged with
up to 25 percent being reused for cooling tower makeup. The grant
units were to be operated and evaluated as appropriate over their
operational ranges. Sampling points were to be established at such
locations and taken at such frequencies as to evaluate the operation
of the plant. The sampling points are shown in Figure 11. These
points are located before and after each unit operation and/or before
and after each point of combination or recirculation of waste, sludge
or effluent.
Chromate Reduction
The chromate reduction unit was placed in operation and evaluated
initially for hydraulic capacity and then for efficiency of chromate
reduction. The evaluation consisted of operating the system at
selected blowdown rates and observing the adequacy of the operation
of the various components. It was established that the unit would
operate properly over the design range of flows and chromate con-
centrations. Thereafter the unit was operated on a day to day basis
at various blowdown rates as dictated by cooling water solids con-
centrations adjustment requirements. This ranged from no blowdown
during some winter periods to 100 gpm blowdown on some summer days.
All effluent from the chromate reduction unit was directed to a
settling pond which also served as a surge pond. Effluent from
this pond was directed to the treatment plant at a constant rate
by valving so that shock loading of the treatment plant would not
occur. The effluent ultimately entered the treatment plant through
the chemical sewer system wherein it was diluted. Data collected
during these evaluation periods is presented in Table 2.
32
-------
TABLE 2
CHROMATE REDUCTION UNIT OPERATIONAL DATA
CO
co
Influent to
Chromate Unit
Blowdown
Rate, gpm
48
80
5-94
25-60
21-91
Duration of
Test (Days)
34
39
30
41
30
Cr "
Range
mg/1
10-20
10-20
10-20
8-26
9-20
Biocide
Range
mg/1 & Type
36 (Note 1)
8-19 (Note 2)
0-37 (Note 3)
30 (Note 4)
8-17 (Note 2)
0-37 (Note 3)
0-57 (Note 5)
Influent to
Waste
Treatment Plant
Cr+0
Range
mg/1
0
0
0
0
0
0
0
Biocide
Range
mg/1
5-7
0-9
(Note 7)
(Note 6)
0-6
(Note 7)
(Note 6)
Effluent
From
Treatment Plant
Biocide
Range
mg/1
0
0
0
0
0
0
0
(1) Betz C-30 bis (trichloromethyl) sulfone and methylene bisthiocyanate blend.
(2) Betz A-9 sodium pentachlorophenate.
(3) Betz C-5 1,3 dichloro-5, 5-dimethylhydantoin.
(4) Betz J-12 N-alkyl dimethyl benzyl ammonium chloride.
(5) Betz C-34 sodium dimethyl dithiocarbamate and disodium ethylene bisdithiocarbamate.
(6) Destroyed in reduction tanks.
(7) Dissipates in cooling tower in six hours and is not contained in blowdown.
-------
Plastic Media Trickling Filter
The plastic media trickling filter was evaluated in a manner similar
to that described by Egan (14), Chipperfield (12, 13), and contained
in the Sewage Treatment Plant Design Manual (11). These methods
are considered standard for the art and are summarized as follows
as they apply to this project:
1. Mode A. In this mode the combined sanitary and chemical waste
including cooling tower blowdown were routed across the tower.
The efficiency of the plastic media was established by the
evaluation of data from samples taken before and after the
tower. 8005 was determined on the settled effluent and not on
a completely mixed sample.
2. Mode B. Mode B is identical to Mode A except that the return
sludge from the clarifier is combined with the sanitary waste,
chemical waste and cooling tower blowdown and this composite is
pumped across the tower. The 6005 reduction (as well as other
parameters) under this mode of operation is derived by calcu-
lations using the volume and BODg concentration in the combined
sanitary waste, chemical waste and cooling tower blowdown with
similar data on effluent from the unit which includes the be-
fore mentioned streams plus the sludge recycle.
3- Mode C. Mode C is a special mode of operation and evaluation
wherein only a portion of the plastic media tower is used with
the same waste volume. Higher hydraulic and organic loadings
per unit area and per unit volume respectively can be obtained.
BOD^ reduction (as well as other parameters) was determined
as in Mode B above.
The BOD5 reduction data obtained during each of the modes described
is presented in Figures 13, 14, 15 and 16. In operating at these
modes and in presenting the data the following terms are used as
they apply to this project.
1. Hydraulic loading. Hydraulic loading is expressed in gallons
per square foot per minute. It is based on the actual cali-
brated pumping rate.
2. Organic loading. This is expressed in pounds per cubic foot
of media per day. It is based on the BOD5 of the treatment
plant influent and does not include BODg contained in recycle,
if any, from the clarifier.
34
-------
3. Recycle rate. Recycle is expressed as the ratio of the trickl-
ing filter pump output to total treatment plant influent.
Instances where sludge return from the clarifier is being
combined with the treatment plant influent and treated across
the tower, the recycle ratio is the ratio of the trickling
filter pump output to the combined treatment plant influent
and sludge return.
Chemical Treatment and Microscreening
The experimental portion of the chemical treatment including the
microscreening unit was broken into two phases. The first phase
utilized polishing pond water as feed and the second phase utilized
clarifier water as feed. In both instances jar tests were conducted
utilizing alum, various polymers and polymer combinations and
powdered carbon. Materials that showed promise in jar tests were
evaluated on a full scale trial. Each chemical additive that was
evaluated on a full scale trial is presented in Table 3 and Table
4. The manufacturers data sheet for each additive used appears in
the appendix.
Sampling
Initially sampling was conducted daily by use of automatic continuous
non-proportional dipper samplers at the points shown on sampling plan
(Figure 11). The use of the automatic samplers was discontinued and
daily grab samples were taken after it was established that the two
methods gave comparable results. Sampling points were selected so
that each unit operation could be bracketed and its performance
evaluated on a daily basis throughout the grant period. The data pre-
sented in the tables and figures which follow was compiled using grab
samples. The data obtained was grouped into classes, the mean and
standard deviation for each class was determined; the mean was then
evaluated and plotted. Each point on the graph in the figures which
follow represents a class consisting of not less than ten analyses.
