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THE ECONOMICS OF
CLEAN WATER
VOLUME III
Inorganic Chemicals Industry Profile
Prepared Under Contract No. 14-12-592
U. S. Department of the Interior
Federal Water Pollution Control Administration
March 1970
For sale by the Superintendent of Documents, U.S. Government Printing Office
Washington, D.C. 20402 - Price $3JO
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UNITED STATES
DEPARTMENT OF THE INTERIOR
OFFICE OF THE SECRETARY
WASHINGTON, D.C. 20240
APR 3 1970
Dear Mr. President:
I am transmitting to the Congress the third report on the national
requirements and cost of water pollution control as required under
Section 16 (a) of the Federal Water Pollution Control Act, as amended.
The decade of the 1970's, a decade which will address itself to improv-
ing the quality of man's environment, will see great strides toward
the effort to abate water pollution. The enclosed report entitled
"The Economics of Clean Water" represents our current estimates of the
investment levels necessary to attain applicable water quality
standards.
This report, along with the two previously submitted, contributes to
closing the information gap in terms of the overall magnitude, geograph-
ical, and financial dimensions, all of which are essential to the
development of national policies and programs directed toward achieving
water quality standards in an efficient and effective manner.
The alternatives analyzed in the course of this study, especially
those aspects contained in Volume I, presented valuable background
for development of proposals on aid to municipal treatment works
presented to the Congress in the President's Environmental Message
and subsequent legislation.
There are four parts to this year's report. The first is a summary of
major findings and conclusions of the analysis. The second, Volume I,
contains the details of the analysis. The third, Volume II, is a
profile of animal wastes. The fourth and last section, Volume III,
is an industrial profile of the inorganic chemicals industry.
Sincerely yours,
Secretaw of the Interior
Hon. Spiro Agnew
President of the Senate
Washington, D, C. 20510
Enclosure
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UNITED STATES
DEPARTMENT OF THE INTERIOR
OFFICE OF THE SECRETARY
WASHINGTON, D.C. 20240
APR 31970
Dear Mr. Speaker:
I am transmitting to the Congress the third report on the national
requirements and cost of water pollution control as required under
Section 16 (a) of the Federal Water Pollution Control Act, as amended.
The decade of the 1970's, a decade which will address itself to improv-
ing the quality of man's environment, will see great strides toward
the effort to abate water pollution. The enclosed report entitled
"The Economics of Clean Water" represents our current estimates of the
investment levels necessary to attain applicable water quality
standards.
This report, along with the two previously submitted, contributes to
closing the information gap in terms of the overall magnitude, geograph-
ical, and financial dimensions, all of which are essential to the
development of national policies and programs directed toward achieving
water quality standards in an efficient and effective manner.
The alternatives analyzed in the course of this study, especially
those aspects contained in Volume I, presented valuable background
for development of proposals on aid to municipal treatment works
presented to the Congress in the President's Environmental Message
and subsequent legislation.
There are four parts to this year's report. The first is a summary of
major findings and conclusions of the analysis. The second, Volume I,
contains the details of the analysis. The third, Volume II, is a
profile of animal wastes. The fourth and last section, Volume III,
is an Industrial profile of the inorganic chemicals industry.
ncerely yours,
Secretary of the Interior
Hon. John W. McCormack
Speaker of the House of
Representatives
Washington, D. C. 20515
Enclosure
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TABLE OF CONTENTS
Page
I. Summary 1
II. Introduction 7
III. The Inorganic Chemical Industry 8
IV. Projected Industry Growth 15
V. Wastewater Characteristics 19
VI. Wastewater Treatment Methods 22
VII. Industrial Waste Treatment Practices Data
Form , 31
VIII. Plant Survey Data 33
IX. Costs of Unit Wastewater Treatment Methods 45
X. Costs Versus Effluent Quality Relation-
ships 53
XI. Projected Industry Costs 55
XII. Qualitative Manpower Requirements 76
XIII. Quantitative Manpower Requirements 97
VI1
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TABLE OP CONTENTS (cont.)
APPENDIX
Page
A. Industrial Waste Treatment Practices Data
Form 122
B. Inorganic Chemical Industry Survey Data 176
C. Inorganic Chemical Industry Product Pro-
files 178
D. Qualitative Personnel Requirements for
Treatment Processes
E. Costs of Unit Wastewater Treatment
o 0*7
Practices .................................... •" '
F. Bibliography
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LIST OF TABLES
Page
CHAPTER III - THE INORGANIC CHEMICAL INDUSTRY
Table I - Financial Ratios for the Industrial
Chemical Industry 10
Table II - Value of Estimated Inorganic Chemical
Shipments
CHAPTER IV - PROJECTED INDUSTRY GROWTH
Table I - Production of Inorganic Chemicals
11
Table II - Industry Segmental Growth Rates
Through 1979 .................................... 17
Table III - Industry Growth Rates Geographically
Through 1975 .................................... 17
CHAPTER V - WASTEWATER CHARACTERISTICS
Table I - Composition of Typical Clean Water
Effluent ........................................ 20
CHAPTER VI - WASTEWATER TREATMENT METHODS
Table I - Water Discharge by SIC... ............... 26
Table II - Employment Distribution ................ 27
Table III - Distribution of Water Use ............. 28
CHAPTER IX - COSTS OF UNIT WASTEWATER TREATMENT
METHODS
Table I - Treatment Level I, Neutralization Costs .
Including Equalization and Sludge Dewatering....
Table II - Treatment Level II, Demineralization
Costs Including Prefiltration and Brine
Disposal 51
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LIST OF TABLES (cont.)
Page
CHAPTER XI - PROJECTED INDUSTRY COSTS
Table I - Numbers of Inorganic Chemical Plants by
Water Intake Volume - 1963 55
Table II - Water Discharges from Large Inorganic
Chemical Plants - 1963 55
Table III - Large Inorganic Chemical Plant Dis-
charges Other Than to Municipal Sewers - 1963... 56
Table IV - Large Inorganic Chemical Plant Intakes
and Usage, by Purpose/ 1963 57
Table V - The Inorganic Chemical Industry, 1958
and 1963 58
Table VI - Number of Plants and Value of Shipments,
1958 Prices 59
Table VII - Values of Inorganic Chemical Shipments,
1966 59
Table VIII - Values of Inorganic Chemical Shipments,
1968 and 1969 60
Table IX - Numbers of Plants in the Inorganic
Chemical Industry 61
Table X - Numbers of Inorganic Chemical Plants for
Study Purposes 61
Table XI - Projected Production of Inorganic
Chemicals, 1968-1974 63
Table XII - The Inorganic Chemical Industry,
1963-74 64
Table XIII - Water Use Data, 1958-67 65
Table XIV - The Inorganic Chemical Industry,
1963-74 67
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LIST OF TABLES (cont.)
Page
CHAPTER XI (cont.)
Table XV - 1967 MCA Survey Data, The Chemical
Industry 68
Table XVI - Ranges of Chemical Plant Production
Capacities 69
Table XVII - Numbers of Plants in the Chemical
Industry, 1963 69
Table XVIII - Chemical Industry Survey Data,
1967 70
Table XIX - Chemical Plant Sizes and Discharges,
1967 71
Table XX - Chemical Industry Discharges, 1967 72
Table XXI - Chemical Industry Costs and Manpower,
1969 72
Table XXII - Cumulative Inorganic Chemical
Industry Capital Costs, 1969-1974 73
Table XXIII - Cumulative Inorganic Chemical
Industry Capital Costs, 1969-1974 73
Table XXIV - Projected Annual Inorganic Chemical
Industry Operating Costs 74
Table XXV - Projected Annual Inorganic Chemical
Industry Operating Costs 74
CHAPTER XIII - QUANTITATIVE MANPOWER REQUIREMENTS
Table I - Equalization, man-hours/year 103
Table II - Chemical Addition, man-hours/year 105
Table III - Lagaoning, man-hours/year 106
xi
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LIST OF TABLES (cont.)
Page
CHAPTER XIII (cont.)
Table IV - Sedimentation, man-hours/year 108
Table V - Filtration, man-hours/year 109
Table VI - Reverse Osmosis, man-hours/year Ill
Table VII - Deep Well Injection, man-hours/year... 113
Table VIII - Large Plant, Level I Treatment-27%
Removal, Equalization, Chemical Addition,
Lagoon 114
Table IX - Large Plant, Level II Treatment-100%
Removal, Equalization, Chemical Addition,
Sedimentation, Filtration, Reverse Osmosis,
Deep Well Injection 115
Table X - Small Plant, Level I Treatment-27%
Removal, Equalization, Chemical Addition, Lagoon,
Total Effluent Assumed Discharged to Municipal
Sewers 116
Table XI - Number of Operator Personnel Assigned
to Waste Treatment 117
Table XII - Assigned Plant Operators 118
Table XIII - Number of Trained Wastewater Treatment
Plant Operators Required 120
APPENDIX B - INORGANIC CHEMICAL INDUSTRY SURVEY DATA
Table 1 177
APPENDIX E - COSTS OF UNIT WASTEWATER TREATMENT
PRACTICES
Table 1 433
xii
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LIST OF FIGURES
CHAPTER III - THE INORGANIC CHEMICAL INDUSTRY
Figure 1 - Location of Major Inorganic Chemical
Plants, SIC Nos. 2812, 2816, 2819 14
CHAPTER VI - WASTEWATER TREATMENT METHODS
Figure 1 - Wastewater Treatment Sequence 23
CHAPTER VIII - PLANT SURVEY DATA
Figure 1 - Total 1969 Production - Millions of
Tons/Year 35
Figure 2 - Production - Thousands of Tons/Year.... 36
Figure 3 - Flow - MGD 37
Figure 4 - Plant Employment 38
Figure 5 - Major Source of Water 39
Figure 6 - Basis of Treatment Decision 40
Figure 7 - Year of Construction 41
Figure 8 - States 42
Figure 9 - Industry Water Use Regions 43
Figure 10 - Operating Costs of Treatment Facilities
Versus Capital Costs 44
CHAPTER IX - COSTS OF UNIT WASTEWATER TREATMENT
METHODS
Figure 1 - Applicable Ranges of Demineralization
Units 46
xiii
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LIST OF FIGURES (cont.)
Page
CHAPTER IX (cont.)
Figure 2 - Schematic Layout of Treatment Plant
for Wastes from the Inorganic Chemical Industry
Showing Various Possible Combinations of Units.. 47
Figure 3 - Flow Sheet for Neutralization Plant.... 48
CHAPTER XI - PROJECTED INDUSTRY COSTS
Figure 1 - No. of Plants Versus Value of Ship-
ments 62
APPENDIX C - INORGANIC CHEMICAL INDUSTRY PRODUCT
PROFILES
Figure 1 - Flowchart for Diaphragm Caustic Soda
and Chlorine Cell 182
Figure 2 - Flowchart of a Standard Medium-Pressure
Air-Separation Plant 187
Figure 3 - Flowchart for Titanium Dioxide 192
Figure 4 - Flowchart for Mixing of Paint 193
Figure 5 - Ammonium Nitrate Plant Locations 198
Figure 6 - Flowchart for 60% Nitric Acid from
Ammonia 207
Figure 7 - Phosphoric Acid Plant Locations 211
Figure 8 - Typical Flowchart for Sulfur-Burning
Contact Plant 223
Figure 9 - Ammonium Phosphate Plant Locations 230
Figure 10 - Estimated Number of Bulk Blend
Fertilizer Plants 234
xiv
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LIST OF FIGURES (cont.)
Page
APPENDIX C (cont.)
Figure 11 - Estimated Number of Liquid Mixed
Fertilizer Plants 236
Figure 12 - Flowchart for Smokeless Powder 243
APPENDIX E
Figure 1 - Applicable Ranges of Demineralization
Units 399
Figure 2 - Schematic Layout of Treatment Plant
for Wastes from the Inorganic Chemical Industry
Showing Various Possible Combinations of Units.. 400
Figure 3 - Flow Sheet for Neutralization Plant 402
Figure 4 - Cap. Cost of Neutralization Facilities
Excluding Sludge Treatment 403
Figure 5 - Cap. Cost Versus Acidity for 1 MGD
Plant 404
Figure 6 - Capital Cost of Equalization Basins.... 405
Figure 7 - Thickener Parameters for Sludge from
Neutralization of Acidic Wastes 408
Figure 8 - Variation of KB with Initial Solids
Concentration 409
Figure 9 - Capital Cost of Thickeners 412
Figure 10 - Operating Costs for Lime Neutralization
Including Sludge Dewatering by Vacuum Filtra-
tion 414
Figure 11 - Cost of Filtration Through Sand or
Graded Media 416
Figure 12 - Annual Operating Cost of Deep Well
Injection Systems for Waste Disposal 418
XV
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LIST OF FIGURES (cont.)
Page
APPENDIX E (cont.)
Figure 13 - Capital Cost of Deep Well Injection
Systems for Waste Disposal ...................... 419
Figure 14 - Area of Membranes as a Function of
Production Rate .................................
Figure 15 - Membrane Area Required Versus Feed
and Product Flows ............................... 422
Figure 16 - Power Consumption as a Function of
Production Rate ................................. 423
Figure 17 - Capital Cost as a Function of
Production Rate ................................. 424
Figure 18 - Capital Cost of Reverse Osmosis
Plant ........................................... 426
Figure 19 - Operating Cost for Reverse Osmosis
Plant ........................................... 427
Figure 20 - Determination of Total Number of
Units Required for Treatment .................... 429
Figure 21 - Relationship of Plate Area Required
for a Desired TDS Removal ....................... 430
Figure 22 - Relationship of Rectifier Size to
Specific TDS Removal Desired .................... 431
Figure 23 - Capital Cost of Membranes, Spacers,
End Plates , and Electrodes ...................... 435
Figure 24 - Capital Cost Curves for DC Rectifier
for Electrodialysis ............................. 436
Figure 25 - Relationship of DC Energy Required for
a Desired TDS Removal ........................... 437
Figure 26 - Operating Cost of DC Energy Required
for Specific TDS Removal ........................ 439
xv i
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LIST OF FIGURES (cont.)
Page
APPENDIX E (cont.)
Figure 27 (capital and Operating Costs for
Electrodialysis Based on Feed Flow to Plant
at 3000 ppm TDS 440
Figure 28 - Capital Cost of Ion Exchange Plant.... 442
Figure 29 - Chemical Cost per Pound TDS
Removed by Ion Exchange 443
Figure 30 - Capital and Operating Cost for
Multiple Effect Evaporation 446
Figure 31 - Vapor Pressure of Water Versus
Temperature 448
Figure 32 - Evaporation Versus Vapor Pressure
Differential 449
Figure 33 - Area Versus Required Evaporation 450
Figure 34 - Capital Cost Relationship for
Lagoons 451
Figure 35 - Relative Rating Factors Versus Wet
Bulb Temperatures 456
Figure 36 - Cooling Towers 458
xvli
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CHAPTER I
SUMMARY
This report presents a description of the inorganic
chemical industry, and the costs that the industry would
incur in attaining various levels of pollution abatement
over a five year period through 1974. Also presented is
a description of the corresponding qualitative and quanti-
tative manpower requirements for the operation and mainte-
nance of the foregoing waste treatment facilities. The
cost estimates have been based upon published data, general
data derived from information in the files of the Contrac-
tors on industrial waste treatment methods and costs, and
specific data from 59 inorganic chemical plants, some of
which were supplied by the Manufacturing Chemists Associa-
tion. (The data supplied by the M.C.A. were presented in
such a manner as to render impossible identification of
proprietary information relating to a specific plant's
construction, operation, maintenance, or production.)
The inorganic chemical industry has been defined for pur-
poses of this study as including establishments producing
alkalies and chlorine, industrial gases, inorganic pig-
ments, paints and allied products, fertilizers (excluding
ammonia and urea), inorganic insecticides and herbicides,
explosives, and other major industrial inorganic chemi-
cals. The complex relationship which exists between
various products and industries, however, make it
extremely difficult to arbitrarily associate certain
products with one category. The overall output of the
industry, since its products are used for a wide variety
of purposes well removed from the final consumer, depends
upon the level of total economic activity rather than
the economic activity in any one segment of the economy.
Since new mineral sources are discovered infrequently and
usually involve large development expenditures, wide
fluctuations in the gap between demand and readily avail-
able supply are quite common.
Total production in the inorganic chemical industry is
estimated to be 328.7 billion pounds in 1969 and projected
at 455.5 billion pounds in 1974. While certain segments
of the industry are growing as rapidly as 18% per year,
the historical situation is for a growth rate 1.5 to 2.0
times that of the gross national product. The overall
price index of inorganic chemicals, however, has fallen
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2.5 percent in the recent past. Thus, expenditures for
pollution control may be of greater relative significance
than in other industries where prevailing rising prices
can more readily absorb increased costs.
The regional growth rates reflect a continuing trend to
move production facilities closer to raw materials and
markets. The industry, as a whole, is thus tending to
concentrate in the Midwest and Southwest.
Inorganic chemical plants vary greatly in size, level of
technology, product mix, and age. The report presents in
considerable detail the description of the various
production processes, the waste treatment methods
practiced, and the possible impact that changes in
processes might have on the volume and cnaracter of the
wastes produced. A typical or average plant exists,
however, only in the statistical sense. The total costs
given in this report are for the construction and opera-
tion of waste treatment facilities for the industry as a
whole and cannot be used to determine costs for individual
plants. The costs given are for the waste treatment
facilities only. The costs entailed in process changes,
restriction of plant operations, sewer segregation,
particularly in older plants, are not included. Treat-
ment system construction and operating costs for a
particular plant can only be estimated by detailed
engineering studies.
Projections based upon the chemical industry data in the
1963 Census of Manufactures, the 1967 Manufacturing
Chemists Association survey, the 1968 FWPCA study of
the organic chemicals industry, and the costs of treat-
ment for the two levels of 27% and 100% removal of
contaminants show the following projected operating
costs and cumulative capital investment for wastewater
treatment.