35
-------
TABLE 3
DATA FROM HICROSCREENING AND CHEMICAL TREATMENT UNIT
UTILIZING POLISHING POND EFFLUENT - TREATMENT ACROSS MICROSCREEN AND CHEMICAL TREATMENT UNIT
CO
COO
Initial Final
Treatment Type mg/1 rnq/1
and Dosage (1,2) (% Reduced)
1. Alum 85.5 mg/1 161 90
Aqua Nuchar A
60 mg/1 (44)
2. Alum 102 mg/1 174 89
Aqua Nuchar A
120 mg/1 (49)
C-25 8 mg/1
3. Alum 43.5 rag/1 197 172
Aqua Nuchar A
84 mg/1 (13)
Poly Floe 1160
1 mg/1
4. Alum 200 mg/1 100 78
Aqua Nuchar A
182 mg/1 (22)
Poly Floe 1160
1 mg/1
5. Alum 163 mg/1 140 117
Aqua Nuchar A
128 mg/1 (16)
Poly Floe 1160
1 mg/1
6. C-225 6.3 ng/1 124 90
C-25 15 mg/1
(27)
7. Aqua Rid 49-701 100 90
13 mg/1
Aqua Rid 96-549 (10)
30 mg/1
8. Alum 44 mg/1 140 80
Poly Floe 1160
4 mg/1 (43)
9. C-2Z5 13 mg/1 126 87
C-25 15 mg/1
Aqua Nuchar (31)
180 mg/1
Total Phosphate
Initial Final
mg/1 mg/1
(% Reduced)
3.6 0.9
(75)
4.3 1.0
(77)
2.9 1.9
(34)
1.7 0.7
(58)
3.9 1.7
(56)
2.5 2.4
( 2)
7.3 7.3
( 0)
3.3 3.2
( 3)
4.6 0.8
(82)
Total Nitrogen
Initial Final
mg/1 mq/1
(% Reduced)
0.23 0.14
(39)
0.12 0.08
(33)
0.0 0.0
(0)
0.0 0.0
( o)
1.3 0.0
(100)
0.0 0.0
( 0)
0.09 0.06
(33)
0.13 0.08
(39)
0.0 0.0
(0)
Turbidity
Initial Final
Units Units
(% Reduced)
( -)
53 22
(63)
88 84
( 5)
36 17
(53)
163 38
(77)
51 17
(67)
50 21
(58)
53 14
(74)
90 30.
(30)
Color
Initial Final
Units Units
(% Reduced)
200 60
(70)
245 80
(67)
260 248
( 5)
124 60
(52)
163 112
(31)
114 50
(56)
90 49
(46)
179 42
(77)
300 98
(67)
Fixed Solids
Initial Final
mg/1 mg/1
(% Reduced)
241 292
( 0)
237 305
( 0)
403 413
( 0)
326 372
( 0)
338 369
( Q)
354 386
( 0)
( -)
346 419
( 0)
352 359
( o)
Notes
19 Days
May 1969
24 Days
May -
June 1969
12 Days
July 1969
8 Days,
August 1969
12 Days.
July -
August 1969
13 Days,
October 1969
8 Days,
October 1969
11 Days,
Nov. 1969
7 Days,
Sept. 1969
Notes: (1) See appendix II for trade name product identification.
(2) Preliminary jar tests gave indication of dosage which was verified and refined by actual plant operation. The actual dosage used
under refined conditions of operation is presented in this table.
-------
TABLE 4
DATA FROM MICROSCREENINS AND CHEHICAl TREATMENT UNIT
CLARIFIER EFFLUENT - TREAWNT ACROSS CHEMICAL UNIT
Treatment Type
and Dosage (1,2)
1. Control, No
Chemical Treat-
ment, screened
& filtered
Z. Alum 75 mg/1
3. Alum 75 mg/1
C-225 3 mg/1
4. Aluia 45 mg/1
C-225 2 mg/1
Aqua Nuchar A
250 mg/1
5. Alum 36 mg/1
C-225 2 mg/1
Oarco S-51
200 mg/1
6. Alum 100 mg/1
Oarco S-51
200 mg/1
COD
Initial Final
mg/1 mg/1
(% Reduced)
320 470
(0)
350 255
(27)
250 223
(11)
160 90
(44)
139 75
(46)
" (-)
Total Phosphate
Initial Final
mg/1 mg/1
(% Reduced)
5.7 2.0
(71)
9.0 1.0
(88)
5.4 5,1
( 6)
10.9 9.2
(16)
6.2 5.9
( 5)
7.5 3.3
(56)
Total Nitrogen
Initial Final
mg/1 mg/1
(Z Reduced)
1.3 0.18
(86)
0.20 0.20
( 0)
5.5 7.1
( 0)
0.52 0.18
(65)
2.3 4.4
(0)
2.7 1.6
(40)
Turbidity
Initial Final
Units Units
(X Reduced)
160 70
(56)
120 45
(63)
54 38
(30)
38 37
( 4)
48 50
( 0)
20
COLOR
Initial Final
Units Units
(% Reduced)
422 183
(57)
193 139
(28)
135 105
(22)
97 85
(12)
120 128
( 7)
60 60
(0)
Fixed Solids
Initial Final
mg/1 mg/1
(% Reduced)
442 392
(11)
489 440
(10)
492 502
( 0)
540 516
( 4)
264 272
( 0)
" (-)
NOTES
7 Days,
Feb. 1970
12 Days,
Feb. i
March 1970
16 Days,
March 1970
8 Days,
March 1970
15 Days,
April 1970 !
8 Days,
April 1970
Notes: (1) See appendix II for trade name product Identification.
(2) Preliminary jar tests gave indication of dosage which was verified and refined by actual plant operation. The actual dosage used
under refined conditions of operation Is presented In this title.
-------
TABLE 5
EFFECTIVENESS OF POLISHING PONDS AS A TERTIARY TREATMENT UNIT
(TWO PONDS, SERIES CONNECTED. THIRTY DAYS DETENTION, FIVE FOOT OPERATION DEPTH)
CO
March- April -Hay
1969
June -July-August
1969
September-Octobe r-
November
1969
December - 1969
January - February
1970
BOD
Initial Final
rng/1 mg/1
(% Reduced)
25 13
(48)
12 12
( 0)
16 9
(44)
75 77
( 0)
COD
Initial Final
.mg/1 mg/1
(% Reduced)
189 164
(13)
149 161
( 0)
160 129
(19)
516 389
(25)
_ - _ _ _ —
Total Nitrogen
Initial Final
mg/1 mg/1
(% Reduced)
0.24 0.19
(21)
1.70 0.23
(86)
1.69 0.10
(94)
1.02 0.22
(78)
TbtaT Phosphate
Initial Final
mg/1 mg/1
(% Reduced)
2.7 1.3
(52)
5.0 3.1
(38)
5.3 2.6
(50)
6.1 3.6
(41)
Fixeci SoTids
Initial Final
mg/1 mg/1
(% Reduced)
249 230
( 8)
436 317
(27)
464 383
(17)
420 349
(17)
-------
CO
vo
COOLING
TOWER
CHEMICAL WASTE
WASTE
TREATMENT
PLANT
EQUALIZATION
BASINS
SLUDGE
POND
DOMESTIC WASTE
SLUDGE RETU
SLUDGE WASTE
\
I
POLISHING
POND NO. 1
POLISHING
POND NO. 2
/^PV,
\5/
ALGAE
SCREEN
— 1
-
-------
60
90
c
€>
.1
3
•o
or
so
0*
0
to
20
10
A
"T
IOO 2<
^^^*
fik-— —
£ !
O
>0 900 40
tit}
FIGURE 12
PLASTIC MEDIA TRICKLING FILTER
OPERATIONAL MODE B 8 C - SLUDGE RECYCLE
HYDRAULIC LOADING
O 0.95 goNoru por *qmro foot por mtairtt
Q 1. 10 folton* por f^tatt fool por minut*
^ 1. 99 galtora por naoro foot por minuto
4
1
O
o
0 SOO 6C
) 1.70 9«NOM por (qitaro foot por ninuto
1 1.90 gallant por tquoro foot por mtnyto
| 6.73 gilloni por taMro foot por minuU
.
O 70
A
fl
B
o ac
•
•
!
i
A
•
)0 9OO
BOO, Load 109, Pounds per 1000 Cubic Fe«t of Media, per Day
-------
s
t)
o
CO
60
50
40
SO
20
10
©— -
— '
- 0
100 ZOO 300 4
•
Q
FIGURE 13
PLASTIC MEDIA TRICKLING FILTER
OPERATIONAL MODE A - NO SLUDGE RECYCLE
HYDRAULIC LOADING-
0 1.70 t*U«M
GJ t.90 grtfcm
Q
B
0 $00 COO 70
pflf C^UM TOO* pC* WMIM0
-j
16 "" abo soo
BOD9 Loading, Pounds per IOOO Cubic Feet of Media, per Day
-------
FIGURE 14
PLASTIC MEDIA TRICKLING FILTER
OPERATIONAL MODE BaC- SLUDGE RECYCLE
RECYCLE RATE
0 i.l:
Q 1.9 •
fO
100
ZOO
300 400 500 «00 TOO
>9 Loading, Pounds per tOOO Cubic Fe«t of Media, p«r Doy
loo
-------
CM
60
90
e
•i
o
£ 40
1
•o
V
5
80D5 Loading, Pounds per IOOO Cubic Feet of Media, per Day
-------
ECONOMIC EVALUATION
This section contains selected cost data on the construction and
operation of the waste treatment facility during the grant. The
waste water treatment plant as constructed, but not including the
grant units, cost in excess of $600,000. The cost of construction
of the grant units (1968 basis) is summarized on a unit basis as
fol1ows :
Construction Costs
A. Summary of Final Construction Costs
Chromate Reduction Unit $ 39,410.26
Trickling Filter- 57,029.80
Algae Screen 16,378.47
Carbon Unit 56,010.44
Site and Distribution Requirements 10,542.03
Engineering 19,136.65
TOTALS $198,507.65
B. Unit Cost Details
1. Chromate Reduction Unit
a. Building Foundations $ 585.00
b. Building Structure 8,110.00
c. Equipment 21,863.00
d. Equipment Foundations 325.00
e. Electrical 4,004.26
f. Piping 2,903.00
g. Paving (Gravel) 250.00
h. Grading (Lagoon) 1,370.00
Direct Cost $ 39,410.26
Engineering & Site Allocation 6.927.00
TOTAL COST $ 46,337.26
44
-------
2. Trickling Filter
a. Equipment $27,000.00
b. Equipment Foundations 15,470.00
c. Painting 705.00
d. Electrical 2,730.00
e. Piping 11,124.80
Direct Cost $57,029.80
Engineering &
Site Allocation 10,025.46
TOTAL COST $67,055.26
3. Algae Screen
a. Equipment $10,140.68
b. Equipment Foundations 2,040.00
c. Electrical 475.00
d. Piping 3,722.79
Direct Cost $16,378.47
Engineering &
Site Allocation 2.878.83
TOTAL COST
Carbon Unit
a. Building Structure
b. Equipment
c. Equipment Foundations
d. Electrical
e. Piping
f. Grading (Lagoon)
$19,257.30
$ 1,804.00
42,670.03
3,081.00
911.16
6,142.65
1,401.60
Direct Cost $56,010.44
Engineering &
Site Allocation 9,847.39
TOTAL COST $65,857.83
45
-------
5. Site and Distribution
a. Electrical $ 4,521.91
b. Piping 5,112.75
c. Paving (Gravel) 907.37
TOTAL COST $10,542.03
6. General Requirements (Overheads)
a. Preliminary Plans
and Specifications $ 3,995.76
b. Final Plans and
Specifications 8,825.00
c. Construction Super. 6,315.89
TOTAL COST $19,136.65
NOTE: Miscellaneous piping changes were made durinq the experi-
mental portion of the grant for evaluation purposes. These
costs are not included above since they could be considered
duplication.
46
-------
Selected Comparative Costs Including Operating Costs
Some selected comparative cost, including operating costs for the
treatment plant and grant units under selected conditions, are as
follows:
1. Cost of treatment plant operation before $0.35/1000 gallons
grant (1967) of waste treated
This includes electricity, maintenance,
operator salary and all other operation
and maintenance costs. No capital costs
are included.
2. Cost of treatment plant operation during $0.64/1000 gallons
grant period of waste treated
This includes all items in 1 above in
addition to extra operating personnel
required by the grant experimental
phase, additional electrical require-
ments, chemicals and flocculants. It
does not include the mobile laboratory
operation.
3. Estimated cost of treatment plant $0.40/1000 gallons
operation in the future utilizing of waste treated
selected grant units on a production
basis as compared to experimental
basis in 2 above.
This includes the operation of the
trickling filter, microscreen and a
greatly reduced operation of the
chemical treatment unit in line with
the findings of this project.