PROJECTED CUMULATIVE INORGANIC CHEMICAL INDUSTRY CAPITAL
COSTS FOR WASTE TREATMENT, 1969-74
Costs in Millions of Current Dollars —
Removal 1969
1970
1971
1972
1973
1974
27 299.3 325.4 359.9 400.1 445.4 494.7
100 1808.4 1964.0 2173.2 2416.3 2689.0 2970.0
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PROJECTED INORGANIC CHEMICAL INDUSTRY ANNUAL OPERATING
COSTS FOR WASTE TREATMENT, 1969-74
Removal
27
100
Costs in Millions of Current Dollars =•'
V
1969
82.0
157.5
1970
89.1
171.0
1971
98.6
189.2
1972
109.6
210.5
1973
122.0
234.2
1974
135.5
260.2
I/ Based on an average 3.6% annual increase in the price
level
Contaminated wastewater from the inorganic chemical indus-
try comes primarily from electrolysis and crystallization
brines, washings from filter cakes, spent acid and alka-
lies, and washings from raw materials. These wastewaters
are generally characterized by dissolved solids and sus-
pended solids. In addition to contaminated waste streams,
process cooling discharges occur, accounting for 40 to 80%
of the total discharge on the average. Treatment practi-
ces vary but involve in-plant segregation of contaminated
wastes from uncontaminated cooling waters.
Many waste treatment methods are available depending on
the degree of treatment required, however, equalization,
neutralization, sedimentation and lagooning processes
are most widely used. Biological treatment is not appli-
cable since the contaminants are primarily dissolved or
suspended inorganic materials. Plants with small dis-
charges tend to employ only equalization and neutraliza-
tion with total discharge to municipal sewer systems for
joint treatment. it is estimated that between 10 and 20%
of the process wastewater discharge from the industry is
to municipal systems (4.2% of the total discharge). No
significant percentage changes in this regard are
expected through 1974. The inorganic chemical industry
has generally found that in-plant, separate treatment has
economic advantages, particularly when significant quanti-
ties of wastewater are involved.
Data from 59 inorganic chemical plants were obtained
and formatted according to the Industrial Waste Treatment
Practices Data Form, which was developed for the study
"The Cost of Clean Water and Its Economic Impact, Volume
IV," United States Department of the Interior, January,
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1969. The data obtained are given in some detail in the
report in terms of bar graphs and various calculated
parameters relating wastewater volumes, plant production,
and costs.
Key parameters of interest regarding waste treatment costs
are the following:
Average capital cost $223/1000 gpd
Average operating cost/yr. $58.49/1000 gpd
Average wastewater flow 16.73 gpd/annual ton of pro-
duction
Average capital cost $3.74/annual ton of production
Average operating cost $0.98 per year/annual ton of
production
An examination of the survey data showed that the reported
bases of waste treatment decisions were generally least
cost, or minimum compliance with pollution control regula-
tions .
The costs of unit wastewater treatment methods were
developed and are presented in the report as a series
of mathematical models and cost function graphs. These
data were used to calculate capital costs of waste
treatment facilities versus two levels of pollutant
removal for a series of typical plants. Treatment Level
I was chosen to represent the average treatment employed
in the industry as a whole and is judged to be equivalent
to 27% removal of suspended and dissolved solids. Treat-
ment Level II represents complete removal of contaminants.
Only two levels were selected because the industrial
wastes are principally inorganic solids that respond only
to physical treatment processes. Because there are no
intervening technologies, intermediate levels of
efficiency are not distinguishable. The two levels then
may be viewed as a range bounded on the one side by the
current level of efficiency and on the other by universal
application of advanced treatment practices. An almost
infinite number of intermediate positions are possible for
the industry as a whole within the range, but only as the
treatment II technology is applied to individual units of
the population. Unlike the case of organic waste, there
is no series of technological plateaus through which the
whole population may progress.
4
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The following table summarizes the capital and operating
costs in 1969 dollars for the two levels of treatment
chosen:
Capital Cost Operating Cost
% Removal Contaminants $/lQOO gpd $/1000 gal
27 (SS and Acidity) 300 26.0
100 (TDS) 2185 51.5
Since the effective and efficient treatment of wastewater
rests with the operators of the waste treatment facility,
qualitative as well as quantitative manpower requirements
have been projected for the inorganic chemical industry.
This report concentrates on the requirements for opera-
tion and maintenance since, while administrative and
technical support is requisite to effective treatment of
wastewater, the qualitative nature of these support
requirements will undergo less of a change in future
years than will the treatment processes and the skills
required for operating and maintaining them. Manpower
projections have been made through 1974 with respect to
both the degree of commitment necessary to achieve
specified levels of effluent quality and the number of
persons who must be specially trained to insure effective
waste treatment. The several projections should be use-
ful primarily for their planning implications, both to
the industry and to affected government agencies. The
following table summarizes the estimated trained manpower
needs through 1974:
ESTIMATED NUMBER OF TRAINED OPERATION AND MAINTENANCE
PERSONNEL REQUIRED FOR WASTEWATER TREATMENT BY
THE INORGANIC CHEMICAL INDUSTRIES, 1969-1974
1969 1970 1971 1972 1973 1974
Large Plants
Treatment Level I 1819 1826 1845 1867 1886 1910
27% Removal
Large Plants
Treatment Level
II 2617 2628 2656 2850 2886 2922
100% Removal
Small Plants
Treatment Level I 8906 8968 9052 9150 9255 9365
Discharge to
Sewers
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It must be noted in connection with the above numbers that
they are based upon 100% of the indicated size plant
utilizing the treatment level shown. There is no estimate
of the fraction of large plants utilizing either treatment
level except for 1969 where other considerations indicate
that on the average all large plants employ Treatment Level
I.
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CHAPTER II
INTRODUCTION
This study was performed pursuant to Contract No. 14-12-
592 with the Federal Water Pollution Control Administra-
tion, United States Department of the interior, and is
part of the annual National Requirements and Cost
Estimate Study required for presentation to Congress by
the Federal Water Pollution Control Act.
The primary objective of this study was to acquire data
and develop cost estimates on the waste treatment
practices of selected industrial categories within the
inorganic chemicals industry over the 1970 to 1974
period, and to develop manpower planning criteria for
each of the waste treatment practices identified. A
secondary objective of the study was to further test
and refine as necessary the generalized methodology for
establishing and projecting industry costs which was
developed in the course of work under FWPCA Contract No.
14-12-435 "Projected Wastewater Treatment Costs in the
Organic Chemicals Industry." This report was transmitted
to the Congress in January, 1969 as The Cost of Clean
Water, Volume IV.
The information contained in this report is not intended
to reflect the cost or waste load situations for any
particular plant. A generalized framework for analyzing
waste treatment practices has been provided instead.
The data and conclusions should be useful to industry
and to government in their efforts to find and implement
the most efficient ways to reduce pollution of the
nation's water bodies.
The study utilized on subcontract the services of
Resource Engineering Associates, Inc., Stamford, Conn.,
Datagraphics, Inc, Allison Park, Pa., and Gurnham,
Bramer, and Associates, Inc., McMurray, Pa. Assistance
from the Manufacturing Chemists Association in supplying
data, comments, and suggestions is gratefully acknowledged,
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CHAPTER III
THE INORGANIC CHEMICAL INDUSTRY
The inorganic chemical industry is not easily definable
in terms of the Standard Industrial Classification (SIC)
numbers. However, for the purpose of this study/ it was
necessary to define the industry as follows:
2812 - Alkalies and chlorine
2813 - Industrial gases (except for organic gases)
2816 - Inorganic pigments
2819 - Industrial inorganic chemicals, n.e.c.
2851 - Paints and allied products
2871 - Fertilizers (not including ammonia and urea)
2879 - Inorganic insecticides and herbicides
2892 - Explosives
The most important of the groups in terms of product value
may be noted as 2819/ 2812, and 2871. However, it is not
sufficient to ignore such groups as 2813 which includes
the important production of nitrogen and oxygen, 2851
which includes the vital surface coatings industry, or
2816 which involves inorganic pigments such as titanium
oxide. The surface coatings industry is typical of the
relationship which exists between segments of the
inorganic industry and the organic chemical industry. The
solvents and film formers which are utilized within the
inorganic chemical industry for the production of surface
coatings are important products of the organic chemical
industry while inorganic pigments, primarily oxides and
salts of titanium, iron and other metals are products
which fall into the inorganic industry category. We have
defined the total product as being part of the inorganic
industry. However, it is obvious that the complex
relationships which exist between various products and
industries (necessary to the smooth functioning of our
technological state) make it extremely difficult, if not
impossible, to arbitrarily associate certain products
with one SIC category. Product profiles are given in
Appendix C, along with typical product process flow
sheets.
The overall output of industrial inorganic chemicals,
since they are utilized in a wide range of industries
and for a wide variety of purposes usually well removed
from the final consumer, depends upon the level of
8
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total economic activity rather than economic activity in
any specific segment of the economy.
Changes in consumer preferences or redistribution of in-
come and spending/ such as changes in tax levels or
defense spending, may affect product mixes, but do not
significantly affect total industry output. In general,
price competition and product substitution are not as
significant in the inorganic chemical industry as in the
organic chemical sector. However, changes although slow
to come tend to be quite profound.
Supplies of raw materials frequently vary and, in the
case of certain materials, the industry may face serious
shortages until new raw material sources (usually ores
or brines) are developed. The widely fluctuating price
of sulfur over the past ten years is a classic case
resulting from supply fluctuations which can be matched
by mercury, potash and silver, among others. Since new
sources of minerals are found infrequently and usually
involve relatively large expenditures to develop, wide
fluctuations in the gap between demand and readily
available supply are quite common in the inorganic
chemical industry.
Industrial chemical industries are generally capital
intensive operations (with a few exceptions such as the
paint manufacturing industry), and are characterized by
high productivity ($75,000 annual output per production
worker), high wages, a low labor turnover, and a con-
tinuing demand for skilled labor. Most of the plants
operate continuous and must operate at 75 to 85 percent
of capacity to maintain adequate levels of efficiency
and profitability. Smaller plants generally operate
batch processes and, hence, tend to produce low volume,
high cost, specialized chemicals. Financial ratios for
the industrial chemical industry are shown in Table
I.
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TABLE I
FINANCIAL RATIOS FOR THE INDUSTRIAL CHEMICAL INDUSTRY
Ratio 1964 1965 1966 1967
Profits after taxes/sales (%) 7.9 7.9 7.8 6.5
Profits after taxes/net worth (%) 14.3 14.7 14.7 10.7
Capital expenditure/gross plant (%) 7.3 8.6 8.7 5.5
Depreciation/gross plant (%) 5.8 5.8 5.8 7.0
Depreciation/sales (%) 4.4 4.4 4.4 4.4
Depreciation/total assets (%) 1.1 1.1 1.1 1.1
First half
SOURCE: U.S. Industrial Outlook, 1969, U.S. Department of Commerce
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Profits after taxes as a percentage of sales in the
inorganic chemical industry ranged from 6.5 in 1967 to
7.9 in 1964-65. By comparison, comparable profits
for all manufacturing industries were 5.0 in 1967 and
5.4 in 1968. It is important to note that while the
inorganic segment attracts less attention than the organic
sector, satisfactory profits are generally associated
with investment in this segment.
The estimated value of inorganic chemical shipments for
1968 and 1969 are shown in II.
TABLE II
VALUE OF ESTIMATED INORGANIC CHEMICAL SHIPMENTS
(1968-9) ($ million)
SIC 1968 1969
2812 891 955
2813 630 665
2816 658 696
2819 4386 4510
2851 3255 3445
2871-72 1815 1815
2879 780 830
2892 501 517
SOURCE: U.S. Industrial Outlook, 1969, U.S.
Department of Commerce
Further comparisons within the inorganic chemical indus-
try show that the price index for the chemical industry
in mid-1969 was 96.7 on the basis of 1957-59 = 100. In
1968, the level was 98.8. The paint industry price
index was 114.4 in 1968 and 118.7 in 1969. The ferti-
lizer industry price level was 102.3 in 1968 and 88.8
in 1969. Several factors distinguish the inorganic
chemical industry and its relationship to waste manage-
ment. Among these are the following:
1. While certain segments of the industry are growing
rapidly, the more common situation is for a growth
rate at 1.5 to 2 times that of the gross national
product and several of the major chemicals have
growth curves which might be substituted for a
11
-------
historical projection of industrial growth in
general. This strong growth will affect the need
for pollution control facilities.
2. Capital investment is generally considerable and,
because of the nature of inorganic chemistry and
its long history of relatively unchanging practice,
rapid technological obsolescence does not occur.
Consequently, new capacity is not quickly built.
This industry moves more slowly to increase plant
capacity than the organic chemical industry
for example. Accordingly, the inorganic chemical
industry with its relatively aged plant in place
faces relatively high expenditures for added pollu-
tion control facilities.
3. The overall price index of chemicals, in contrast
with the general experience of American industry,
has fallen two to five percent in the recent past.
Thus, expenditures for pollution control may be of
greater relative significance than in other indus-
tries where prevailing rising prices can more
readily absorb increased costs.
4. Inorganic chemical plants tend to be located to
take advantage of such business factors as the
availability of raw materials, low cost power, or
markets. Considerations relating pollution con-
trol and plant location have been of minor
importance in the past.
5. Many facilities are old and completely depreciated.
Accordingly, there is little incentive to build
pollution control facilities to handle wastes from
an obsolete operation. Because of the nature of the
industry, obsolete units remain sufficiently profit-
able to continue in use.
6. Characteristically, inorganic chemicals are handled
in only two or three steps from raw material (brine
or ore, usually) to product for use by industry
elsewhere. While the inorganic chemical industry
includes a large number of products and processes
with the possibility of many different products at a
particular production site, there are a limited
number of products which comprise the bulk of the
12
-------
value of this industry's production; these are
discussed in detail in Appendix C to this report
along with the wastes generated by their production.
The location of this portion of the industry's
production is shown on Map A.
13
-------
LOCATION OF MAJOR INORGANIC CHEMICAL PLANTS
SIC NOS. 2812, 2816, 2819
over 1000 employees
500 -999 employees
250 -499 employees
This map represents a compilation, in content and configuration, of the location of major inorganic chemical plants classified by SIC 2812,
2816, and 2819. The source of this information was the book by Barry R. Lawson, Atlas of Industrial Water Use - A Report to till
Water Resources Council, Cornell University Water Resources Center, Ithaca. Ne* York, Publication No. 18, September , 1967, pp. 21,25
a 29.
-------
CHAPTER IV
PROJECTED INDUSTRY GROWTH
During the next decade, the inorganic chemical industry
will be characterized by new technology and many new
products. Many large volume chemicals are likely to
face changing markets as synthetic materials replace
natural products and one inorganic chemical is replaced
by another. Some of the processes that will bring changes
in inorganic chemicals utilization include hydrocracking
in gasoline refining, oxygen use in steelmaking and in
blast furnaces, holopulping to eliminate chemical markets
in papermaking, the use of hydrochloric acid in steel
pickling, the production of phosphoric acid from hydro-
chloric or nitric acid, the recovery of chlorine from
by-product hydrochloric acid, the recovery of sulfur com-
pounds from power plant flue gases, the use of oxygen in
sparging rivers, streams, and sewers as a pollution
abatement measure.
Inorganic chemicals represent a rapidly growing sector
of the chemical industry. In the 1963-69 period, the
production of inorganic chemicals as measured by the
U.S. Department of Commerce production index rose about
12% per year compounded, compared to a 7% rate for the
previous five years. Prices in the industry, however,
have risen only 5.3% per year during 1963-68 due to
both competitive pressures and to improved production
efficiencies.
Projected growth in the industry, for the purposes of
the present study, are best expressed in terms of the
volume of production based upon the tonnages of chemicals
produced. Growth estimates have been obtained from a
study by Resource Engineering Associates, Stamford,
Conn., utilizing an analysis which incorporates estimates
of overall employment, rate of growth of the economy,
and other economic parameters, as well as specific
characteristics of the industry and marketability pros-
pects for its products. These data are considered to
be the most reliable available and are tabulated in
Table I.
15
-------
TABLE I
PRODUCTION OF INORGANIC CHEMICALS
(millions of tons unless otherwise noted)
SIC
1968
1969
1970
1971
1972
1973
1974
2812
2813 ±f
2816
2819
2851 3/
2871
2879
2892
24
365
1.20
70
843
41.50
0.20
250
25
420
1.25
72
899
41.80
0.20
264
26
495
1.29
74
944
42.25
0.19
274
28
595
1.37
77
1000
43.94
0.18
282
30
715
1.44
80
1060
46.14
0.18
293
32
850
1.51
84
1124
47.99
0.17
305
34
1000
1.59
88
1191
49.91
0.15
322
I/ High purity oxygen and nitrogen only (billions of cu.
2/ Millions of dollars
3/ Millions of gallons
ft.)
-------
The above data are applicable to the inorganic chemical
industry as a whole, but rates of growth vary in the
various segments of the industry and from one geographi-
cal region to another. Expected rates of growth over
the next decade according to industry segment and
according to geographical region are given in Tables II
and ill.
TABLE II
INDUSTRY SEGMENTAL GROWTH RATES THROUGH 1979
SIC No. Growth Rate (%/year)
2812 6
2813 18
2816 5
2819 4
2851 6
2871 4
2879 1
2892 4
SOURCE: REA Projections
The above growth rates are based upon volumes of produc-
tion and assume a real growth in the Gross National Product
of 3.5% per year.
TABLE III
INDUSTRY GROWTH RATES GEOGRAPHICALLY
THROUGH 1975
Region Growth Rate (%/year)
Northeast and Middle Atlantic 4
Southeast 6
Gulf Coast 5
North Central 10
Mid South 10
Mountain States 4
Pacific Coast 5
SOURCE: REA Projections
17
-------
The regional growth rates reflect the continuing trend
to move production facilities closer to raw materials
and markets. The industry will thus tend to concentrate
more heavily in the Midwest and Southeast.