4. The average market value of polyester
produced in the Fiber Industries, Inc.,
Shelby plant during the grant period
was $0.88 per pound. During this
period 0.604 gallons of waste con-
taining 0.0056 pounds of 6005 was produced
per pound of polyester produced. The
cost of treatment of the waste from the
production of one pound of polyester, using
item 2 above as a basis, is $0.00039. This
is the operational cost and does not
include any capital cost considerations.
47
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5. The chromate reduction unit chemical costs are based on the
chemicals required to treat one pound of chromate. The
theoretical and actual costs are as follows:
Theoretical cost per pound of CrCL =
0.85 pounds S0? @ 0.075 = $0.064
0.30 pounds H2S04 @ 0.027 = 0.008
1.10 pounds NaOH @ 0.060 = 0.066
TOTAL THEORETICAL COST $0.138
In actual operation about 50 percent excess chemicals are
required to assure complete reaction. The actual cost of
treating one pound of Cr04 =
Actual Total Cost = 0.138 x 1.5 = $0.21
6. The chemical and./or flocculant costs must be based on the
water quality desired and the flocculant selected for use.
A typical cost for chemical post treatment at the Fiber
Industries, Inc., Shelby operation is as follows:
Cost per 1000 gallons
Aqua Rid 49-701 13 mg/1 $0.022
Aqua Rid 96-549 30 mg/1 0.025
$0.047
7. The cost of the plastic media trickling filter unit as com-
pared to an equivalent mechanical aeration unit may be de-
rived by comparing the tower, complete with pump and sump,
with a single 75 HP aerator installation complete.
Plastic media trickling filter (see Items 1, 5 and 6, above)
Construction Contract $57,029.80
Prorated site, distribution and
General Requirements 10,025.46
$67,055.26
48
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Mechanical Aerator Installation
Aerator $17,000.00
Platform and Miscellaneous Structures 6,500.00
Electrical 6,000.00
Basin 30,000.00
Prorated site and distribution 2,000.00
Prorated general requirements 4,000.00
$65,500.00
49
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SECTION VII
OPERATION OF THE TREATMENT SYSTEM ON A PRODUCTION BASIS
The waste treatment system can be operated on a full scale basis
with water reuse at 0.1 MGD using the following treatment units at
the below listed estimated costs:
Pre Treatment
Chromate Reduction and Equalization $0.034 / 1000 gallons
Primary and Secondary Treatment
Roughing Filter 0.019 / 1000 gallons
Aeration and Clarification 0.300 / 1000 gallons
T_e_r_tj_ary_ Treatment
Polymer Addition and Final Filter 0.047 / 1000 gallons
ESTIMATED TOTAL OPERATING COST $0.400 / 1000 gallons
The estimated total capital cost for such a treatment facility, using
design criteria contained in Section V of this report, is $800,000
(1968 basis).
51
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SECTION VIII
ACKNOWLEDGEMENTS
The support of Mr. J. B. Phelps, Vice President and Mr. Richard
Shalie, Director of Engineering of Fiber Industries, Incorporated
is acknowledged with sincere thanks.
Mr. W. J. Day and Mr. E. C. Burrell of Davis & Floyd, Inc.,
Consulting Engineers, directed the design and operation of the
Grant and prepared this report. Mr. C. E. Steinmetz, Engineering
Associate, Fiber Industries, Incorporated, functioned as Project
Coordinator on this project.
The support of the project by the Federal Water Quality Adminis-
tration and the timely guidance of Dr. Ray Thacker, Mr. William Lacy
and Mr. Charles Ris is acknowledged.
53
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SECTION IX
REFERENCES
1. Udy, Marvin J., "Chromium, Volume 1", Reinhold Publishing
Company, New York (1956).
2. Sienko, Michel! J. and Plane, Robert A., "Chemistry", Third
Edition, McGraw Hill, New York (1966).
3. "Interaction of Heavy Metals and Biological Sewage Treat-
ment Processes", Robert A. Taft Sanitary Engineering Center,
Cincinnati (1965).
4. Anonymous, "Removal of Chromate from Coolinq Tower Slowdown,"
Betz Laboratories, Inc., Philadelphia (1967).
5. "Manual on Industrial Water and Industrial Waste Water",
ASTM Special Technical Publication No. 148-H, American
Society for Testing and Materials, Philadelphia (1965).
6. "Water Quality Criteria", Federal Water Pollution Control
Administration, Washington (1967).
7. Hesler, J. C., The Ion Exchange Recovery Process, Proceedings
International Water Conference, Engineers Society of Western
Pennsylvania, Pittsburgh (1964).
8. Puckorius, P. R. and Farnsworth, N. B., The Role of the Pro-
cess in Cooling Water Technology. Proceedings International
Water Conference, Engineers Society of Western Pennsylvania,
Pittsburgh (1964).
9. McKee and H. W. Wolf, "Water Quality Criteria", 2nd Edition,
California State Water Quality Board, Publication No. 3-A
(1963).
10. Sewage Treatment Plant Design, Water Pollution Control
Federation, Washington, D. C. (1967).
11. Chipperfield, P. N. J. "The Use of Plastic Media in Biological
Treatment of Sewage and Industrial Waste", Fifteenth Canadian
Chemical Engineering Conference, Universite Laval, Quebec
(1965).
12. Chipperfield, P. J. J. "Experiences in Great Britain by
Imperial Chemical Industries Limited with Plastic Filter
Media", Annual Conference of the Water Pollution Control
Federation, Kansas City, Missouri (1966).
55
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13. Egan, John T. and Sandlin, M., "The Evaluation of Plastic
Trickling Filter Media", Fifteenth Industrial Waste Con-
ference, Purdue University, Lafayette, Indiana (1961).
14. Crook, E. H. and Pollio, F. X. "Removal of Soluble Organic
and Insoluble Organic and Inorganic Materials by Flocculation",
Twenty Sixth Annual Meeting of the International Water Con-
ference, Pittsburgh, Pennsylvania (1965).
15. Summary Report, Advanced Waste Treatment (July 1964 - July 1967)
U. S. Department of the Interior, Federal Water Pollution Control
Administration, Publication WP-20-AWTR-19.