18
-------
CHAPTER V
WASTEWATER CHARACTERISTICS
Wastewater from inorganic chemical processing consists
both of contaminated and relatively clean effluent streams.
In general, the contaminated wastewaters are those taken
from processes while the cleaner wastewaters are those used
for indirect heat exchange, general washing, etc.
Contaminated Wastewaters
The major sources of contaminated wastewaters are as
follows:
1. Brines arising from electrolysis and crystallization
2. Filter cake washings
3. Waste acid and alkaline streams
4. Washing streams containing substantial amounts of
suspended particulate matter
These waters are generally characterized by dissolved
solids and suspended solids. Typical sources are
discussed in connection with the various processes
described in detail in Appendix C of this report.
Clean Wastewaters
Clean waters, which are basically uncontaminated and
can be discharged untreated, are not included in the
total flows given in wastewater totals. Cooling water
and steam condensates are the primary sources of such
water, and a typical breakdown is given in Table I.
Also included is an indication of potential pollutants
and associated sources and concentrations. Because
these clean wastewaters are relatively uncontaminated
and exert little pollutional effect (except thermal)
on the environment, care must be exercised to prevent
their contamination.
The thermal effects cannot be ignored. Effluent heat
loads can adversely affect the surface receiving
waters, causing decreased oxygen solubility and greater
oxygen utilization. Both of these effects significantly
19
-------
TABLE I
COMPOSITION OF TYPICAL CLEAN WATER EFFLUENT
Water Sources
% of Total
Wastewater
Flow Range (gpm)
Potential Pollutant
Sources
Cooling Water
(excluding sea water)
40 - 80
to
o
Steam Equipment
10
100 - 10,000
(500 - 200,000
(gal. water ton
product)
50 -
1,000
Process leaks:
Bearings, exchangers
etc.
Water treatment
Scrubbed from air
through tower
Make-up water
Boiler blowdown
Waste condensate
-------
reduce the ability of the receiving water to assimilate
waste loads. Through the use of cooling towers, the
quantity of high temperature wastewaters discharged has
been greatly reduced.
The segregation of clean wastewater flows is widely
practiced throughout the inorganic chemical industry, as
a result of overall wastewater treatment economics and
regulatory requirements. Although there is a limited
possibility that wastewater flows can be further
reduced by segregating additional clean waters, most
major clean waters are currently collected and either
recirculated or discharged separately in those in-
organic chemical plants with treatment facilities.
Thermal Pollutants
Many process facilities in the inorganic chemical industry
generate large amounts of thermal energy which must be
removed by the circulation of cooling waters or air.
Additional heat is released through the release of hot
brines from evaporators, etc. Of particular significance
are the gas producing plants because of their need to
discharge the thermal energy extracted from air or
natural gas during their compression and cooling to sub-
zero temperatures. In many cases, the problems of
thermal pollution are reduced through the use of cooling
towers. In the latter case, the blowdown from such re-
circulating systems may contain substantial amounts of
chemicals added to the cooling water such as chromates,
zinc, phosphates, bactericides, organics, etc., which
may constitute a pollution problem.
In the case of many industries, there is concerted
effort to produce by-product steam from excess thermal
energy. In the manufacture of sulfuric acid, for
example, by-product steam is important to process
economics. In many other cases, however, waste hot
brines and other similar waste flows are held in ponds
for cooling prior to discharge into surface waters.
21
-------
CHAPTER VI
WASTEWATER TREATMENT METHODS
A variety of sequences of wastewater treatment are avail-
able for wastes from inorganic chemical manufacture.
Their use depends on the nature of the waste and treatment
requirements. These sequences are indicated in Figure 1.
Three typical cases will be presented. These are:
I. Waste-containing dissolved and suspended solids
II. An excess thermal energy discharge
III. Waste-containing dissolved solids
Treatment Sequence I
In this case, the proposed treatment sequence might be:
Liquid 2-3-4-7-11-15 (Note that 8, 9, and 10 can
substitute for 7 and 11)
Solids 15-14-12-19
In this sequence, the waste flow is equalized and oil
is removed, clarification is used for suspended solids
removal, and the dissolved solids are concentrated and
sent to a deep well for disposal. The effluent dis-
tillate is then discharged or reused. The suspended
solids slurry will be thickened, centrifuged, and dis-
posed of in a lagoon. Alternately, chemical addition
could be used for dissolved solids removal if the dis-
solved ions have a common insoluble salt. Then the
dissolved ion problem has been converted to a suspended
solids problem and a suspended solids removal and disposal
sequence of 4-15-14-12 would be followed. It is also
possible to concentrate the dissolved ions by electro-
dialysis, or by ion exchange instead of distillation
and the sequence would be similar to that described
above.
The blowdown from the dissolved solids concentration
step instead of being disposed in a deep well may be
distilled to dryness, solar evaporated, or converted to
a saleable product.
22
-------
to
CO
PRETREATMENT
WASTE WATER
SUSPENDED
SOLID REMOVAL
DISSOLVED
SOLID REMOVAL
LIQUID DISPOSAL
SLUDGE TREATMENT
.
HEAT REMOVAL
FIGURE I
WASTEWATER TREATMENT SEQUENCE
-------
Treatment Sequence II
Here the proposed treatment sequence would be:
17-6-4-13
That is, a cooling tower (or a spray pond) would be
installed and the cooled effluent discharged or recycled.
If recycling is used/ then the blowdown from the system
may be treated by chemical addition and clarification to
remove undesirable components (especially hexavalent
chrome and zinc added for corrosion control) prior to
discharge. The suspended matter would then go into a
suspended solids disposal sequence discussed above.
Treatment Sequence III
With a very light suspended solids load but a heavy dis-
solved solids load, the sequence (with excess acidity)
would be:
2-1-7-11-13
where neutralizing would be prescribed following equaliza-
tion. This would be followed by reverse osmosis (or
distillation, electrodialysis, ion exchange or chemical
addition depending upon the circumstances) and discharge.
The concentrate would be disposed of in a deep well or
evaporated to dryness.
At this point, it is important to note the existence of
two significant treatment sequences of general impor-
tance. They are:
Treatment Sequence
a) excessive acidity or alkalinity
streams 1
b) many high dissolved solids streams 2-5-11
The above two treatment sequences are commonly used in
many circumstances in this industry. These treatment
sequences, of course, do not represent all those used by
the industry but are considered to be the most prevalent.
24
-------
Joint Industrial Municipal Treatment
According' to the U.S. Department of Commerce's 1963 publi-
cation/ Water Use in Industry, (the most recent available
report), a total of 1.178 trillion gallons of water
(excluding SIC 2813 Industrial Gases) were discharged from
plants of this industry group. Of this total, some 48
billion gallons, or 4.2%, were discharged to municipal
systems. No significant changes with regard to the per-
cent discharged to municipal systems has occurred in the
intervening years. However, these studies, which are
supported by others, indicate that there is tremendous
variation within groups. The study (see Table I) indi-
cates that the SIC groups 2812, 2819, 2871, and 2892 do
not make significant use of municipal systems, undoubtedly
because of the nature of their discharges (high chlorides,
conservative species, low or high pH) and their volume as
well as the location of the plants. SIC 2813 and 2851
make extensive use of municipal systems. The data for
2813 were not available, but because of the plant locations
and the fact that the waters discharged are primarily
cooling waters, it is estimated that 40 percent goes into
municipal systems. The data on SIC 2879 are inconclusive
and that on 2816 indicate that a significant though not
necessarily major percentage of the plants do use munici-
pal facilities.
The data in Table I apply only to plants reporting water
use of at least 20 million gallons per year or having
more than 100 employees. The distribution of employees
and water use is shown in Tables II and III.
More up to date data were not available from the Bureau
of Census and probably will not be available until the
latter part of 1970. However, the general trend of
data is not significantly changed and the conclusions
expressed are based on a review of updated trends.
25
-------
TABLE I
WATER DISCHARGE BY SIC (1)
to
(Tl
Inorganic
industry SIC
Alkalies 2812
Gases 2813
Pigments 2816
Chemicals 2819
Paints 2851
Fertilizers 2871
Herbicides 2879
Explosives 2892
Total Discharge
(billion gals/yr)
509
Not available
100
447
5
89
1
27
Discharge to
Municipal Systems
(billion gals/yr)
21
11
13
3
Less than 0.5
Less than 0.5
Less than 0.5
Percent to
Municipal Sewers
4.2
Estimated at 40% -'
11.0
2.9
60.0
0.0
0.0
0.0
i/ by Research Engineering Associates, Stamford, Conn.
(1) U.S. Census Bureau, Census of Manufactures (1963), Water Use in
.Manufacturing
-------
TABLE II
EMPLOYMENT DISTRIBUTION (1)
Number of
Employees
1-4
5-9
10-19
20-49
50-99
100-249
250-499
500-999
1,000-2,499
2,500 and more
SIC
2812
1
-
-
1
9
10
4
7
5
1
2813
134
70
106
98
35
12
1
_
-
—
2816
20
14
13
14
11
10
8
4
2
—
2819
168
90
93
111
75
74
33
18
8
4
2851
500
309
325
343
160
114
29
6
2
-
2871
44
20
18
71
73
40
13
1
1
-
2879
105
61
62
71
26
9
5
1
-
-
2892
12
4
5
7
9
18
6
3
3
1
(1) U.S. Census Bureau, ibid
-------
o>
Number of
Establishments
Reporting
Indicated
Water Use
(mil, gal/yr)
Less than 1
1-9
10-19
20-99
100+
TABLE III
DISTRIBUTION OF WATER USE (1)
SIC
2812
4
2
1
2
29
2813
197
106
36
33
49
2816
32
13
4
7
20
2819
189
98
39
60
138
2851
981
162
28
38
15
2871
104
50
24
32
31
2879
218
23
2
7
3
2892
28
4
5
4
17
(1) U.S. Census Bureau, ibid
-------
The smallest plants tend to discharge effluent to munici-
pal sewers but they also tend to discharge small volumes
of water. If we assume that they discharge all of their
effluent water -to municipal sewers, the figures change as
shown below:
Percent to Municipal Sewers
SIC From Table I Recalculated
2812 4.2 4.2
2816 11.0 11.2
2819 2.9 3.3
2851 60.0 75.0
2871 0.0 1.6
2892 0.0 0.0
Thus, the total discharge on a percentage basis is not
significantly changed and would approximate 4.5 percent
of the total.
It is significant to note that the total percentage, and
that within an SIC group, is not going to increase
significantly in the future. Spreading municipal systems
and increasing pressure on industry to treat its wastes
will be counter-balanced by restrictions on discharges
into municipal systems which will be especially true
with regard to discharges from the inorganic chemical
industry. It is likely that waste streams currently
being discharged into municipal systems from this indus-
try's establishments will be reduced because of increas-
ingly stringent sewer restrictions. The main point is
that there is not much point in co-treating a highly
conservative, dissolved solids waste stream in a facility
designed to treat non-conservative, suspended and
colloidal solids wastewaters.
Sewer restrictions which may bar or establish limita-
tions on chlorides, total dissolved solids, suspended
solids, heavy metals, color, pH, etc., are the princi-
pal barriers to the acceptance of wastewaters from this
industry into a municipal system. Economics rarely
play a role since almost any charge levied by a munici-
pality would be cheaper than known techniques for treat-
ing inorganic dissolved solids in most locations where
direct discharge to receiving streams is not permitted.
Rates vary from the infrequent zero cost to a rate on a
par with residential customers up through above average
costs based on surcharges or intentional industrial
burdens. Charges may run from $0.10-$1.00/1000 gallons
29
-------
with a level of $0.30-$0.40/1000 gallons at the 30-50
mgd treatment level believed to be average.
The chemical industry has generally found that in-plant,
separate treatment for neutralization and suspended solids
removal has economic advantages, particularly when
significant quantities of contaminated wastewaters are
involved. No significant percentage increase in the
amount of wastewaters treated in municipal systems is
expected in the near future. If complete, water renova-
tion of municipal wastewater becomes common, however,
then joint treatment for this industry's wastewater might
become more common and desirable.
30
-------
CHAPTER VII
INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM
An important secondary objective of this study has been to
further develop and refine as necessary generalized
methodology for establishing and projecting industry costs.
The Industrial Waste Treatment Practices Data Form was
developed as a part of the study entitled "Projected Waste-
water Costs in the Organic Chemicals Industry" under
Federal Water Pollution Control Administration Contract
No. 14-12-435 and published as a part of "The Cost of Clean
Water and Its Economic Impact - Volume IV," United States
Department of the Interior, January, 1969.
This form has been utilized in the acquisition of data
for the present study and has been expanded to include
data on manpower requirements in waste treatment practices.
Although no major changes were made in the original form,
an additional card (Card 10) has been added to incorporate
manpower data. Those changes that were made were generally
either to enlarge or reduce code fields as indicated by the
volume of data.
The Industrial Waste Treatment Practices Data Form now
consists of ten or more data sheets corresponding to ten
types of punched cards. Data sheets 1, 2, and 5 require
only one punched card, whereas sheets 3, 4, 6, 7, 8, 9,
and 10 may each require several cards in order to satisfy
large volumes of data.
In the course of completing both the present and previous
studies, an operating set of instructions along with a
dictionary for coded materials was prepared and expanded.
Since all data must be prepared in a uniform manner to
facilitate either manual or machine tabulation, the
operating instructions shall interpret all questions for
the data collector, while the dictionary will provide
alternative answers.along with the codes. If an entry
cannot be adequately described by a dictionary code, the
code fields are to be left blank; such codes will be
assigned by the Data Center.
The ten data sheets comprising the Industry Waste Treat-
ment Practices Data Form along with the operating
instructions and dictionary are shown in Appendix A.
31
-------
The data forms have now been tested on 111 plants in the
chemical industry which vary widely along the selected
parameters. The utility in tabulating data for either a
single plant or general industry has proved successful
and acceptable.
32
-------
CHAPTER VIII
PLANT SURVEY DATA
The Industrial Waste Treatment Practices Data Form was
used to tabulate data from 59 inorganic chemical plants.
The basic data obtained are tabulated in Appendix B and
are portrayed in the bar graphs of Figures 1 to 9.
From those plants for which adequate information was
available, the following average statistics were calcu-
lated:
Average production = 280,734 tons per year
Water use per plant = 27,034,619 gpd
Wastewater discharge per plant = 4.697 mgd
Average treatment efficiency = 85%
Average capital costs of treatment facilities =
$1,048,578
Average operating costs of treatment facilities =
$274,730 per year
Generalizing the above data:
Average capital cost = $223/1000 gpd
Average operating cost = $58.49 per year/1000 gpd
Average wastewater flow = 16.73 gpd/annual ton of
production
Average capital cost = $3.74/annual ton of
production
Average operating cost = $0.98 per year/annual ton
of production
The generally fragmentary nature of the survey data is
indicative of the status of wastewater treatment in
this segment of the chemical industry. Wastewater
treatment practices tend to be those which reduce gross
pollutants such as acidity, oil, and suspended solids.
The refractory nature of the wastes from most of the
industry's processes would require more advanced treat-
ment technologies than have generally been applied.
The production, capital costs, and operating costs
data reported per plant are judged to be reliable.
Such data are easily obtained from plant records. The
data reported on wastewater flows, however, are not
sufficiently reliable to be used for projection calcula-
33
-------
tions; these data are in error in that contaminated
wastewater flows are not accurately differentiated from
cooling water effluents.
Even though an extensive correlation study was made,
no statistically significant relationships were found
among the various cost-related parameters. The relation-
ship indicated in Figure 10 showing operating costs of
treatment facilities per ton of annual production as a
function of capital costs of facilities per ton of annual
production is the most useful found; it can be used to
indicate at least order-of-magnitude variations.
Among the plants in the survey sample, production
capacities were generally low while wastewater volumes
reported tended to be high. Most of the plants employed
more than 100 persons and were less than 10 years old.
The plants were widespread geographically and, accord-
ingly, may be considered to be representative in this
regard. The bases of treatment decisions for these plants
were generally least cost or minimum compliance with
regulations. A few decisions were made on the basis of
a projected economic return and only one plant decision
was based on ultimate treatment.
34
-------
FIGURE I
o:
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LU- TOTAL PRODUCTION
• -SURVEYED PRODUCTION
2812 2813 2816 2819 2851 2871 2879
STANDARD INDUSTRIAL CATEGORY
2892
35
-------
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14
13
12
It
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7
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FIGURE 2
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39
-------
FIGURE 6
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40
-------
FIGURE 7
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41
-------
FIGURE
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FIGURE 9
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10 20 30 40
CAPITAL COSTS
50 60 70 80
($ PER ANNUAL TON)
90
100
-------
CHAPTER IX
COSTS OF UNIT WASTEWATER TREATMENT METHODS
Introduction
The composition of wastes from the inorganic chemical indus-
try are very unpredictable, but the types of pollutant in
the waste can be classified under one of the following head-
ings:
1. Acidity or alkalinity
2. Suspended solids
3. Filterable solids
4. Dissolved solids
5. Temperature
Various combinations of the above types of pollution may
occur in an inorganic chemical waste. Care must be taken
when discussing these types of pollutants that the correct
references are used, e.g., the total dissolved solids (TDS)
referred to here refers to TDS after neutralization when
there is no excess acidity or alkalinity, since a large
amount of TDS may be removed in the process of neutraliza-
tion.
The ranges of the values for pollutants found from the
industry were as follows:
Process Water
Flow rate 0.5 mgd to 50 mgd
Acidity 200 mg/1 (as CaCOa) to 20,000 mg/1
Suspended solids 0-500 mg/1
Dissolved solids 1000-150,000 mg/1
Cooling Water
Flow rate Up to 150 mgd
Temperature range 140°F-180°F
It is evident from many studies of distribution of pollu-
tant concentration with flow rate that the combination of
high pollutant load with high flow rate is improbable.
Thus, generally with high process water flow rates such
as 50 mgd, the probability of having a TDS of 150,000 mg/1
is remote. For this reason, an envelope of extreme values
45
-------
CTi
200,000
100,000
FIGURE I
APPLICABLE RANGES OF
DEMINERALIZATION UNITS
en
o
o
en
o
CO
CO
50,000
10,000
5,000
o
H
1.0 5.0 10.0
PLANT CAPACITY ( MGD )
50.0 100.0
-------
NO NEUTRALIZATION FOR DEEP WELL EVAPORATION
" OR DEMINERALtZATION
FILTRATE
OR
CENTRATE
ALTERNATIVE:
SETTLING POND
Vacuum Filter
or
Centrifuge
Sludge
DIRECT TO EVAPORATION OR CONTROLLED DISCHARGE
REUSE OR
DISCHARGE
EVAPORATION
(alternative
to deep well)
FIGURE 2
SCHEMATIC LAYOUT OF TREATMENT PLANT FOR WASTES FROM THE INORGANIC
CHEMICAL INDUSTRY SHOWING VARIOUS POSSIBLE COMBINATIONS OF UNITS
-------
lime
GO
»•• Lime storage
1 1
'" " flash Mix!
filtrate
Vacuum filter
or "^
Centrifuge
1
Sludge to
disposal
occ
re IT
O Blower
ime V
lakes
Oxidation
Flocculation ,
ng 1
/Clarifier\ 1
1 VThlckener I '
\ \
1 ,
^Alternative
/s^"^ flow pat
asiona!^ ( 'm'" | i
loval of V pond/
To stream or
demineralization
plant
sludge after
drying
FIGURE 3
FLOW SHEET FOR NEUTRALIZATION PLANT
-------
of TDS and flow rate that have been considered for cost
calculations are shown in Figure 1. The following combina-
tions within the triangle and values of acidity were chosen
for this cost-study:
Flow rate 0.5, 1.0, 10.0, 50.0 mgd
Acidity 500, 1000, 20,000 mg/1 (as CaCOa)
Suspended solids 100, 500 mg/1
TDS 3000, 30,000, 150,000 mg/1
The flow sheet suggested for analysis is shown in Figure
2. When neutralization of the acidity is not required, the
neutralization plant will be bypassed. At low acidities
and a low flow rate, it may be more economical to eliminate
neutralization if high TDS must be removed anyway. This
will depend on the cost structure of the various units, the
quantities of waste, the use to which product wastes may
be used, the economy of brine disposal versus solids dispo-
sal , and other such considerations.
The neutralization plant suggested for cost analysis is
shown in Figure 3, and discussed in Appendix E under
the heading of neutralization. The plant included aeration
flocculation to precipitate ferrous and other metal ions.
The costs are shown in Table I.
The removal of TDS in any of the five units, i.e., deep
well disposal, reverse osmosis, electrodialysis, distilla-
tion, or ion exchange will require filtration of the
liquid as a pretreatment.
All of the last four processes that were considered will
produce brine. The concentration of brine produced will
depend first, on the process used, but also on the cost
of brine disposal and on the possible market value of the
usable water produced.
For this study, it was assumed that all brine produced
will be disposed of in deep wells or at a similar cost.
Other disposal methods include disposition to the ocean,
solar evaporation ponds, and evaporation ponds that use
applied heat. The process used depends on the location
and the brine concentration, as well as the cost of brine
disposal. These factors are too unpredictable to be
included in a study and the costs are given based on the
above assumptions.
49
-------
TABLE I
TREATMENT LEVEL I
NEUTRALIZATION COSTS INCLUDING EQUALIZATION
AND SLUDGE DEWATERING
Flow
mgd
0.5
0.5
0.5
0.5
0.5
0.5
1.0
1.0
1.0
1.0
1.0
1.0
10.0
10.0
10.0
10.0
50.0
50.0
Acidity
mg/1
500
500
1,000
1,000
20,000
20,000
500
500
1,000
1,000
20,000
20,000
500
500
1,000
1,000
500
500
SS
mg/1
100
500
100
500
100
500
100
500
100
500
100
500
100
500
100
500
100
500
Capital Cost
$1000
120.0
145.0
184.0
190.0
514.0
514.0
183.0
236.0
300.0
320.0
807.0
807.0
1,120.0
1,290.0
1,540.0
1,640.0
3,420
3,980
NOTE:
$/1000 gal
15
20
27
29
108
108
14.5
25
26
26
103
103
11
12.5
18
20
10.5
11
Costs based on the sum of unit processes 1, 2,
3, and 4 in Figure 1.
50
-------
TABLE II
TREATMENT LEVEL II
DEMINERALIZATION COSTS INCLUDING PREFILTRATION AND BRINE DISPOSAL
CAPITAL COSTS
OPERATING COST
tn
Flow IDS
mgd mg/1
0.5 3,000
0.5 30,000
1.0
5 150,000
3,000
Total
Product
Water §
500 rag/1
mgd
0.35
0.25
0.47
0.45
0.167
_
0.25
_
_
_
0.75
0.50
0.95
—
0.9
0.33
0.50
7.5
5.0
8.0
9.5
3.3
0.50
45.0
45.0
Brine
Filtra-
Disposal tion
mgd $1000
0.15
0.25
0.03
0.05
0.33
0.25
0.25
0.50
0.05
0.1
0.67
0.50
2.5
5.0
2.0
0.5
6.7
0.50
5.0
5.0
66
66
66
66
-
66
66
66
_
66
66
—
102
102
102
102
-
102
102
102
450
450
450
450
—
450
450
1,350
1,350
Demineraliza-
tion
Process
No.
6
7
8
10 ,
11—
9
6
7
11
9
6
11
6
7
8
10
11
9
7
9
7
8
9
10
11
7
9
7
9
Cost
$1000
430
640
455
1,700
40
806
430
784
40
806
430
40
290
1,120
896
3,020
100
1,610
1,340
1,610
6,700
6,400
9,070
14,800
410
8,400
9,070
29,100
34,700
Brine
Disposal Total
Cost
$1000
_
360
398
190
-
388
412
397
397
431
360
370
447
430
740
925
646
430
-
1,200
925
925
925
Cost
+35%
670
1,439
1,240
2,551
40
1,701
670
1,704
40
1,713
670
40
529
2,185
1,929
4,700
75
2,810
2,550
2,892
10,651
10,496
13,724
21,160
410
13,567
14,100
42,356
49,920
Filtra-
tion «:/
1000 gal)
8.5
8.5
8.5
8.5
8.5
8.5
8.5
8.5
7.0
7.0
7.0
7.0
-
7.0
7.0
7.0
3.0
3.0
3.0
3.0
-
3.0
3.0
2.0
2.0
Deminerali-
Brine
zation (C/1000
(C/IOOO gal) gal)
35.0
40.0
65.0
25.0
5.0
98.0
35.0
75.0
5.0
98.0
25.6
31.0
54.0
33.3
85.0
50.0
85.0
18.5
38.0
38.0
30.0
5.0
25.0
38.0
15.0
22.0
_
18.0
24.0
16.0
16.0
-
29.0
24.0
13.5
18.3
8.5
11.0
20.6
18.3
4.5
8.0
3.0
1.0
-
10.0
8.0
2.0
2.0
Total
Cost
(«/1000
gal)
43.5
66.5
97.5
49.5
5.0
122.5
43.5
112.5
5.0
130.5
43.5
5.0
51.5
79.3
48.8
5.0
103.0
77.6
110.3
26.0
49.0
44.0
34.0
5.0
38.0
49.0
19.0
26.0
30,000
10.0 3,000
10.0 30,000
50.0 3,000
45.0
—/ For evaporation ponds, consider only those states or areas where the evaporation rate is twice the average
annual rainfall. Consider land value a nominal $100/acre. Capital costs in thousand dollars.
-------
The literature was searched for the amount of brine pro-
duced by the desalting units under "normal" operating
conditions. Assumptions were made based on this informa-
tion and the quantities used are shown in Table II,
which presents the capital and operating costs for
various combinations of capacities and processes. Avail-
able data usually refers to brine production as a by-
product of potable water production and not of waste
treatment as such. For potable water production, the
disposal of brine is of secondary importance.
Where land is available and the evaporation rate exceeds
the average annual rainfall by a sufficient margin,
solar evaporation ponds will be an economical treatment
method that will not require pretreatment. Operating
costs will also be low.
In the regions of regular (as compared with seasonal)
rainfall, it may be more economical to store the waste
in lagoons and discharge to the stream only at
sufficiently high stream flow rates to provide the
necessary dilutions. This method is limited to a small
number of locations in the country. The size of the
ponds will be determined by the flow rate and variance
of the stream flow, the TDS content of the stream and
the later use of the stream. It is difficult to base
a cost function on these factors and for this reason,
only the method is shown.
Cooling water would normally need only to be cooled down
sufficiently so as not to raise the stream temperature
unduly. Cooling towers may be constructed based on the
mean low flow condition in summer or cooling ponds may
be used if land is cheap.
The calculated costs are summarized in two separate
tables mentioned in the foregoing. Table I considers
neutralization for Treatment Level I only, and Table II
considers the dissolved solids removal and brine dispo-
sal costs of waste treatment at Treatment Level II.
52
-------
CHAPTER X
COSTS VERSUS EFFLUENT QUALITY RELATIONSHIPS
The data from the survey of 59 plants was not
sufficiently complete in regard to effluent quality to
construct any statistically significant relationship
between numbers of plants, and effluent quality
parameters such as acidity, suspended solids and
dissolved solids.
The methods of treatment currently employed by the
inorganic chemical industry, as previously discussed,
are quite limited in number and, in general, involve as
a group (1) equalization, (2) neutralization, (3) floccu-
lation, (4) sedimentation, and (5) sludge dewatering.
This combination then is judged to account for the typical
situation and to be equivalent to approximately 27% level
of treatment, the reported average industry level.
The nature of the waste substances, inorganic soluble
salts, and the treatment processes available to re-
duce or remove such salts is such that there are,
practically speaking, no intermediate levels of treatment.
That is to say, treatment for removal of dissolved salts,
if applied at all, produces a quality of effluent water
equivalent or better than plant influent supply water.
An increase in the level of treatment of inorganic chemi-
cal plant effluents thus goes in one step from the 27%
level involved in neutralization and suspended solids
removal to 100% removal of the contaminants. For design
purposes, demineralization effluent quality is set at
500 rag/1.
On the basis of the range of volumes of plant effluents
and the foregoing considerations of only two levels of
treatment, a series of likely design combinations was
constructed, one for each level and the capital and
operating costs determined. Table I in Chapter IX pre-
sented the cost data for Treatment Level I which, as
previously mentioned, is judged equivalent to 27% removal.
Table II in Chapter IX presented the cost data for
Treatment Level II which represents 100% removal with
ultimate disposal of the residues. Figure 2 in Chapter
IX is a schematic diagram showing the generalized layout
for treatment of water from the inorganic chemical
industry. The numbers identifying each unit process
53
-------
correspond to the unit process numbers in Tables I and II.
Note from Figure 2 in Chapter IX that the brine from the
demineralization processes is taken to deep well disposal
or to solar evaporation alternatively. Figure 1 in Chapter
IX shows the applicable ranges of the alternative de-
mineralization units employed in the construction of Table
II data.
An examination of the information shown in the afore-
mentioned Tables I and II of Chapter IX, coupled with a
judgment as to the typical level of wastes to be
encountered, leads to the selection of 1000 ppm acidity
and 100 ppm suspended solids as representative of present
practice to establish the basis of industry cost pro-
jections covered in Chapter XI for Treatment Level I.
Similarly, 3000 ppm TDS is judged representative of wastes
for application of Treatment Level II. In this latter
connection, the capital and operating costs for deminerali-
zation process No. 7 reverse osmosis, were chosen for
projection purposes .even though simple deep well disposal
is clearly lower in both costs.
It is believed that any generalization developed based
upon wide use of large volume deep well disposal for
Treatment Level II would be misleading since such general
application of deep wells is considered impractical.
54
-------
CHAPTER XI
PROJECTED INDUSTRY COSTS
According to the U.S. Census Bureau's 1963 publication,
Water Use in Manufacturing, inorganic chemical plants
reported annual water intake volumes as shown in Table
I.
TABLE I
NUMBERS OF INORGANIC CHEMICAL PLANTS BY
WATER INTAKE VOLUME-1963 (1)
INTAKE VOLUMES
millions of gallons per year
Total
less
than 1
1-9 10-19 20-99
2812
2813
2816
2819
2851
2871
2879
2892
TOTAL
38
421
76
524
1224
241
253
58
T835
1
36
4
39
28
24
2
5
IJ9"
2
33
7
60
38
32
7
4
T8T
more
than 100
29
49
20
138
15
31
3
17
102"
(1) U.S. Census Bureau, Census of Manufactures-1963,
"Water Use in Manufacturing"
Water discharges from large plants (intakes of more than
20 million gallons per year) are given in Table II.
TABLE II
WATER DISCHARGES FROM LARGE INORGANIC
CHEMICAL PLANTS-1963 (1)
2812
2813
Discharge to
Total Discharge Municipal Sewers
(109 gal/yr) (109 gal/yr)
509
10.4
21
4.2
Percent to
Sewers
4.2
40.2 ±/
55
-------
TABLE II (cont.)
Discharge to
SIC Total Discharge Municipal Sewers Percent to
No. (109 gal/yr) (10 9 gal/yr) Sewers
2816 100 11 11.0
2819 447 13 2.9
2851 5 3 60.0
2871 89 0.5
2879 1 0.5
2892 27 0.5
Estimated from 02 and N2 production, use of 13 gal.
per lb., and use rate of 7
Estimated by Research Engineering Associates
3 Oxygen and nitrogen only
(1) U.S. Census Bureau, ibid
Assuming that all plants having intakes of less than 20
million gallons per year discharge to municipal sewers,
the total industry discharge to municipal sewers in
1963 is estimated to have been 48.0 billion gallons.
Discharges from large plants to other than municipal
sewers are given in Table III.
TABLE III
LARGE INORGANIC CHEMICAL PLANT DISCHARGES
OTHER ThAN TO MUNICIPAL SEWERS-1963 (1)
SIC No. of Discharge Average Discharge
No. Plants 1Q9 gal/yr 10 9 gal/yr _
2812 31 488 15.74
2813 82 V 6.2 I/
2816 27 89.0
2819 198 434
2851 53 2.0
2871 63 88.5
2879 10 0.5
2892 21 26.5
TOTAL 485 1134.7
' All industrial gases
2/ Oxygen and nitrogen plants only
(1) U.S. Census Bureau, ibid
56
-------
Water intakes and usages by purpose are given in Table
IV.
TABLE IV
LARGE INORGANIC CHEMICAL PLANT INTAKES
AND USAGE, BY PURPOSE, 1963 (1)
Billions of Gallons per Year
SIC
No.
2812
2813
2816
2819
2851
2871
2879
2892
TOTAL
Total
Intake
528
21
91
499
5
113
2
28
1287
Process
16
-
-
74
1
32
-
_2
-
Cooling
478
-
-
392
3
60
-
24
-
Other
35
-
-
33
1
22
-
_3
—
Gross
Use
628
146
112
1312
8
217
8
35
2466
Use
Rate
1.19
7.0
1.23
2.63
1.6
1.92
4.0
1.25
T79T
— ' Oxygen and nitrogen plants only
(1) U.S. Census Bureau, ibid
Assuming that contaminated wastewaters will be equivalent
to that withdrawn for process and other non-cooling
purposes, and that percentage disappearances are constant
for all purposes, the total of such wastewaters for large
plants in the industry in 1963 is estimated to have been
211.8 billion gallons to other than municipal sewers.
The average contaminated wastewater discharge from large
plants to other than municipal sewers is thus estimated
to have been 1.196 mgd. The average discharge to munici-
pal sewers from large plants is estimated to have been
0.303 mgd, and from small plants 6122 gpd.
Numbers of plants, values of shipments, and price indexes
for the inorganic chemical industry in 1958 and 1963
are given in Table V.
57
-------
TABLE V
THE INORGANIC CHEMICAL INDUSTRY, 1958 AND 1963
1963
1958
01
00
SIC
No.
2812
2813
2816
2819
2851
2871
2879
2892
No.
Total
37
460
97
678
1779
279
329
67
of Plants
+20 Emp.
34
148
52
326
650
198
108
47
Val. of Ship.
($1000)
523,944
387/912
486,464
3,008,028
2,281,967
734,314
453,521
180,817
Price Index
'57-59=100
94.8
94.8
91.1
94.8
91.1
99.9
99.9
99.0
No. of Plants
+20 Emp.
32
178
57
301
600
207
101
58
Val. of Ship,
($1000)
425,431
262,581
412,011
2,146,254
1,753,923
611,103 ±!
347,628
169,699
Estimated from value added by manufacturing and 1963 "Water Use In Manu-
facturing" data.
These data are shown in terms of 1958 prices in Table VI.
-------
TABLE VI
NUMBER OF PLANTS AND VALUE OF SHIPMENTS,
1958 PRICES
1963
1958
2812
2813
2816
2819
2851
2871
2879
2892
No. Plants
more than
20 Emp.
34
148
52
326
650
198
108
47
wo. rj-ants
Val. of Ship, more than Val. of Ship,
($1000-'58) 20 Emp. ($1000)
552
409
533
3,173
2,504
735
453
182
,684
,190
,989
,025
,903
,049
,975
,643
32
178
57
301
600
207
101
58
425,431
262,581
412,011
2,146,254
1,753,923
611,103
347,628
169,699
Values of shipments in 1966 are given in Table VII in
terms of current and 1958 prices.