56
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SECTION X
APPENDIX I
LABORATORY ANALYTICAL PROCEDURES
The basic analytical procedures used for the determination of Bio-
chemical Oxygen Demand (BOD), Chemical Oxygen Demand (COD), dissolved
oxygen (DO), pH, solids, nitrogen, phosphorus, temperature, color,
turbidity, alkalinity, hardness, sulfate, chloride, were taken from
Standard Methods for the Examination of Water and Wastewater, Twelfth
Edition, American Public Health Association, Inc., New York. Secon-
dary procedures and reagents used for these same determinations were
taken from Methods Manual, Fifth Edition, Hach Chemical Company, Ames,
Iowa. Special procedures for determinations not contained in Standard
Methods were as fol1ows:
Chromium (Total, Hexavalent, Trivalent)
Total chromium - A Beckman Atomic Absorption system Model 930 utiliz-
ing a Beckman DB-G Grating Spectrophotometer was used for this deter-
mination. The procedure was in accordance with Beckman Instruments,
Inc., Flame Notes, Vol. 1, No. 2, July 1966, pages 49 and 50.
Hexavalent chromium - this procedure was taken from Standard Methods
for the Examination of Water and Wastewater, Twelfth Edition, American
Public Health Association, Inc., New York, pages 123 and 124.
Coagulation - Flpeculation Jar Test
This procedure used for flocculation jar tests is presented in Part
23, Industrial Water; Atmospheric Analysis. American Society for
Testing and Materials, Philadelphia, Pa., (1967), pages 523 - 525.
Zinc
A Beckman Atomic Absorption system Model 979 utilizing a Beckman DB-G
Grating Spectrophotometer was used for this determination. The pro-
cedure was in accordance with Beckman Instruments, Inc., Flame Notes,
Vol. 1, No. 3, September 1966, page 91.
57
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Determination of Sodium Pentachlorophenates (Betz A-9) in Hater
This procedure was furnished by Betz Laboratories and is a colormetric
analysis for sodium pentachlorophenate through an extraction and color
development.
A representative 5 ml. sample is pipetted into a 125 ml. separator
funnel. To this is added 10 ml. of ethylene dichloride. Immediately
add 0.25 grams of sodium bicarbonate and 0.5 ml. safranine "A"
reagent (Matheson Coleman & Bell). Proceed to shake for 30 seconds
and allow to stand for one minute. Draw off the bottom layer into
a 100 ml. beaker and add 0.25 to 1.00 grams sodium sulfate while
swirling the sample after the addition of each 0.25 grams portion
until the solution is crystal clear. Transfer the solution to a
cell and with the use of a spectrophotometer read percent transmission.
Ethylene dichloride is used in a cell to establish the zero reference
point.
Determination of Methyl and Ethyl Bis-dilthiocarbamate (Betz C-34) in
Water
This method was also furnished by Betz Laboratories. It is based on
the fact that methyl and ethyl bis-dithiocarbamate decomposes to
liberate carbon disulfide when boiled in sulfuric acid. The gas is
then swept through several scrubbers to remove interferences and then
through a scrubber containing Viles reagent (a copper amino solution).
The intensity of the color resulting from the reaction between the
carbon disulfide and Viles reagent is used to quantitate the amount
of active carbamates present.
A. Reagents and Equipment.
1. Methanolic Potassium Hydroxide 2N
2. Lead Acetate Solution 10%
3. Sulfuric Acid 50%
4. Viles Reagent - In a liter flask containing 50 ml. distill-
ed water add 0.060 gram of reagent grade copper acetate
monohydrate, followed by 20 ml. USP triethanol amine and
10 ml. of purified diethylamine. Dilute to the 1 liter
mark with reagent grade isopropanol and mix. Store in a
well capped amber bottle.
5. Copper Acetate Monohydrate - reagent grade
6. Triethanol Amine - USP
7. Diethylamine - purified
58
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8. Isopropanol - reagent grade
9. Absorption Train - as illustrated in sketch - all joints
must be ground glass
10. Spectrophotometer or Colorimeter - capable of isolating
a reasonably small wavelength band at 420 nanometers
11. Stock C-34 Solution - pipet 1.0 ml..of C-34 into a 1 liter
volumetric flask and dilute to 1 liter with distilled water.
12. Standard C-34 Solution - pipet 2.0 ml. of the stock sol-
ution into a 1 liter volumetric flask and dilute to 1 liter
with distilled water.
Sample Procedure.
1. Add 10 ml. of Viles reagent to the carbon disulfide
scrubber, 20 ml. lead acetate solution to each hydrogen
sulfide scrubber and 65 ml. of methanolic potassium hydro-
xide to the air scrubber.
2. Turn on the condenser water.
3. Add 1 liter of test sample to the reaction flask followed
by 100 ml. of the 50% sulfuric acid.
4. Immediately fasten the flask to the condenser, close all
connections, and start the air flow through the system at
a rate of approximately 40 ml. per minute.
5. Turn on the heating mantle and bring the sample to a gentle
boil.
6. Reflux (with continual air sweep) for one hour.
7. Discontinue heating and open the connections in the follow-
ing order to avoid "back-up", (a) inlet to reaction flask;
(b) inlet to lead acetate scrubbers; (c) inlet to carbon
disulfide scrubber containing the Viles reagent.
8. Shut off the air sweep and remove the graduated carbon
disulfide scrubber containing the Viles reagent.
9. Make up the volume of the Viles reagent to 10 ml. with
isopropanol.
10. Transfer solution to a 1 cm. or equivalent cell and read
the color intensity at 420 nanometers. Use isopropanol
for the 100% T setting.
59
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11. Carry 1 liter of distilled water through the above steps.
This will be used as the reagent blank.
12. Subtract the absorbance of the reagent blank and read
the concentration of the C-34 from the standard curve.
C. Preparation of the Standard Curve.
1. Pipet into clean beakers 0 (reagent blank), 10, 25, 50,
75, 100 ml. of the standard C-34 solution. This represents
0, 0, 20, 0.50, 1.00, 1.50 and 2.00 parts per million of
the biocide.
2. Transfer each sample, in turn, to a 1-1/2 liter round
bottom flask and dilute to one liter with distilled water.
3. Continue on, starting with step (1) through step (7)
under "Sample Procedure".
4. Subtract the absorbence of the reagent blank from each
reading.
5. Plot absorbence against PPM C-34.
D. Calculations.
1. If 1000 ml. sample
PPM C-34 = PPM C-34 read from standard curve
2. If sample volume other than 1000 ml.
PPM C-34 = (PPM C-34 from standard curve)(1000)
(Sample volume in mis.)