TABLE VII
VALUES OF INORGANIC CHEMICAL SHIPMENTS, 1966
2812
2813
2816
2819
2851
2871
2879
2892
Val. of
Ship., '66
($1000)
625,870
493,779
573,598
3,658,633
2,709,788
947,216
672,788
236,139
Price Index
'57-59=100
95
95
90
95
90
104.4
104.4
100.3
Val. of
Ship., '66
($1000-'58)
653,992
515,966
636,624
3,823,023
3,007,534
907,295
644,433
235,433
Values of shipments in 1968 and 1969 are given in Table
VIII.
59
-------
TABLE VIII
VALUES OF INORGANIC CHEMICAL SHIPMENTS, 1968 AND 1969
1968
SIC
No.
2812
2813
2816
2819
2851
2871
2879
2892
Val. of
Ship.
($1000)
891,000
630,000
658,000
4,386,000
3,255,000
1,089,000
780,000
501,000
Price Index
(•57-59=100)
98.4
98.4
92.2
98.4
92.2
100.3
100.3
110.0
Val. of
Ship.
($1000-'58)
905,488
640,244
713,666
4,457,317
3,530,369
1,085,743
777,667
455,455
1969
Val. of
Ship.
($1000)
955,000
665,000
696,000
4,510,000
3,445,000
1,089,000
830,000
517,000
Price Index
('57-59=100)
98.4
98.4
92.2
98.4
92.2
100.3
100.3
110.0
Val. of
Ship.
($1000-'58)
970,528
675,813
754,881
4,583,333
3,736,443
1,085,743
827,517
470,000
-------
In Figure 1, the number of plants with more than 20
employees is plotted against the values of shipments in
1958 dollars. Using the data in Figure 1 and assuming
that (1) the number of plants having water intakes of over
20 million gallons, (2) those having more than 20 employees,
and (3) the total number of plants will remain in the 1963
ratio, numbers of plants are estimated by year in Table IX.
TABLE IX
NUMBERS OF PLANTS IN THE INORGANIC
CHEMICAL INDUSTRY
Year
1958
1963
1966
1968
1969
Val. of
Ship.
($1000-I58)
6,128,630
8,545,458
10,424,300
12,565,949
13,104,261
No. of
Plants
(more than
20 Emp.
1534
1563
1586
1613
1620
No. of
Plants No. of
(more than Plants
20 mil, gal/yr) (Total)
476 2782
485 2835
492 2877
501 2926
503 2938
In 1963, the value of shipments of oxygen and nitrogen
totaled $202 million dollars, or 52% of the total value
of industrial gases. In 1967, the value of oxygen and
nitrogen was $282 million dollars, or 50.2% of the total
for SIC 2813 (Industrial Gases). Assuming that the
numbers of plants are in the ratio of the values of ship-
ments, the number of plants in the industry as defined
by this study are estimated as in Table X.
Year
1963
1966
1968
1969
TABLE X
NUMBERS OF INORGANIC CHEMICAL PLANTS
FOR STUDY PURPOSES
Number of Plants —
+20 mil, qal/yr
Total
2633
2675
2724
2736
446
453
462
464
i/ Nitrogen and oxygen only in SIC 2813
61
-------
FIGURE I-NO. OF PLANTS VERSUS VALUE OF SHIPMENTS
1750
ro
S
UJ
Q.
LU
O
CM
(A
I-
1700 -
1650 -
£ 1600
1550 -
1500
89 10 II f2
OF SHIPMENTS XMILUONS V95S
-------
In Table XI, productions of inorganic chemicals are
given for 1968 and projected by year through 1974.
TABLE XI
PROJECTED PRODUCTION OF INORGANIC CHEMICALS, 1968-1974
(millions of tons)
SIC
No. 1968 1969 1970 1971 1972 1973 1974
2812 . 24 25 26 28 30 32 34
2813 -/ 17.5 20.1 23.7 28.5 34.3 40.8 47.9
2816 1.20 1.25 1.29 1.37 1.44 1.51 1.59
2819 . 70 72 74 77 80 84 88
2851 -' 3.51 3.74 3.93 4.16 4.41 4.68 4.96
2871 41.5 41.0 42.3 43.9 46.1 48.0 49.9
2879 0.20 0.20 0.19 0.18 0.18 0.17 0.15
2892 ±f 0.98 1.04 1.08 1.11 1.15 1.20 1.27
From Chemical and Engineering News 1968 production and
Resource Engineering Associates projections
.?_/ From Resource Engineering Associates projection and
sp. gr.=1.0
,3/ From 1963 production and values and Resource
Engineering Associates projections
Production in the industry/ numbers of plants, and waste
discharges are projected from the above data in Table
XII. Numbers of plants are estimated as in proportion
to total industry production and in the ratios of plant
sizes and SIC distributions as in 1963. Eighty five
percent of the total production is assumed to have been
produced in large plants, as- is indicated by the plant
capacity data in Appendix B.
63
-------
TABLE XII
THE INORGANIC CHEMICAL INDUSTRY, 1963-74 I/
1963 1968
1969
1970
1971
1972
1973
1974
No. of Plants, Total
No. of Small Plants ±/
No. of Large Plants •*/
Production Total (billion Ibs)
Production/ Large Plants (bil.
Production, Small Plants (bil.
Municipal Sewer Discharges
(billion gal)
Large Plants (billion gal)
Small Plants (billion gal)
Wastewater, Not to Sewers,
Large Plants (bil. gal)
Cooling Water, Not to Sewers,
Large Plants (bil. ^al)
Gross Water Use, Large Plants
(bil. gal)
Value of Shipments, Total
(bil. 1958 $)
—' Based upon 1963 water use data and projected production
<20 million gallons per year
million gallons per year
Ibs)
Ibs)
2633
2187
446
-
-
—
59.0
53.7
5.3
211.8
922.9
2466
8.545
2724
2262
462
317.8
270.1
47.7
86.7
78.9
7.8
311.1
1356
3625
12.566
2736
2272
464
328.7
279.4
49.3
90.0
81.9
8.1
322.9
1407
3763
13.104
2754
2288
466
345
293
51
94
85
8
338
1475
3947
_
.0
.3
.7
.3
.8
.5
.4
2780
2309
471
368.4
313.1
55.3
100.5
91.5
9.1
360.7
1572
4211
_
2810
2334
476
395
335
59
107
98
9
386
1684
4514
_
.2
.9
.3
.6
.0
.7
.3
2842
2361
481
424
361
63
115
105
10
414
1807
4848
_
.7
.0
.7
.4
.2
.4
.5
2876
2389
487
455.5
387.2
68.3
123.6
112.7
11.1
443.9
1935
5197
_
-------
The data in Table XII are based upon the water uses
reported in 1963 and discharges are estimated from gross
water uses based upon projected production. In 1963,
large plants in the inorganic chemical industry used
(including recirculation) 2466 billion gallons of water
for all purposes and discharged 1134.7 billion gallons,
taking in 1287 billion gallons. The entire chemical
industry (SIC 28) reported a use of 7577 billion gallons
that year; the inorganic chemical industry thus used
about 32.5% of the total. A 1967 survey of the chemical
industry by the Manufacturing Chemists Association (2)
indicated a gross water use of 8340 billion gallons that
year. These data and the data in Table XII indicate
water uses in the inorganic chemical industry of 2711 and
3393 billion gallons per year, respectively. Inorganic
chemicals have shown a long term decrease in percentage
of the overall chemical market from 49.5% in 1958 to 40%
in 1968.
Data from the 1958 and 1963 Census of Manufactures and
from the 1967 MCA survey are shown in Table XIII.
These data generally apply to large plants in the chemi-
cal industry.
(2) "Toward a Clean Environment," Manufacturing Chemists
Association, 1967
TABLE XIII
WATER USE DATA, 1958-67
1958 y 1963 I/ 1967 I/
CHEMICALS & ALLIED PRODUCTS:
Intake, bil. gal. 3240 3889 4269
Gross Use, bil. gal. 5225 7577 8340
Discharges, bil. gal. 3061 3662 4085
Use Rate 1.61 1.95 1.95
Discharges as % of Use 58.5 48.3 48.9
65
-------
TABLE XIII (cont.)
1958 I/ 1963 y 1967 -
INORGANIC CHEMICALS:
Intake, bil. gal. 1287
Gross Use, bil. gal. 2466
Discharges, bil. gal. 1134.7
Use Rate 1.92
Discharges as % of Use 46.0
—' U.S. Bureau of Census, 1963 Census of Manufactures,
Water Use in Manufacturing
2/ Ref (2) MCA Survey, ibid
Table XIV shows projections of water uses and discharges
which incorporate all of the above data from Tables XII
and XIII. The data in Table XIII indicate that 1963 use
rates and discharge ratios may be used with confidence
since no significant changes are indicated. As indicated
above, the water use figures from Table XII have been
revised to incorporate the 1967 survey data, using the
average water use in 1967 of 3059 billion gallons calcu-
lated from use increases 1958-63, and a linear extrapola-
tion from 1963 to 1967 based upon values of shipments,
and the 1967 indicated use.
Data from the 1967 MCA survey of the chemical industry
are given in Table XV and ranges of plant capacities
in the inorganic chemical industry are shown in Table XVI.
Table XVI indicates an average plant capacity of 0.783
billion pounds per year and a median capacity of 0.319
billion pounds per year. This compares favorably with the
1969 average capacity in Table XIV of 0.602 billion pounds
per year. The data in Table XV indicate an average dis-
charge from large plants of wastewater to other than
municipal sewers of 0.657 billion gallons per year per
plant in 1967 for the chemical industry as a whole. Table
XIV and figures from the organic chemical industry study
(3) made in 1968 by this research team indicate an
average wastewater discharge of 0.755 billion gallons per
year per plant in 1968 from large plants. These figures
show an agreement within expected limits of accuracy.
(3) Projected Wastewater Treatment Costs in the Organic
Chemicals Industry, January, 1969, Federal Water
Pollution Control Administration, United States
Department of the Interior
66
-------
TABLE XIV
THE INOBGANIC CHEMICAL INDUSTRY, 1963-74 ±'
1963 1968 1969 1970
I/
Total No. of Plants
No. of Small Plants
No. of Large Plants
Production:
Total (billion Ibs.)
Large Plants (billion Ibs.)
Small Plants (billion Ibs.)
Municipal Sewer Discharges:
Total (billion gal}
Large Plants (billion gal)
Small Plants (billion gal)
Large Plant Discharges & Use:
Wastewater, Not to Sewers
(Ml. gal)
Cooling Water/ Not to Sewers
(bil/gal)
Gross Water Use (bil. gal)
Large Plants, Average Data:
Production, bil Ibs/yr/plant
Wastewater, bil gals/yr/plant
1971
1972
1973
211.8
275.4 284.9 298.9
319.2
342.4
367.9
1974
2633
2187
446
_
-
—
59.0
53.7
5.3
2724
2262
462
317.8
270.1
47.7
76.7
69.8
6.9
2736
2272
464
328.7
279.4
49.3
79.3
72.2
7.1
2754
2288
466
345.0
293.3
51.7
83.3
75.8
7.5
2780
2309
471
368.4
313.1
55.3
38.9
80.9
8.0
2810
2334
476
395.2
335.9
59.3
95.4
86.3
8.6
2842
2361
481
424.7
361.0
63.7
102.5
93.3
9.2
2876
2389
487
455.5
387.2
68.3
109.9
100.0
9.9
394.6
922.9
2466
0.475
1200
3207
0.585
0.596
1241
3317
0.602
0.614
1303
3481
0.629
0.641
1391
3717
0.665
0.678
1492
3987
0.706
0.719
1603
4284
0.751
0.765
1720
4595
0.795
0.810
i/ Ref (1) U.S. Census Bureau, ibid
Ref (2) Manufacturing Chemists Association 1967 Survey, ibid
-------
TABLE XV
1967 MCA SURVEY DATA
THE CHEMICAL INDUSTRY (2)
No. of Plants
Capital Investment in Wastewater
Treatment through 1966
Capital Investment in Wastewater
Treatment, 1962-1966
Capital Investment in Wastewater
Treatment, 1967-1971
Annual Operating Cost, 1967
Water Withdrawals
Water Used
Discharge to Surface Waters:
Cooling Water
Process Wastewater
Discharge to Public Sewers:
Cooling Water
Process Wastewater
Inorganic Waste Discharges:
To Surface Waters:
Dissolved
Undissolved
To Public Sewers:
Dissolved
Undissolved
Total Discharged
Total Discharged with No
Treatment
987
$385,268,000
$140,640,000
$235,700,000
$59,638,000
11.696 bil. gal/day
22.848 bil. gal/day
9.224 bil. gal/day
1.777 bil. gal/day
0.078 bil. gal/day
0.114 bil. gal/day
135.3 mil. Ibs/day
11.65 mil. Ibs/day
2.156 mil. Ibs/day
0.192 mil. Ibs/day
149.3 mil. Ibs/day
205.1 mil. Ibs/day
(2) Manufacturing Chemists Association 1967 Survey,
ibid
68
-------
TABLE XVI
RANGES OF CHEMICAL PLANT PRODUCTION CAPACITIES
Capacity Range,
Product tons/day
Caustic Potash 13.7 - 98.6
Caustic Soda 300 - 7800
Chlorine 180 - 7050
Soda Ash 205 - 10274
Titanium Dioxide 49.3 - 474
Ammonium Nitrate 30.1 - 1164
Nitric Acid 43.8 - 1096
Phosphoric Acid 47.4 - 1342
Phosphorous 16.4 - 389
Sodium Dichromate 41.1 - 247
Sodium Sulfate 21.9 - 753
Superphosphate 63.0 - 959
Ammonium Phosphate 19.2 - 630
Potash 27.4 - 1699
Calcium Carbide 54.8 - 822
Hydrofluoric Acid 27.4 - 137
Sodium Sulfite 8.2 - 397
—' Industry Product Profiles, Appendix C
Numbers of plants in the chemicals and allied products
industries in 1963 are shown in Table XVII by industry
segments and by intake water volumes.
TABLE XVII
NUMBERS OF PLANTS IN THE CHEMICAL INDUSTRY, 1963
Large Plants Small Plants
(more than 20 (less than 20
mil, gal) mil, gal)
Industry Total -/ 1129 6382.
Organic Chemicals
Industry 2/ 211 550
Inorganic Chemicals
Industry I/ 446 2187
Other Industry Segments 472 3645
69
-------
I/ 1963 Census of Manufactures
~2/ Ref (3) FWPCA Organic Chemicals Industry, ibid
3_/ Present study
Data from the 1967 survey of the chemical industry by
the Manufacturing Chemists Association as shown in Table
XV are extended on an annual basis and given in Table
XVIII.
TABLE XVIII
CHEMICAL INDUSTRY SURVEY DATA, 1967 (2)
No. of Plants
Total Employment
Capital Investment in Wastewater
Treatment through 1966
Capital Investment in Wastewater
Treatment, 1962-1966
Capital Investment in Wastewater
Treatment Projected, 1967-1971
Annual Operating Cost, 1967
Annual Manpower Requirements, 1967
Annual Water Intake, bil. gal.
Annual Water Use, bil. gal
Use Rate
Plant Effluents:
Cooling Water, to Public Sewers,
bil. gal
Process Wastewater, to Public
Sewer, bil. gal*
Cooling Water, to Surface Waters,
bil. gal.
Process Wastewater, to Surface
Waters, bil. gal.
Total Effluents, bil. gal
Contaminants in Effluents to
Surface Waters:
Dissolved Inorganics, mil..Ibs.
Undissolved Inorganics, mil. Ibs.
Dissolved Organics, mil. Ibs.
Undissolved Organics, mil. Ibs.
Contaminants in Effluents to
Public Sewers:
Dissolved Inorganics, mil, Ibs.
Undissolved Inorganics, mil. Ibs.
Dissolved Organics, mil. Ibs.
Undissolved Organics, mil. Ibs,
987
393,657
$385,268,000
$140,640,000
$235,700,000
$59,638,000
2096.1 man-years
4269
8340
1.95
28.33
41.65
3367
648.6
4085
49370
4252
1284
155.5
786.9
70.1
292
74.8
70
-------
TABLE XVIII (cont.)
Total Contaminants Produced:
Inorganics, mil. Ibs. 74857
Organics, mil. Ibs. 4191
(2) MCA 1967 Survey, ibid
The chemical industry, other than those segments defined
as "inorganic chemicals" and as "organic chemicals,"
includes operations producing inorganic and organic
compounds which appear in effluents. Assuming (1) that
process wastewaters from the inorganic chemical industry
contain only inorganic contaminants, (2) that process
wastewaters from the organic chemical industry contain
only organic contaminants, and (3) that effluents from
other segments contain proportionate amounts of each
wastewater volume, the characteristics of the industry's
discharge are estimated below in Table XX from the 1967
MCA survey, the 1963 census data, and the 1969 FWPCA
study of the organic chemicals industry.
Table XIX shows the estimated numbers of plants and
wastewater discharges in the chemical industry in 1967,
based upon the above three data sources.
TABLE XIX
CHEMICAL PLANT SIZES AND DISCHARGES-1967
Industry Segment
Inorganic Organic Other Total
Numbers of Plants:
Total 2706 833 4290 3829
Large G>20 mgy) 459 231 496 1186
Small (<20 mgy) 2247 602 3794 6643
Wastewater, Large Plants:
Not to Sewers (bil. gal) 263 383 133 779
Discharge to Sewers
(bil. gal). 73.2 78.2 70.1 221.5
71
-------
TABLE XX
CHEMICAL INDUSTRY DISCHARGES-1967
Industry Segment Discharges
Inorganic Organic Other Total
Discharges to Public Sewers:
Inorganics (mil. Ibs) 696.5 - 333.5 1030
Organic? (mil. Ibs) - 304.5 136.5 441
Discharges to Surface Waters:
Inorganics (mil. Ibs) 51429 - 13004 64433
Organics (mil. Ibs) - 1474 256 1730
Using the data in Tables XIX and XX and the MCA survey
data, prorating costs and manpower requirements on the
basis of wastewater discharges and relative contaminant
removals, the data in Table XXI are estimated for large
plants in the chemical industry in 1969.
TABLE XXI
CHEMICAL INDUSTRY COSTS AND MANPOWER-1969
Industry Segment
Inorganic Organic Other Total
Investment, mil. $ 130.306 399.773 102.473 632.552
Operating Costs,
mil. $/yr. 20.170 61.880 15.862 97.912
Manpower Use,
man-years/yr. 709 2175 558 3442
Assuming, as discussed in Chapter X, that the average
plant in the industry produces wastewaters containing 100
ppm suspended solids, 1000 ppm acidity and 3000 ppm
dissolved solids, and that present practice as defined by
the MCA survey (27% removal of contaminants) is achieved
by neutralization with equalization and sludge dewatering/
the following unit costs are as shown in Chapter IX for
the typical plant. Reverse osmosis is the method of
choice for demineralization (100% removal of contaminants)
as indicated by reasonable capital and operating costs.
Deep well disposal and evaporation ponds, although lower
in cost, are not always applicable due to local conditions
and, hence, were not shown.
72
-------
Capital Costs
% Removal Contaminants $/1000 gpd
27 (SS and Acidity)
100 (TDS)
300
2185
Operating Costs
C/1000 gal
26.0
51.5
Assume also that the capital costs involved in discharg-
ing to public sewers are those entailed in removing
suspended solids and neutralizing acidity. Therefore,
based upon the flows shown in Table XIV and the above
assumptions on unit capital costs, the capital costs for
the inorganic chemicals industry are estimated as shown
in Table XXII and XXIII. The capital costs for the 27%
removal level shown in 1969 thus represent the in place
capital for the existing levels of treatment in the in-
organic chemical industry in 1969 dollars.
TABLE XXII
CUMULATIVE INORGANIC CHEMICAL INDUSTRY CAPITAL COSTS,
1969-1974
Costs in Millions of 1969 Dollars
Removal 1969
1970
1971
1972
1973
1974
27
100
299.3 314.1 335.4 359.8
1808.4 1897.5 2026.3 2173.0
386.6 414.7
2335.0 2507.0
In terms of current dollars, and using an average of 3.6%
annual increase in the price level, total industry capital
costs are projected in Table XXIII.
TABLE XXIII
CUMULATIVE INORGANIC CHEMICAL INDUSTRY CAPITAL COSTS,
1969-1974
Costs in Millions of Current Dollars
Removal 1969
1970
1971
1972
1973
1974
27 299.3 325.4 359.9 400.1 445.4 494.7
100 1808.4 1964.0 2173.2 2416.3 2689.0 2970.0
73
-------
It should be underscored that the capital costs shown in
Tables XXII and in Table XXIII for 1969 are in terms of
1969 dollars. The capital costs for the chemical
industry shown in Table XXI are in terms of sums spent
over perhaps the preceding 30 years. Allowing for price
increases over such a period of time, the costs shown in
Table XXI for the inorganic segment of the industry
compare well with that portion of the 1969 costs in Table
XXII for the 27% level of treatment attributable to
large plants. Assuming that the operating costs
associated with discharges to municipal sewers at 10
cents per 1000 gpd, projected industry operating costs
are given in Table XXIV in 1969 dollars and in Table
XXV in current dollars.
TABLE XXIV
PROJECTED ANNUAL INORGANIC CHEMICAL
INDUSTRY OPERATING COSTS
Costs in Millions of 1969 Dollars
Removal 1969 1970 1971 1972 1973 1974
27 82.0 86.0 91.9 98.6 105.9 113.6
100 157.5 165.1 176.3 189.2 203.2 218.0
TABLE XXV
PROJECTED ANNUAL INORGANIC CHEMICAL
INDUSTRY OPERATING COSTS
Costs in Millions of Current Dollars
%
Removal 1969 1970 1971 1972 1973 1974
27 82.0 89.1 98.6 109.6 122.0 135.5
100 157.5 171.0 189.2 210.5 234.2 260.2
The plant survey data shown in Chapter VIII, based upon
costs per unit of wastewater flow, indicate that the
industry costs to achieve 85% removal of contaminants
other than dissolved solids in large plants in 1969 are
as follows:
74
-------
In place capital costs =
$223 x 978356 (1000 gpd) = $218,173,425
In place operating costs =
$58.49 x 978356 (1000 gpd) = $57,224,042/year
Addition of the costs associated with discharges to
municipal sewers by small plants show that the total
industry costs for the level of treatment described can
be estimated as follows:
In place capital costs =
224.0 million dollars
In place operating costs =
57.9 million dollars per year
The above costs would represent an overall removal of
wastewater contaminants of approximately 23%, i.e.,
85% removal of contaminants constituting 27% of the
total in the wastewaters. Comparison of these figures
with those in Tables XXII and XXIV shows good agreement
and tend to support the projections made.
75
-------
CHAPTER XII
QUALITATIVE MANPOWER REQUIREMENTS
Waste Treatment Manpower Structure
The effective operation and maintenance of an inorganic
chemical industry waste treatment facility requires the
combined efforts of many disciplines and vocations.
There is a need for administrative and support services,
technical management and services, treatment process
operations, and equipment maintenance. The relationship
of these four functional areas to waste treatment is
briefly described below.
Administrative Support and Services
Managerial-level support to waste treatment is required
to make decisions affecting waste treatment; to main-
tain cognizance over local, state, and Federal regula-
tory requirements; to establish organizational structures
to accomplish effective waste treatment; and to super-
vise subordinates in the implementation of waste
treatment objectives. The management staff is also
responsible for preparing reports to regulatory agencies
and maintaining an operational interface with such
agencies. Non-professional administrative services are
required in the form of supervisory personnel in the
areas of engineering and laboratory support, operations,
and maintenance.
Technical Managemer^t^ and Seryice^s
Technical services in support of waste treatment are
required in three principal areas: (1) to meet day-to-
day water analysis requirements necessary for effective
waste treatment; (2) to handle investigations into
special waste treatment problems which may arise; and
(3) to design and implement modifications or additions
to improve waste treatment efficiency/effectiveness.
Laboratory and engineering personnel within the regular
production organization of a large or medium sized plant
ordinarily provide all of these services. In the case
of smaller plants with limited personnel resources,
consultants in waste treatment and engineering are often
called upon to supplement technical staffs in dealing
with special problems.
76
-------
Typical chemical plants will have engineering and
laboratory personnel of the following types assigned to
production and research/development efforts within the
plant, and draw upon on a part-time basis for support
of the waste treatment facility:
DOT ±'
Chemical Engineer 008.081
Mechanical Engineer 007.181
Analytical Chemist 022.081
Inorganic Chemist 022.081
Engineering Analyst 020.088
Laboratory Technician 029.181
i/ Dictionary of Occupational Titles
Waste Treatment Operations
Just as a treatment system can vary from a single, rather
simple, process to a system with many complex individual
treatment processes, the skill and knowledge requirements
for competent water treatment operations vary consider-
ably. Specific demands depend on the nature of the
waste being treated and the processes comprising the
treatment system.
A common situation in the chemical industries is that
personnel operating the waste treatment facilities are
either grossly over-trained or grossly under-trained.
Professional people, such as chemical engineers, are
often in charge of the waste treatment facility without
a staff of properly trained personnel to direct. While
there is little doubt that professionals can properly
operate the facility, it is a poor utilization of their
skills and training. With under-trained personnel,
there is considerable risk of ineffective waste treat-
ment and damage to treatment equipment representing a
sizable capital investment, also a poor cost-effective
situation. Professionals cannot devote large amounts
of time to waste treatment operations without neglecting
their primary mission in the chemical plant, that of
efficiently producing chemical products. In a very
competitive industry such as the chemical industry,
there is not sufficient slack in the manpower pool to
permit uneconomic use of expensive talent. The practice
of assigning members of the production staff, often with
little or no formal or on-the-job training, to the
operations function of a treatment facility is equally
77
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unsound. The need for specially trained waste treatment
operators is obvious.
The lack of training in waste treatment has not neces-
sarily doomed past efforts to failure and, in fact, many
operations personnel are quite competent without having
the benefit of special training. There are two basic
reasons why the lack of specially trained operators has
not always spelled disaster in the treatment of chemical
industry wastes. First, much of the treatment process
equipment and appurtenances is very similar or identical
to unit process equipment used in the production of
chemicals, requiring significantly less additional skill
and knowledge than would otherwise be required. Secondly,
the relatively loose requirements of past years on the
permissible level of contaminants have resulted in many
typically marginal, uncomplicated, and easy-to-operate-
and-maintain treatment systems. However, with effluent
restrictions becoming increasingly more stringent, the
skill and knowledge requirements for operator personnel
will become more complex as more effective and complica-
ted systems are installed. With this in mind, major
emphasis in this chapter has been placed on the operator
role in waste treatment as waste treatment operation will
be in the near future, rather than as it now exists in
the chemical industries. It is the operations function,
along with an interwoven maintenance function, which will
undergo dramatic change in future years, with less of an
impact taking place in other functional areas.
Maintenance
Maintenance of treatment process equipment and appur-
tenances in the chemical industries is carried out by
both the operations personnel and skilled workers in
many vocational specialties. It is common practice
for operations personnel to perform routine preventive
maintenance while the more complicated maintenance,
primarily of a corrective nature, is the responsibility
of specialists drawn from the production manpower pool.
For example, preventive maintenance tasks, such as
lubricating pumps, are normally performed by waste
treatment operator personnel while corrective maintenance,
such as major repair or overhaul, is performed by a
specialist in the repair of pumps. The regular mainte-
nance staff of a typical medium or large sized chemical
plant will generally encompass the following occupa-
tional areas:
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DOT
Instrument Repairman 710.281
Maintenance Mechanic 638.281
Maintenance Machinist 600.280
Water Pump Serviceman 630.281
Pipe Fitter, Maintenance 862.381
Electrician, Maintenance 829.281
Carpenter, Maintenance 860.281
The smaller chemical plants often have quite small mainte-
nance staffs and supplement their maintenance capability
through contracts with equipment manufacturers and inde-
pendent maintenance firms.
Qualitative Manpower Requirements
It is obvious that critical responsibility for effective
and efficient treatment of wastewater rests with the
operators of the waste treatment facility. Therefore,
it is the operator of the facility and the equipment for
which he is responsible that govern the basic content of
this chapter.
Time was not available to develop specific qualitative
information for the administrative support and technical
management occupations. Such development would have
required augmenting existing DOT classifications with
information concerning duties involving water pollution
control and the type of training required.
While administrative and technical support is requisite
to the effective treatment of waste in the inorganic
chemical industry, the qualitative nature of these
support requirements will undergo less of a change in
future years than will the treatment processes and skills
required for operating and maintaining them. Descriptions
of the qualitative requirements for waste treatment in
the chemical industry will be concentrated on operations
and maintenance functions.
It is difficult to describe qualitative personnel re-
quirements in the chemical industry in terms of specific
industry segments or treatment systems. The contaminants
of wastewater vary considerably between inorganic indus-
try components and between plants producing the same
products. The volume of waste and options for treatment
are also quite varied, often due to geographic location
of the plant and restrictions placed upon disposal of
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industrial wastes into municipal sewerage systems. For
the sake of simplicity and clarity, qualitative personnel
requirements will be considered on a treatment process
basis. Just as chemical engineers look upon a chemical
processing system in terms of the unit processes which
comprise the system, it would appear most logical to look
at manpower requirements for a treatment system in terms
of the system's unit treatment components. Utilizing
this approach, each of the following treatment processes
has been analyzed individually to identify skill and know-
ledge requirements for operations and maintenance:
Chemical Addition
Equalization
Oil Removal
Sedimentation
Filtration
Reverse Osmosis
Electrodialysis
Ion Exchange
Multiple Effect Evaporation
Deep Well Injection
Lagooning/Cooling Ponds/Solar Evaporation Ponds
Centrifugation
Cooling Towers
Manpower requirements for each of these processes have
been subdivided into the basic categories of operations,
preventive maintenance, and corrective maintenance.
In so doing, it is anticipated that all of the critical
manpower requirements will have been identified for each
process. To identify the qualitative requirements for a
specific treatment system, it is only necessary to sum
the requirements of the treatment processes involved.
Naturally, the total requirements for a treatment system
will also involve the incorporation of administrative
and technical support requirements.
In determining personnel requirements, the following
assumptions were made with respect to manpower in the
chemical industries:
1. Waste treatment plant operators will perform routine
preventive maintenance tasks in addition to their
primary mission of operating and controlling unit
treatment equipment and appurtenances.
2. Professional and para-professional support in solv-
ing exceptional waste treatment problems will be
provided either through in-plant resources or
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through technical consultants hired on an as-needed
basis. Operator personnel should be capable of
recognizing the presence of problems, but they can-
not be expected to handle research investigations
to solve the problems.
3. Skilled craftsmen will perform all complex correc-
tive maintenance tasks on unit treatment equipment
and appurtenances. These craftsmen will be drawn
from in-plant resources in most cases, although in
some plants the repair and overhaul of equipment will
be handled through maintenance contracts with equip-
ment manufacturers or independent construction and
maintenance firms.
4. Laboratory analysis requirements for the treatment
of waste will be fulfilled through the use of
laboratory personnel and facilities currently
available in nearly all plants. Laboratory personnel
will be responsible for conducting routine analytical
tests, such as settleable solids, pH, oils, total
dissolved solids, acidity, alkalinity, phenols,
ammonia, cyanides, total sulfate, total chlorides,
and COD. The operator(s) of the waste treatment
facility will normally collect and label samples for
analysis. Operator(s) may perform simple tests, but
they will rely primarily upon automatic instrumenta-
tion (such as pH meters) and laboratory results for
controlling the waste treatment facility.
The above assumptions are currently valid for the chemical
industry, and it is felt that they will continue to be
valid well into the future.
Personnel requirements for each treatment process are
presented in two ways: a listing of the tasks neces-
sary for operating and maintaining the treatment
process, and a summary description of the occupational
areas encompassed by the tasks. The summary descrip-
tion represents a broad look at the occupations in-
volved in the operation and maintenance of waste treat-
ment facilities, while the task enumeration is intended
to relate the specific requirements for each occupa-
tional area.
Included as part of the task enumerations for each treat-
ment process, as shown in Appendix D, are several columns
indicating the occupational area to which the task is
related and the skill level judged appropriate to the
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task. There is also a column to indicate the frequency
with which the task would be performed under average
conditions. Task frequency is intended for general guid-
ance purposes only; quantitative aspects of manpower
requirements are covered in Chapter XIII.
It should be noted that for the corrective maintenance
function within each treatment process, no frequency
data are presented. Quantitative measures for this
function are presently unavailable; many of the processes
have never been fully exploited for waste treatment other
than on a pilot basis, and meaningful data concerning
frequency of task repetition have typically been neglected
by industry. The frequency for corrective maintenance
tasks is also subject to great fluctuation due to equip-
ment age and the environmental factors to which equipment
is exposed.
Skill levels for the tasks are defined on a numerical
scale of three discrete levels. Skill level numbers are
provided for the purpose of illustrating the relative
difficulty of the tasks as they relate to effective waste
treatment and, consequently, the skill and knowledge
requirements for the individual who has responsibility
for performing the tasks. The three skill levels are
defined as:
Skill Level 1
Skill Level 2
Relatively simple task which does not
require extensive training or experi-
ence. A high degree of proficiency
can generally be acquired without a
great deal of practice where there are no
stringent demands for speed or accuracy
and no requirements for drawing conclu-
sions or making decisions. Being shown
or told how to perform the task is
usually sufficient training.
Relatively complex task which requires
formal training on the procedures,
operating principles, and theory
involved. At least some on-the-job
training and experience are required
to gain specific equipment knowledge
and proficiency, facts and principles
must be analyzed and conclusions drawn,
and relatively routine decisions must
be made in order to preserve effective
waste treatment. There are some demands
for speed and accuracy.
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Skill Level 3 Highly complex task which requires for-
mal training and a great deal of
experience. Nomenclature, procedures,
operating principles, and complete
theory must be mastered for effective
completion of the task. Facts and
principles must be analyzed and evaluated
in order to reach proper decisions, speed
and accuracy requirements are quite
stringent, and non-routine situations
must be dealt with. Failure in perform-
ing the task will yield ineffective
waste treatment and may result in great
expense for damage or repairs.
The skill level indications can be most effectively used
after consolidating treatment process requirements
according to a particular system. The skill levels
will then provide a dimension for ascertaining appro-
priate quantitative proportions of personnel by skill
level. Greater attention is focused on this in the
next chapter.
It will be necessary for the user of the qualitative man-
power requirements to make certain deductions in order to
put the information into the context of a specific treat-
ment system application. In operating and maintaining
pumps, for example, the user must deduce that the tasks
listed will be performed on the particular type of pump
best suited to the liquids and volume, pressure, and head
requirements of this system. Tasks inappropriate to that
specific pump would be deleted, e.g., if only centrifugal
pumps would be used, those tasks for reciprocating and
diaphragm pumps would be unnecessary as personnel require-
ments.
Descriptions of Personnel
The following descriptions are provided as a brief con-
solidation of the qualitative manpower requirements for
waste treatment in the chemical industries. It should
be noted that there is not currently a Dictionary of
Occupational Titles (DOT) listing to accurately describe
the job responsibility of operations personnel in the
treatment of chemical industry waste. The titles of
waste treatment plant operator (inorganic wastes), waste
treatment plant attendant (inorganic wastes), and
waste treatment plant worker (inorganic wastes), are
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suggested on an interim basis and are not to be found in
the DOT. It is felt that standard listings adequately
describe qualitative requirements in other functional
areas of waste treatment; their inclusion here is for
completeness.
To determine the specific tasks included within each of
the job classifications, refer to Appendix D, Qualita-
tive Personnel Requirements for Treatment Processes.