Determination of Methylene Bis Thiocyanate (Betz C-3Q) in Water
Methylene bis-thiocyanate (Betz C-30) is converted to cyanide and thio-
cyanate by an alkaline hydrolysis. After suitable sample cleanup the
cyanide and thiocyanate are converted to their respective bromide com-
pounds, reacted with a pyridine - benzidine reagent and the color read
at 532 nm. The intensity of the red color is an indirect measure of
the amount of methylene bis-thiocyanate present in the paper. This
procedure was also provided by Betz Laboratories.
A. Reagents and Equipment.
1. Arsenous acid - a 2.0% solution of arsenous acid is pre-
pared by refluxing 2.0 gms of arsenous acid with distilled
water until disolution is complete. It is then diluted
to 100 ml.
60
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2. Bromine water - a standard solution of bromine distilled
water.
3. Pyridine solution - a solution is prepared by adding 100
ml. of concentrated hydrochloric acid to 1 liter of 60%
pyridine in water (v/w).
4. Trichloroacetic acid - a solution of 20% trichloroacetic
(w/v) in distilled water.
5. Benzidine De-Hydrochloride - reagent grade.
6. Pyridine-Benzidine Reagent - 0.2 grams of benzidine dihy-
drochloride in 5 ml. of distilled water is added to 25 ml.
of pyridine reagent. This solution must be prepared
fresh daily.
7. Stock "Standard Methylene Bis-Thiocyanate Solution" -
0.200 gram of Stauffer N-948 is hydrolyzed for 60 minutes
in 5 ml. of 20% NaOH at room temperature. The solution is
then filtered into a 1 liter volumetric flask and the
filter paper is washed several times with 0.10 M NaOH.
Dilute to 1 liter with distilled water.
8. "Standard Methylene Bis-Thiocyanate Solution" - 10 mis. of
stock solution is diluted to 1 liter with distilled water.
This solution contains a 2 micrograms of M-bis-Thiocyanate
per mi Hi liter.
9. Pyridine - reagent grade.
10. 0.10 M Sodium Hydroxide (NaOH) - Betz Code 206 or equi-
valent.
11. Sodium Hydroxide Solution 20% - dilute 20 gms of NaOH to
100 ml. with distilled water.
12. Hydrochloric acid - reagent grade.
13. n-Amyl Alcohol - reagent grade.
14. Filter paper - Munktell's 00 or equivalent.
15. 10 ml. Volumetric flasks.
16. 125 ml. separatory funnels.
17. Spectrophotometer or colorimeter - capable of isolating a
reasonably small wavelength band at 532 manometers.
61
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Sample Procedure.
1. To 50 ml. of sample add 10 ml. of 0.1 NaOH and hydrolyze
at room temperature for one hour. The sample should be
strongly alkaline prior to hydrolysis - if not add more
0.1 M NaOH until strongly basic, i.e., pH 12.
2. Filter the sample thru a Munktell 00 filter paper washing
the paper two times with distilled water.
3. Add 5 ml. of trichloroacetic acid followed by 3 ml. of
bromine water to the filtrate.
4. Swirl the beaker contents for one minute.
5. Add 3 ml. of the arseneous acid to discharge the bromine
color. Blow off any vapors of bromine above the solution.
6. Quantitatively transfer the contents to a clean 125 ml.
separatory funnel and add 5 ml. of pyridine-benzide rea-
gent. Shake well and let sit 1/2 hour.
7. Add 5 ml. of n-amyl alcohol and shake well.
8. When the phases separate drain the upper alcohol layer
through a glass wool plug into a 10 ml. volumetric flask.
Rinse the funnel several times with small portions of
alcohol.
9. Dilute to make with alcohol and read the color intensity
at 532 nanometers. Use distilled water for the 100% T
setting.
10. Carry 50 ml. of the water sample through the above steps
omitting the hydrolysis step. This will be used as the
reagent - sample blank.
11. Subtract the absorbance of the reagent - sample blank and
read the concentration of the M-bis-Thiocyanate from the
standard curve.
Preparation of the Standard Curve.
1. Pi pet into clean 100 ml. beakers 0 (reagent blank), 1, 2,
3, 4, and 5 ml. of the standard methylene bis-thiocyanate
solution. This is equivalent to 0, 2, 4, 6, 8, and 10
micrograms of biocide.
2. Add 5 ml. of the 0.1 M NaOH solution to each.
62
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3. Continue on, starting with step (3) through (14) under
"Sample Procedure".
4. Subtract the absorbence of the reagent blank from each
reading.
5. Plot absorbence against micrograms of methylene bis-
thiocyanate.
D. Calculations.
PPM MBT micrograms MBT read off of
in = std. curve .___
water mi Hi liters of sample
PPM C-30* PPM MBT
in =
Water ^5B
* assuming C-30 contains 5% methylene bis-thiocyanate
E. Comments.
All operations should be carried out under a hood. None of the
concentrated methylene bis-thiocyanate solutions should come in
contact with acids. All solutions should be pipetted using a
rubber bulb, never by mouth. Both cyanide and arsenous acid
solutions are very poisonous and extreme care should be exercised
when handling.
Larger samples can be used simply by evaporating the sample to
approximately 50 mis. only after make the solution basic to
litmus with 0.1 N NaOH.
Determination of N-Alkyl Dimethyl Benzyl Ammonium Chloride (Betz J-12)
in Water
A complete analytical method for J-12 is not available. However, an
atomic absorption method for tin in tributyl tin oxide was used and
this was related the N-alkyl dimethyl benzyl ammonium chloride. See
appendix II for product description and proportion of tributyl tin in
J-12.
To a 50 ml. sample add with stiring, 20 ml. perchloric-sulfuric mixture;
this is to destroy any organic matter which may be present. Allow to
stand for 5 minutes and then extract this solution with 50 ml. of
chloroform. The analysis may now be completed on the extracted portion
using the atomic absorption method and procedures of the Beckman
Instrument Company.