Abbreviations found in the Appendix are defined as:
OP Waste Treatment Plant Operator
Ins Repmn Instrument Repairman
Mech Main Maintenance Mechanic
Lab Test Laboratory Technician
Pump Serv Water Pump Serviceman
Pipe Ftr Pipe Fitter, Maintenance
Elec Electrician, Maintenance
Waste Treatment Plant Operator (Inorganic Waste)
Suggested Occupational Classification Code; 955.120
Operates water treatment plant to remove thermal and
inorganic contamination from industrial wastewaters.
Monitors instrumentation panels and adjusts valves and
gates manually or by remote control to regulate the
processing and disposal of wastewater. Operates and main-
tains chemical addition, oil removal, sedimentation, fil-
tration, reverse osmosis, electrodialysis, ion exchange,
multiple effect evaporation, deep well injection, centrifu-
gation, and cooling tower treatment processes. Gives
directions and on-the-job training to waste treatment plant
technicians and waste treatment plant assistants in
operating and maintaining water treatment equipment.
Interprets instrumentation readings and water test re-
sults, compiles various operating records, and may perform
tests for pH, alkalinity, suspended solids, and total
dissolved solids.
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Qualifications Profile;
GED:i/ Applies principles of waste treatment
systems to solve a variety of practical
problems and deal with concrete variables
in situations where only limited standard-
ization exists. Interprets a variety of
instructions furnished in written, oral,
diagrammatic, or schedule form. Performs
ordinary arithmetic, algebraic, and geo-
metric procedures in standard, practical
applications. Comprehension and expres-
sion ability appropriate to the interpreta-
tion of technical manuals as well as draw-
ings and specifications such as layouts,
blueprints, and schematics.
SVP:^./ Over one year and up to two years of
vocational training, special short course
training, and essential experience on-the-
job. Technical skills and knowledge must
be acquired in all phases of the waste
treatment system for which the Waste
Treatment Plant Operator will assume
responsibility.
APTITUDE:
Intelligence - Middle third of the popula-
tion, ranging from slightly below to
slightly above average.
General Educational Development embraces those aspects
of education(formal and informal) which contribute to
the worker's (a) reasoning development and ability to
follow instructions, and (b) acquisition of "tool"
knowledges, such as language and mathematical skills.
It is education of a general nature which does not have
a recognized, fairly specific, occupational objective.
Ordinarily, such education is obtained in elementary
school, high school, or college. It also derives from
experience and individual study.
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Verbal - Middle third of the population,
ranging from slightly below to slightly
above average.
Numerical - Middle third of the population,
ranging from slightly below to slightly
above average.
Spatial - Middle third of the population,
ranging from slightly below to slightly
above average.
Form Perception - Middle third of the
population, ranging from slightly below
to slightly above average.
Clerical Perception - Lowest third of the
population, excluding the bottom 10 per-
cent of the population.
Specific Vocational Preparation refers to the time re-
quired to learn the techniques, acquire information,
and develop the facility needed for average performance
in a specific job-worker situation. This training may
be acquired in a school, work, military, institutional,
or avocational environment. It does not include
orientation training required of even fully qualified
workers to become accustomed to the special conditions
of any new job. Specific vocational training includes
training given in any of the following circumstances:
a. Vocational education (such as high school shop
training, technical school, and that part of college
training which is organized around a specific
vocational objective);
b. Apprentice training;
c. In-plant training (given by an employer in the form
of organized classroom study);
d. On-the-job training (serving as trainee on the job
under the instruction of a qualified worker);
e. Essential experience on other jobs (serving in less
responsible jobs which lead to the higher grade job
or serving in other jobs which qualify).
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Motor Coordination - Middle third of the
population, ranging from slightly below
to slightly above average.
Finger Dexterity - Middle third of the
population, ranging from slightly below to
slightly above average.
Manual Dexterity - Middle third of the
population, ranging from slightly below to
slightly above average.
Eye-Hand-Foot Coordination - Lowest third
of the population, excluding the bottom
10 percent.
ColorDJ.S crimination - Middle third of the
population, ranging from slightly below
to slightly above average.
INTERESTS: Preference for activities dealing with:
- things and objects;
- situations of a scientific or technical
nature; and
- situations of a routine, concrete,
organized nature.
TEMPERAMENTS: Worker must adjust to:
- situations involving the evaluation of
information against measurable or veri-
fiable criteria; and
- situations involving the precise attain-
ment of set limits, tolerances, or
standards.
PHYSICAL DEMANDS:
Light and medium work primarily limited
to reaching, handling, and feeling and
visual functions of acuity, near and far,
and color vision.
WORKING CONDITIONS:
The worker must adapt to working both
inside and outside, situations in which
he will be exposed to the definite risk
of bodily injury, and situations in
which he will be exposed to toxic dust,
fumes, gases, vapors, mists, or liquids
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which can cause localized disabling as
a result of inhalation or action on the
skin.
Related DOT Classifications:
Waste Treatment Operator (chem.) DOT 559.782
Senior Sewage-Plant Operator
(san. ser.) DOT 955.130
Waste Treatment Plant Attendant (Inorganic Waste)
Suggested Occupational Classification Code; 955.462
Tends pumps, liquid and dry chemical feeders, blowers,
sedimentation tanks, reverse osmosis units, electro-
dialysis units, ion exchange units, and other equipment
used to decontaminate inorganic industrial wastewaters.
Adjusts valves and gates manually or by remote control to
regulate the flow and pressure of feedwater to treatment
processing equipment; reads and interprets charts, flow
meters, and other gages to determine operating efficiency
of equipment; cleans, lubricates, and performs other
preventive maintenance on water treatment equipment and
appurtenances. Extracts samples, prepares process logs,
and records meter and gage readings. Assists and gives
directions to waste treatment plant assistants in perform-
ing routine operations as directed by the waste treatment
plant operator.
Qualifications Profile:
GED: Applies common sense in carrying out in-
structions furnished in written, oral,
or diagrammatic form. Deals with problems
involving several concrete variables in or
from standardized situations. Makes
arithmetic calculations involving frac-
tions, decimals, and percentages. Compre-
hension and expression ability must be
appropriate for the posting of data in logs
and on special report forms and records.
SVP: Over six months up to and including one
year of vocational training, special short
course training, and essential on-the-job
experience. Technical skills and knowledge
must be acquired in each of the treatment
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processes for which the Waste Treatment
Plant Attendant will assume responsibility.
APTITUDE:
Intelligence - Middle third of the popula-
tion, ranging from slightly below to
slightly above average.
Verbal - Middle third of the population,
ranging from slightly below to slightly
above average.
Numerical - Middle third of the population,
ranging from slightly below to slightly
above average.
Spatial - Middle third of the population,
ranging from slightly below to slightly
above average.
Form Perception - Middle third of the popu-
lation, ranging from slightly below to
slightly above average.
Clerical Perception - Lowest third of the
population, excluding the bottom 10 percent
of the population.
Motor Coordination - Middle third of the
population, ranging from slightly below to
slightly above average.
Finger Dexterity - Middle third of the
population, ranging from slightly below to
slightly above average.
Manual Dexterity - Middle third of the
population, ranging from slightly below to
slightly above average.
Eye-Hand-Foot Coordination - Lowest third
of the population, excluding the bottom
10 percent.
Color Discrimination - Middle third of the
population, ranging from slightly below to
slightly above average.
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INTERESTS: Preference for activities dealing with:
- things and objects;
- situations of a scientific or technical
nature; and
- situations of a routine, concrete,
organized nature.
TEMPERAMENTS: Worker must adjust to:
- situations involving the evaluation of
information against measurable or veri-
fiable criteria; and
- situations involving the precise attain-
ment of set limits, tolerances, or
standards.
PHYSICAL DEMANDS:
Light and medium work primarily limited to
reaching, handling, and feeling and visual
functions of acuity, near and far, and
color vision.
WORKING CONDITIONS:
The worker must adapt to working both in-
side and outside, situations in which he
will be exposed to the definite risk of
bodily injury, and situations in which he
will be exposed to toxic dust, fumes, gases,
vapors, mists, or liquids which can cause
localized disabling as a result of inhala-
tion or action on the skin.
Related DOT Classifications:
Waste Treatment Operator (chem.) DOT 559.782
Sewage Plant Attendant (san. ser.) DOT 955.885
Water Treatment Plant Mechanic
(water works) DOT 630.281
Sewage Plant Operator DOT 954.782
Waste Treatment Plant Worker (Inorganic Waste)
Suggested Occupational Classification Code; 955.787
Performs any combination of the following tasks in a
waste treatment plant to assist in the removal of
inorganic contaminants from industrial wastewater:
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Cleans and refills chemical tanks and hoppers/ cleans
filter screens using brushes and hose, and opens or
closes manually or remotely controlled valves or gates
according to warning lights, gage readings, and the
directions of waste treatment plant operator or waste
treatment plant technician. Scrapes and scrubs process-
ing tanks and equipment using chemicals and detergents,
loads and removes grit and sediment from tanks, sumps,
and catch basins using hand pumps, hoses, skinner hoes,
shovels, and pails. Cleans and paints process equipment
and appurtenances, lubricates pumps, valves and other
equipment using grease guns and oil cans, and checks for
leaks or other faults with process equipment.
Qualifications Profile:
GED: Applies common sense understanding to carry
out simple one or two step instructions.
Deals with standardized situations with
occasional or no variables in or from these
situations encountered on the job. Per-
forms simple addition and subtraction,
reading or copying of figures, or counting
and recording. Comprehension and expres-
sion ability must be appropriate to the
learning of job duties from oral instruc-
tions or demonstration and requesting
orally, or in writing, such supplies and
necessities as may be required on the job.
SVP: Anything beyond short demonstration up to
and including 30 days of vocational train-
ing, special short course training, and
on-the-job experience. Extensive skill
and knowledge of the waste treatment plant
operations are not pre-requisite to the
work.
APTITUDE:
Intelligence - Lowest third of the popula-
tion, excluding the bottom 10 percent.
Verbal - Lowest third of the population,
excluding the bottom 10 percent.
Numerical - Lowest third of the population,
excluding the bottom 10 percent.
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Spatial - Lowest third of the population,
excluding the bottom 10 percent.
Form Perception - Lowest third of the
population, excluding the bottom 10 percent.
Clerical Perception - Lowest third of the
population, excluding the bottom 10 percent,
Motor Coordination - Lowest third of the
population, excluding the bottom 10 percent,
Finger Dexterity - Middle third of the
population, ranging from slightly below to
slightly above average.
Manual Dexterity - Middle third of the
population, ranging from slightly below to
slightly above average.
Eye-Hand-Foot Coordination - Lowest third
of the population, ranging from slightly
below to slightly above average.
Color Discrimination - Middle third of the
population, ranging from slightly below to
slightly above average.
INTERESTS: Preference for dealing with:
- things and objects;
- situations of a routine, concrete,
organized nature; and
- situations that are non-social in nature,
and are carried out in relation to
processes, machines, and techniques.
TEMPERAMENTS: Worker must adjust to:
- situations involving repetitive or short
cycle operations carried out according
to set procedures or sequences; and
- situations involving doing things only
under' specific instructions, allowing
little or no room for independent action
in working out job problems.
PHYSICAL DEMANDS:
Medium and heavy work centered around
lifting, carrying, stooping, reaching, and
handling.
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WORKING CONDITIONS:
The worker must adapt to working both in-
side and outside, situations in which he
will be exposed to the definite risk of
bodily injury, and situations in which he
will be exposed to toxic dust, fumes,
gases, vapors, mists, or liquids which can
cause localized disabling as a result of
inhalation or action on the skin.
Related DOT Classifications:
Sewage Disposal Worker (san. ser) DOT 955.887
Sewage Plant Operator DOT 954.782
Instrument Repairman (Any Ind.) DOT 710.281
Installs, repairs, maintains, and adjusts indicating,
recording, telemetering, and controlling instruments used
to measure and control variables such as pressure, flow,
temperature, motion, force, and chemical composition,
using hand tools and precision instruments. Disassembles
malfunctioning instruments, and examines and tests
mechanism and circuitry for defects. Troubleshoots
equipment in or out of control system and replaces or
repairs defective parts. Reassembles instrument and
tests assembly for conformance with specifications, using
instruments such as potentiometer, resistance bridge,
manometer, and pressure gage. Inspects instruments
periodically and makes minor calibration adjustments to
assure functioning within specified standards. May
adjust and repair final control mechanisms such as
automatically controlled valves or positioners. May be
designated according to type of instrument repaired as
meter serviceman; panel-instrument repairman, pneumatic
control equipment repairman.
Carpenter, Maintenancej Any Ind.) DOT 860.281
Carpenter, repair; carpentry repairman. Constructs and
repairs structural woodwork and equipment in an establish-
ment, working from blueprints, idrawings, or oral instruc-
tions: Builds, repairs, and installs counters, cabinets,
benches, partitions, floors, doors, building framework,
and trim, using carpenter's handtools and power tools.
Installs glass in windows, doors, and partitions. Re-
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places damaged ceiling tile, floor tile, and sheet plas-
tic wall coverings. May build cabinets and other wooden
equipment in carpenter shop, using woodworking machines,
such as circular saw, bandsaw, and jointer.
Maintenance Mechanic (Any Ind.) II DOT 638.281
Repairs and maintains, in accordance with diagrams,
sketches, operation manuals, and manufacturer's specifi-
cations, machinery and mechanical equipment, such as
cranes, pumps, engines, motors, pneumatic tools, convey-
or systems, production machines, and automotive and con-
struction equipment, using handtools, power tools, and
precision-measuring and testing instruments: Observes
mechanical devices in operation and listens to their
sounds to locate causes of trouble. Dismantles devices
to gain access to and remove defective parts, using
hoists, cranes, handtools, and power tools. Examines
form and texture of parts to detect imperfections.
Inspects used parts to determine changes in dimensional
requirements, using rules, calipers, micrometers, and
other measuring instruments. Adjusts functional parts
of devices and control instruments, using handtools,
levels, plumb bobs, and straightedges. Repairs or replaces
defective parts, using handtools and power tools. In-
stalls special functional and structural parts in devices,
using handtools. Starts devices to test their perform-
ances. Lubricates and cleans parts. May set up and
operate lathe, drill press, grinder, and other metal-
working tools to make and repair parts. May initiate
purchase order for parts and machines. May repair
electrical equipment.
Laboratory Technician (Any Ind.) DOT 029.181
Performs laboratory tests according to prescribed stan-
dards to determine chemical and physical characteristics
or composition of solid, liquid, or gaseous materials
and substances for purposes such as quality control,
process control, product development, or determining
conformity to specifications: Sets up and adjusts
laboratory apparatus, and operates grinders, agitators,
centrifuges, ovens, condensers, and vibrating screens to
prepare material for testing according to established
laboratory procedure.-. Performs physical tests on samples
of cement or raw materials and controls quality of
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materials and mix during manufacturing process. Tests
raw materials, such as aggregate, limestone, and sand,
for s,uch qualities as permeability, load-bearing
capacity, or cohesiveness. Tests dry and liquid sub-
stances used as ingredients in adhesives, propellants,
lubricants, refractories, synthetic rubber, paint,
paper, and other compounds for purity, viscosity,
density, absorption or burning rate, melting point, or
flash point, using viscosimeter, torsion balance scale,
and pH meter. Tests solutions used in processes, such
as anodizing, water-proofing, cleaning, bleaching, and
pickling, for chemical strength, specific gravity, or
other specifications. Tests materials for presence and
content of elements or substances, such as hydrocarbons,
manganese, natural grease or impurities, tungsten,
sulfur, cyanide, ash, or dust. Tests samples of
manufactured products, such as cellophane or glassware,
to verify conformity with heat resistance, tensile
strength, ductility, and other specifications. Examines
materials, using microscope. Records test results on
standard forms, writes test reports describing proce-
dures used, and prepares graphs and charts. Cleans and
sterilizes laboratory apparatus. May prepare chemical
solutions according to standard formulas. May add
chemicals or raw materials to process solutions or
product batches to correct deviations from specifications
Water Pump Serviceman (Any Ind.) DOT 630.281
Repairs pumps and pump power units, such as centrifugal
and plunger-type pumps, and diesel-engine, gasoline-
engine, and electric-motor power units, using hoists and
mechanics' and electricians' handtools. Diagnoses
trouble in pumps. Dismantles pumps and repairs or
replaces defective parts, using handtools. Reseats and
grinds valves. Tests performances of repaired pumps.
May wire motor to switchboard and install fuse box.
May be designated according to type of pump repaired as
Water Pump Serviceman.
Pipe Fitter, Maintenance (Any Ind.) DOT 862.381
Determines defects in and maintains piping systems for
steam, gas, water, air, acid, and paints in industrial or
commercial establishments: Inspects system to ascertain
cause of malfunction. Reads blueprint or schematic
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drawings to determine work aids and procedures/ using
knowledge of high and low pressure systems, plumbing, and
pressure capacities of piping materials. Measures, cuts,
threads, and installs pipes, valves, gages, and other
fixtures, using handtools, pipe cutter, pipe-threading
machine, and pipe-bending machine. Paints and insulates
pipe and fittings. May repair, clean, and adjust control
devices, such as thermal and magnetic switches and relays.
May maintain and repair auxiliary equipment, such as
pumps and motors.
Electrician, Maintenance (Any Ind.) DOT 829.281
Repairs, maintains, and installs electrical systems and
equipment, such as motors, transformers, wiring, switches,
and alarm systems: Locates and determines electrical
malfunction, using test instruments, such as ammeter,
oscilloscope, and test lamp. Repairs malfunction by such
methods as replacing burnt-out elements and fuses, bypass-
ing or replacing defective wiring, filing switch contact
points, and cleaning or rewiring motors, using handtools.
Tests electrical equipment, such as generators and heaters
for safety and efficiency, using standard test equipment,
and by observing functioning. Installs fixtures, motors,
and other electrical equipment. Makes equipment adjust-
ment, using handtools. Inspects circuits and wiring for
specified shielding and grounding and repairs or rewires
system according to building codes and safety regulations.