63
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APPENDIX II
IDENTIFICATION OF TRADE NAME PRODUCTS
BIOCIDES
1. Betz A-9.
Sodium pentachlorophenate 24.7%
Sodium 2, 4, 5-trichlorophenate 9.1%
Sodium salts of other chlorophenates 2.9%
Sodium dimethyl dithiocarbamate 4.0%
N-Alkyl (C12-4%, (44-50%, C16-10%
dimethyl benzyl ammonium chloride 5.0%
Inert ingredients (including solubilizing and
dispersing agents) 54.3%
2. Betz C-5.
1, 3, dichloro-5, 5-dimethylhydantoin 50 %
Inert ingredients (including solubilizing and
dispersing agents) 50 %
3. Betz C-30.
Bis (trichloromethyl) sulfone 20.0%
Methylene bisthiocyanate 5.0%
Inert ingredients (including solubilizing and
dispersing agents) 75.0%
4. Betz C-34.
Sodium dimethyl dithiocarbamate 15.0%
Nabam(disodium ethylene bisdithiocarbamate) 15.3%
Inert Ingredients (including solubilizing and
dispersing agents) 69.7%
5. Betz J-12.
N-Alkyl (Ci2-5%, (44-60%, C16-30%, C18-5%)
dimethyl benzyl ammonium chloride 24.0%
Bis (tributyl tin) oxide 5.0%
Inert Ingredients (including solubilizing and
dispersing agents) 71.0%
64
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FLOCCULANTS
1. Coagulant Aid 25 - A pulverized clay, off white in color.
Calgon Corporation, Pittsburgh, Pa.
2. Coagulant Aid 27 - A tan pulverized clay.
Calgon Corporation, Pittsburgh, Pa.
3. Coagulant Aid 225 - A cationic polyelectrolyte.
Calgon Corporation, Pittsburgh, Pa.
4. Coagulant Aid 226 - A cationic polyelectrolyte.
Calgon Corporation, Pittsburgh, Pa.
5. Coagulant Aid 227 - A slightly cationic polyelectrolyte.
Calgon Corporation, Pittsburgh, Pa.
6. Coagulant Aid 228 - A slightly cationic polyelectrolyte.
Calgon Corporation, Pittsburgh, Pa.
7. Cat-Floe - A cationic polyelectrolyte.
Calgon Corporation, Pittsburgh, Pa.
8. Primafloc A-10 - An anionic polyelectrolyte.
Rohm and Haas Company, Philadelphia, Pa.
9. Primafloc C-3 - A polyamine cationic polyelectrolyte.
Rohm and Haas Company, Philadelphia, Pa.
10. Primafloc C-5 - A polyamine cationic polyelectrolyte.
Rohm and Haas Company, Philadelphia, Pa.
11. Primafloc C-7 - A cationic polyamine bisulfate polyelectrolyte.
Rohm and Haas Company, Philadelphia, Pa.
12. Aqua-Rid 49-700 - A cationic polyamine polyelectrolyte.
Reichhold Chemicals, Inc., Tuscaloosa, Ala.
13. Aqua-Rid 49-702 - A polyamine polyelectrolyte.
Reichhold Chemicals, Inc., Tuscaloosa, Ala.
14. Aqua-Rid 49-703 - A anionic poly-aromatic polyelectrolyte.
Reichhold Chemicals, Inc., Tuscaloosa, Ala.
15. Aqua-Rid 49-701 - A cationic polyamine polyelectrolyte.
Reichhold Chemicals, Inc., Tuscaloosa, Ala.
16. Aqua-Rid 96-549 - A correctant and catalyst for use with
49-701, 49-702, 49-703, or 49-700 Aqua Rids.
Reichhold Chemicals, Inc., Tuscaloosa, Ala.
65
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17. Natron 86 - A cationic polyelectrolyte.
National Starch and Chemicals Corporation, New York, N. Y.
18. Resyn 3285 - A anionic polyelectrolyte.
National Starch and Chemical Corporation, New York, N. Y.
19. Poly-Floe 1160 - A copolymer of acrylamide.
Betz Laboratories, Inc., Treuose, Pa.
20. Magnifloc 900-N - A nonionic polyacrylamide.
American Cyanamid Company, Wayne, New Jersey.
21. Magnifloc 905-N - A nonionic polyacrylamide.
American Cyanamid Company. Wayne, New Jersey.
22. Magnifloc 865-A - A anionic polyacrylamide.
American Cyanamid Company, Wayne, New Jersey.
23. Aluminum Sulfate.
Allied Chemical Corporation.
CARBON
1. Aqua Nuchar "A"
West Virginia Pulp and Paper Company, New York, N. Y.
2. Darco S-51.
Atlas Chemical Industries, Inc., Wilmington, Delaware.
66
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BIBLIOGRAPHIC:
Fiber Industries, Incorporated. Reuse of Chemical Fiber Plant
Uastewater and Cooling Water Slowdown, Final Report FWQA Grant
No. 12090 EUX 10/70.
ABSTRACT:
Demonstration studies were conducted to determine the feasibility
of reusing Industrial and domestic wastnwaters from a FORTREL Poly-
ester manufacturing plant. The wastewaters consisted of organic
chemical process wastes, cooling system blowdown and domestic waste-
waters from the plant. Selected unit processes and operations were
superimposed on an existing activated sludge system In an effort to
Improve the quality of the treated discharge. The cooling system
bloudown was pretreated with sulfur dioxide 1n an acidic environment
to remove chromium. The cooling water blocldes which passed through
the chromium reduction unit were observed for their possible effect on
the biological treatment system.- A plastic media trickling filter was
evaluated for its effectiveness as a roughing filter ahead of an acti-
vated sludge unit. The effluent from the secondary treatment system
was filtered through a mtcroscreen, and treated with polymers and/or
carbon to remove color, COD, dissolved and suspended solids*
The results of these studies Indicate that chromium can be removed
from the cooling tower blowdown for 21* per pound of chromate and that
the type and concentration of Dlocldes normally used 1n cooling water
are either destroyed In the chromate reduction system or exhibit no
adverse effect on the secondary and tertiary treatment system. The
plastic media trickling filter, operated with a sludge recycle from
the clarlfier and reduced the BOD by 401. The 0.33 ngd Industrial
and domestic wastewater can be treated and reused at a rate of 0.10
mgd for approximately 40«yiOOO gallons.
This report was submitted In fulfillment of project 12090 EUX under
partial sponsorship of the Federal Water Quality Administration.
ACCESSION NO.
KEY WORDS:
Cool Ing Water
Chromium Reduction
Chemical Precipitation
Trickling Filters
Filtration
Tertiary Traatnnt
Water Reuse
BIBLIOGRAPHIC:
Fiber Industries, Incorporated, Reuse of Chemical Fiber Plant
Wasttwater and Cooling Water Slowdown, Final Report FNQA Srant
Na. 12090 EUX 10/70.
ABSTRACT:
Demonstration studies were conducted to determine the feasibility
of reusing Industrial and domestic Hastfiwaters from a FORTREL Poly-
ester manufacturing plant. The wastewaters consisted of organic
chemical process wastes, cooling -ystem blowdown and domestic waste-
waters from the plant. Selected unit processes and operations were
superimposed on an existing activated sludge system In an effort to
Improve the quality of the treated discharge. The cooling system
blowdown was pretreatad with sulfur dioxide in an acidic environment
to remove chromium. The cooling water btoctdes which passed through
the chromium reduction unit were observed for their possible effect on
the biological treatment system. A plastic media trickling filter was
evaluated for Its effectiveness as a roughing filter ahead of an acti-
vated sludge unit. The effluent from the secondary treatment system
was filtered through a microscreen, and treated with polymers and/or
carton to remove color, COD, dissolved and suependcd solids
The results of these studies Indicate that chromium can be removed
from the cooling tower blowdown for 2U per pound of chronate and that
the type and concentration of blocldes normally used In cooling water
are either destroyed 1n th« chromate reduction system or exhibit no
adverse effect on the secondary and tertiary treatment system. The
plastic madia trickling filter, operated with a sludge recycle from
the clarlfier and reduced the BOD by 40X. The 0.33 mgd Industrial
and domestic wastewater can be treated and reused at a rate of 0.10
•gd for approximately W/1000 gallons.
This report was submitted in fulfillment of project 12090 EUX under
partial sponsorship of the Federal Water Duality Administration.
ACCESSION NO.
KEY WORDS:
Cooling Water
Chromium Reduction
Chemical Precipitation
Trickling Filters
Filtration
Tertiary Treatment
Water Reuse
BIBLIOGRAPHIC:
Fiber Industries, Incorporated, Reuse of Che«1c,al Fiber Plant
Wastewater and Cooling Hater Blowdown, Final Report FUQA Grant
No. 12090 EUX 10/70.
ABSTRACT:
Demonstration studies were conducted to determine the feasibility
of reusing Industrial and domestic wattmeters from a FORTREL Poly-
ester Manufacturing plant. The wastewaters consisted of organic
chemical process wastes, cooling system blowdown and domestic waste-
waters from the plant. Selected unit processes and operations were
superimposed on an existing activated sludge system in an effort to
improve the quality of the treated discharge. The cooling system
blowdown was pretreatad with sulfur dioxide in an acidic environment
to remove chromium. The cooling water blocldes which passed through
the chromium reduction unit were observed for their possible effect on
the biological treatment system. A plastic media trickling filter was
evaluated for Its effectiveness as a roughing filter ahead of an acti-
vated sludge unit. The effluent from the secondary treatment system
was filtered through a microscreen. and treated with polymers and/or
carbon to remove color, COO, dissolved and suspended solids
The results of these studies Indicate that chromium can be removed
froet the cooling tower blowdown for 2U per pound of chromate and that
the type and concentration of blocldes normally used 1n cooling water
are either destroyed in the chromate reduction system or exhibit no
adverse effect on the secondary and tertiary treatment system. The
plastic media trickling filter, operated with a sludge recycle from
the clarlfier and reduced the BOD by 40*. The 0.33 ngd Industrial
and domestic wastewater can be treated and reused at a rate of 0.10
mgd for approximately 40(71000 gallons.
This report was submitted In fulfillment of project 12090 EUX under
partial sponsorship of the Federal Water Quality Administration.
ACCESSION NO.
KEY WORDS:
Cooling Water
Chromium Reduction
Chemical Precipitation
Trickling Filters
Filtration
Tertiary Treatment
Water Reuse
-------
Accession Number
Subject Field & Group
05 D
SELECTED WATER RESOURCES ABSTRACTS
INPUT TRANSACTION FORM
Organization
Fiber Industries, Incorporated
P. O. Box 10038
Charlotte. North Carolina 28201
Title
Reuse of Chemical Fiber Plant
wastewater and cooling water blowdown
10
Authors)
William J.
Da/
16
21
Project Designation
FWQA 12090 EUX
Note , . . . .
In conjunction with:
Davis & Floyd Engineers, Inc
Greenwood, South Carolina
22
Citation
23
Descriptors (Starred First)
Cooling water
Chromium
Chemical Reduction
Chemical Precipitation
Trickling Filters
Tertiary Treatment
Filtration
Water Reuse
or Identifiers (Starred First)
Abstract - Uemonstration studies were conducted to determine the feasibility of reusing industrial and
domestic wastewaters from a FORTREL Polyester manufacturing plant. The wastewaters consisted of
organic chemical process wastes, cooling system blowdown and domestic wastewaters from the plant.
Selected unit processes and operations were superimposed on an existing activated sludge system in an
effort to improve the quality of the treated discharge. The cooling system blowdown was pretreqted with
sulfur dioxide in an acidic environment to remove the chromium. The cooling water biocides which passed
through the chromium reduction unit were observed for their possible effect on the biological treatment
system. A plastic media trickling filter was evaluated for its effectiveness as a roughing filter ahead of an
activated sludge unit. The effluent from the secondary treatment system was filtered through a microscreen,
and treated with polymers and/or carbon to remove color, COD, dissolved and suspended solids.
The results of these studies indicate that chormium can be removed from the cooling tower blow-
down for 21$ per pound of chromate and that the type and concentration of biocides normally used in
cooling water are either destroyed in the chromate reduction system or exhibit no adverse effect on the
secondary and tertiary treatment system. The plastic media trickling filter, operated with a sludge
recycle from the clarifier and reduced the BOD by 40%. The 0.33 mgd industrial and domestic waste-
water can be treated and reused at a rate of 0.10 mgd for approximately 40$/1000 gals.
This report was submitted in fulfillment of project 12090 EUX under partial sponsorship of the
Federal Water Quality Administration •
27
Abstractor
W. J. Day
Institution
Davis & Floyd Engineers, Inc.
WR: 102
WRSIC
(REV. JUL Y 1969)
SEND TO: WATER RESOURCES SCIENTIFIC INFORMATION CENTER
U.S. DEPARTMENT OF THE INTERIOR
WASHINGTON, D. C. 20240
GPO: 19Q9-3B9»33g
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