May replace bearings in electric motors. May repair
mechanical, pneumatic, hydraulic, or electronic components
of electrical equipment, using standard tools, gages,
and procedures. May plan layout and wire new installa-
tions (Electrician). May be required to hold license.
May be designated according to equipment repaired as
Electrician, Crane Maintenance; Time Clock Repairman
(elec, equip.); or according to work location as Electri-
cian, Machine Shop (mach. shop); Electrician, Refinery
(petrol, refin.).
96
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CHAPTER XIII
QUANTITATIVE MANPOWER REQUIREMENTS
General
The next decade will witness a tremendous growth in the in-
vestment of manpower necessary to improve and preserve this
nation's water resources. The need for additional quali-
fied manpower will result primarily from an increase in the
volume of industrial waste effluent and an accelerated pro-
gram to decrease the level of wastewater contamination.
The latter factor, that of increasingly stringent require-
ments being placed upon waste effluent, is by far the more
important of the two factors. This chapter concerns itself
with projections of manpower requirements for effective
waste treatment in the inorganic chemical industry from two
basic views. First, manpower is projected through 1974
with respect to the degree of commitment felt necessary for
achieving specified levels of effluent quality. These pro-
jections are designed to reflect units of time, either in
man-hours per day or man-hours per year, for each occupa-
tional area defined in Chapter XII. The most important ap-
plication of these data will be in determining the human
resources necessary for operating a waste treatment system.
Secondly, manpower is projected with respect to the number
of persons who must be specially trained, or otherwise
qualified, to ensure effective wastewater treatment. These
projections are distinguished from the former in that they
deal with whole numbers of people and are directed spe-
cifically toward specific skills and knowledge related to
wastewater treatment. These projections are more useful
for their training implications than for forecasting ab-
solute labor requirements in wastewater treatment.
The method chosen for developing manpower projections cen-
ters around the unit treatments which comprise a waste
treatment system. Despite wide variation between chemical
plants, the nature of the waste, and the volume of waste
produced, the configuration and operational aspects of in-
dividual wastewater treatment units remain essentially con-
stant. It is felt that the development of manpower data
for unit treatments will not only assist in formulating the
manpower forecasts contained in this report, but will pro-
vide a prototype for future projections and for wastewater
treatment manpower needs in other industries.
A major assumption in utilizing quantitative measures on a
•unit treatment basis is that the data developed for unit
97
-------
treatment processes will be effectively additive across
processes within a system. If this is accepted (there has
been no evidence shown for rejecting it), then manpower re-
quirements for a total wastewater treatment system can be
estimated by summing across the treatment processes in-
volved in that system. While the technique shows real
promise, there are insufficient data at the present time to
fully verify the concept. To collect and organize statis-
tically significant data through empirical observation was
beyond the scope of the present effort. However, suffi-
cient data were collected through field visits and survey
forms to permit gross verification of the quantitative man-
power measures. In addition, the measures were judged to
be reasonably accurate through the subjective opinions of
a panel of experts in the field of waste treatment.
Although there is a profound lack of wastewater treatment
personnel data, there is a relative wealth of maintenance
cost information for chemical process equipment. J. D.
Leonard (1) conducted a rather comprehensive survey on this
subject during the late 1940's and early 1950's. If one
assumes that the maintenance requirements for waste treat-
ment equipment are similar to those for process equipment,
one can derive econometrically labor requirements from cost
data. Given D. E. Pierce's (2) equation
C = X (a + by)
where c = cost, dollars per year
x * KWHR per year/1000
y » cost in dollars per man-hour with
overhead
a = repair material in dollars/1000 KWHR
b « repair labor in man-hours/1000 KWHR
which states that maintenance cost is a function of use,
materials, and labor, one may with some confidence utilize
Leonard's cost data (in 1969 dollars). On further examina-
tion, it was soon realized that Pierce's equation must be
revised since available data would not support all of the
(1)J. D. Leonard, What Does Maintenance Cost, Chem. Eng.,
58(9): 149 (1951).
(2)D. E. Pierce, A Common Denominator for Repair Costs,
Chem. Eng. Procr., 44: 252 (1948).
98
-------
required variables. A more general equation was derived as
follows. If the ratio of labor cost to material cost is
known, one may show that
b = (R) (C) (S) / L
where b = operating and maintenance labor in
man-hours
R - ratio of labor costs to total operating
and maintenance costs
C = operating and maintenance cost per
year (1)
S = use of size factor
L = labor rate (3)
Many of the quantitative manpower measures in this report
are the result of applying this equation to available data
for treatment processes. R in each case was derived
through professional judgment of a number of experts in
the field of waste treatment.
Labor man-hours were distributed across the four functional
areas of Operations/ Maintenance, Technical Management and
Services, and Administration and Support Services in the
following manner. Based on professional judgment and his-
torical documentation, it would seem reasonable to split
total operating and maintenance time so that 85% of the
total would be considered operations plus preventive main-
tenance, and the remaining 15% would be corrective mainten-
ance. Assuming that "operator" personnel are responsible
for operating treatment equipment and performing necessary
preventive maintenance, and "maintenance" personnel perform
only corrective maintenance, it becomes possible to allo-
cate the calculated measure across the two functional areas,
Further, assume that Operations and Maintenance functions
combined represent only 80% of the total manpower require-
ments for a treatment system and the remaining 20% account
for Technical Management Services, and Administrative and
Support Services. Inspection of military and industrial
manpower data suggests that these two functional areas rep-
resent about 12.8% and 7.2%, respectively, of the total
manpower required for a typical organizational structure in
(1) J. D. Leonard, ibid
(3) Manufacturing Chemists Association, Inc., Chemical
Statistics Handbook, Washington, D.C., MCA, 1966.
99
-------
a technical environment. With the value already generated
for operating and maintenance labor, it is a simple matter
to calculate a grand total for the treatment process and
proportion labor time to Technical Management and Adminis-
trative functions. Having distributed time across the four
functional areas, distribution of time within each func-
tional area was based upon judgment of the proportional
contributions of each personnel type to the treatment pro-
cess. Each of the treatments applicable to manpower pro-
jections considered in this report was developed in this
manner. For treatment processes not included as part of
the manpower projections, but applicable to the inorganic
chemical industry, limited data are provided in a less re-
fined form.
Manpower projections were developed for two levels of treat-
ment, two sizes of plant, and for the years 1969 through
1974. Plants were categorized as large or small according
to volume of wastewater flow. Projected industrial growth
was expressed in terms of daily wastewater flow and number
of large and small plants. Average flow for large and
small plants and treatment levels are consolidated in the
following table:
LARGE PLANTS:
Level 1-27% removal
1969
1970 1971 1972 1973 1974
equalization
chemical addition
lagooning
1.
0.
1.
9
19
9
mgd
mgd
mgd
2.
0.
2.
0
2
0
2.
.
2.
1
21
1
2
2
.2
.22
.2
2
2
.4
.24
.4
2.5
.25
2.5
Level II - 100% removal
equalization
chemical addition
sedimentation
filtration
reverse osmosis
deep well
1.9
1.9
1.9
1.9
1.9
0.19
mgd
mgd
mgd
mgd
mgd
mgd
2.0
2.0
2.0
2,0
2.0
.20
2.1
2.1
2.1
2.1
2.1
.21
2.2
2.2
2.2
2.2
2.2
.22
2.4
2.4
2.4
2.4
2.4
.24
2.5
2.5
2.5
2.5
2.5
.25
100
-------
SMALL PLANTS:
Level I - 27% removal*
1969 1970
1971
1972
1973
1974
equalization 9,800 10,200 10,800 11,400 12,000 12,800
chemical
addition 9,800 10,200 10,800 11,400 12,000 12,800
lagoon 9,800 10,200 10,800 11,400 12,000 12,800
*It has been assumed that ultimate disposal of effluents
from small plants will be to municipal sewerage systems.
Quantitative Personnel Requirements for Treatment Processes
Quantitative personnel requirements on a treatment process
and waste volume basis are presented in the following para-
graphs. Operation and maintenance labor as a function of
use or size factor is included for reference purposes.
Labor values generated by this function are presented in
tabular form according to the proportional distributions
discussed earlier. It should be noted that the distribu-
tion of labor among specific personnel types varies among
treatment processes. Inspection of the qualitative data,
along with subjective rationalization of the ratios of per-
sonnel appropriate to the tasks involved, resulted in tai-
lored allocations for each treatment process.
Equalization
The primary components of an equalization treatment process
are pumps and tanks. The manpower estimates for this treat-
ment were derived by summing man-hour requirements for the
two components.
Using an R factor of 0.9 for centrifugal pumps, operations
and maintenance labor for pumps was computed to be:
26.5 man-hrs/year for 30 gpm, 50 ft. head
36.0 man-hrs/year for 100 gpm, 50 ft. head
90.0 man-hrs/year for 2,000 gpm, 50 ft. head
Labor associated with operation and maintenance of concrete,
stainless steel, or aluminum tanks was computed using the
formula, which was reduced to the simple function
man-hrs/year * 1.42 N, where N is tank capacity in gal./lOOO
101
-------
Labor for tanks was computed to be:
1.4 man-hrs/year for 1000 gal tank
11.3 man-hrs/year for 8000 gal tank
113 man-hrs/year for 80,000 gal tank
Combining the two yielded the following operations and
maintenance labor for equalization:
8,000 gpd to 13,000 gpd » 28 man-hrs/year
0.19 mgd to 0.25 mgd = 47 man-hrs/year
1.9 mgd to 2.5 mgd =203 man-hrs/year
Table I indicates how this labor was distributed across per-
sonnel for the various volumes of flow.
Chemical Addition
Operating and maintenance labor requirements for chemical
addition treatment were derived by extrapolating data for
limestone neutralization of acid mine drainage (4) . The
data are based on an acid content of 2,000 ppm to be neu-
tralized.
9,800 gpd = 650 man-hrs/year
10,200 = 700
10,800 = 740
11,400 = 760
12,000 = 780
12,800 - 800
0.19 mgd = 1750 man-hrs/year
0.20 « 1900
0.21 - 2100
0.22 = 2250
0.24 = 2400
0.25 = 2500
1.9 mgd = 4860 man-hrs/year
2.0 = 5020
2.1 » 5600
2.2 - 5900
2.4 = 6000
2.5 - 6100
(4) Engineering Economic Study of Mine Drainage Control Tech-
niques. Appendix B to Acid Mine Drainage in Appalachia,
A report by the Appalachian Regional Commission. Cyrus
Wm. Rice and Company, Pittsburgh, Pa., 1969
102
-------
TABLE I
EQUALIZATION
MAN-HOURS/YEAR
1.9 8,000-13,000
mgd gpd
Operation
17 2 Waste Treatment Plant Operator
51 7 Waste Treatment Plant Attendant
103 13 Waste Treatment Plant Worker
Maintenance
6 1 Instrument Repairman
15 2 Water Pump Serviceman
Maintenance Mechanic
3 1 Pipe Fitter, Maintenance
6 1 Electrician, Maintenance
Other Maintenance
Technical Management & Services
22 3 Laboratory Technician
10 1 Technical Management & Services
Administrative & Support
18 3 Administrative & Support Services
103
-------
The following Table II indicates how this labor was dis-
tributed across personnel for the various volumes of flow.
Lagooning
Operations and maintenance labor for lagoons was obtained
by summing the labor requirements for pumps with an esti-
mate of labor required for cleaning a lagoon on a periodic
basis. Labor for the cleaning operation was determined by
calculating the settleable solids likely to be deposited
as a function of waste volume and solids content of the ef-
fluent.
Assuming a settleable solids content of 500 ppmf the fol-
lowing estimates were made for removing settled solids on
a yearly basis:
9,800 gpd to 12,800 gpd = 7.5 cu.yd./yr =» <1 man-hr/yr
(Based on man-hours/year of heavy equipment operator time,
assuming that with the proper equipment [such as high lift]
solids can be removed at the rate of 35 tons per hour.)
1.9 mgd = 1295 cu.yd/year - 37 man-hours/year
2.0 « 1344 = 38
2.1 » 1436 - 41
2.2 = 1484 = 42.4
2.4 = 1619 » 46.3
2.5 = 1686 = 48.2
Adding 26.5 man-hours per year for a 30 gpm, 50 foot head
centrifugal pump (for 9,800 - 12,000 gpd volume) and 90.0
man-hours per year for a 2,000 gpm, 50 foot head centri-
fugal pump (for 1.9-2.5 mgd volume) yields the following
operations and maintenance labor for lagoons:
9,800 to 12,800 gpd = 27 man-hours/year
1.9 mgd =127 man-hrs/year
2.0 = 128
2.1 = 131
2.2 = 132
2.4 - 136
2.5 = 138
The following Table IJI indicates how this labor was dis-
tributed across personnel for the various volumes of flow.
It should be noted that corrective maintenance for this
treatment was assumed to be 85%, and preventive maintenance
and operations represent the remainder. Operational aspects
of lagooning are minimal.
104
-------
TABLE II
CHEMICAL ADDITION
MAN-HOURS/YEAR
O
Ui
Operation
2.5
2.4
2.2
2.1
2.0
1.9 mgd
0.25
0.24
0.22
0.21
0.20
0.19mgd
12,800
12,000
11,400
10,800
10,200
9,800gpd
Haste
Treat.
Plant
Operator
037
1020
1003
952
853
826
425
408
382
357
323
298
136
133
129
126
119
111
Haste
Treat.
Plant
Attendant
074
2040
2006
1904
1707
1652
850
816
765
714
646
595
272
265
258
252
238
221
Waste
Treat.
Plant
Horker
2074
2040
2006
1904
1707
1652
850
816
68
714
646
595
272
265
258
252
238
221
Instrument
Repairman
183
180
177
168
151
146
75
72
68
63
57
53
24
23
23
22
21
20
Hater Pump
Serviceman
183
180
177
168
151
146
75
72
68
63
57
53
24
23
23
22
21
20
Maintenance
Haint.
Mechanic
183
180
177
168
151
146
75
72
68
63
57
53
24
23
23
22
21
20
Pipe
Fitter
Maint.
183
180
177
168
151
146
75
72
68
63
57
53
24
23
23
22
21
20
Elect. Other
Maint. Maint.
183
180
177
168
151
146
75
72
68
63
57
53
24
23
23
22
21
20
Technical
Management
b
Services
Lab.
Tech.
488
480
472
448
402
389
200
192
180
168
152
140
64
63
61
59
56
52
Tech.
Mgt. 6
Serv.
488
480
472
448
402
389
200
192
180
168
152
140
64
63
61
59
56
52
Adro.
&
Support
Adm. &
Support
Serv.
549
540
531
504
451
437
225
216
202
189
171
158
72
70
68
67
63
59
-------
TABLE III
LAGOONING
MAN-HOURS/YEAR
2.5 2.4 2.2 2.1 2.0 1.9 9,800-12,800
mgd mgd mgd mgd mgd mg_d
4
25
12
4
25
12
4
24
12
4
23
12
4
23
11
4
23
11
19
19
10
19
19
10
18
18
9
18
18
9
18
18
9
18
18
9
49 48 46 46
45
45
18 18 17 17 16 16
444444
12 12 12 12 12 11
gpd
1
5
2
4
4
2
10
3
1
Operation
Waste Treatment Plant Operator
Waste Treatment Plant Attendant
Waste Treatment Plant Worker
Mai ntenance
Instrument Repairman
Water Pump Serviceman
Maintenance Mechanic
Pipe Fitter, Maintenance
Electrician, Maintenance
Other Maintenance I/
Technical Management & Services
Laboratory Technician
Technical Management & Services
Administrative & Support
Administrative & Support Services
=/Heavy Equipment Operator
-------
Sedimentation
Operating and maintenance labor for the sedimentation treat-
ment was developed using the general formula, which was re-
duced to
man-hours/year - 169.8 V
where V is tank volume in gal./2,000. The following data
were generated for clarifiers on the basis of handling 62
gallons per day per cubic foot of volume:
1.9 mgd = 1936 man-hrs/year
2.0 = 2053
2.1 * 2157
2.2 » 2258
2.4 = 2464
2.5 - 2567
The following Table IV indicates how this labor was dis-
tributed across personnel for the various volumes of flow.
Filtration
Operating and maintenance labor for filtration was based on
the utilization of a rotary vacuum filtration unit. The
general formula was reduced to
man-hours/year = .70 S
where S is the surface area of the filter in square feet.
Assuming suspended solids of 500 ppm and a filter capa-
bility of eight pounds per day per square foot, the follow-
ing was developed:
1.9 mgd » 623 man-hours/year
2.0 « 654
2.1 - 688
2.2 « 721
2.4 » 787
2.5 * 820
The following Table V shows the distribution of this labor
across personnel for the various volumes of waste flow.
107
-------
TABLE IV
SEDIMENTATION
MAN-HOURS/YEAR
2.5 2.4 2.2 2.1 2.0 1.9
mgd jngd mgd mgd mgd mgd
Operation
436 418 384 367 349 329 Waste Treatment Plant Operator
655 628 576 550 524 494 Treatment Plant Attendant
1091 1047 960 917 873 823 Waste Treatment Plant Worker
H
eo Maintenance
77 74 68 65 62 58 Instrument Repairman
77 74 68 65 62 58 Water Pump Serviceman
77 74 68 65 62 58 Maintenance Mechanic
77 74 68 65 62 58 Pipe Fitter, Maintenance
68 65 62 58 Electrician, Maintenance
Other Maintenance
Technical Management & Services
206 197 181 173 164 155 Laboratory Technician
206 197 181 173 164 155 Technical Management & Services
Administrative & Support
231 222 203 194 185 174 Administrative & Support Services
-------
TABLE V
FILTRATION
MAN-HOURS/YEAR
2.5 2.4 2.2 2.1 2.0 1.9
mgd mgd mgd mgd mgd mgd
Operation
139 134 122 117 116 106 Waste Treatment Plant Operator
209 201 184 176 167 159 Waste Treatment Plant Attendant
349 335 306 293 278 265 Waste Treatment Plant Worker
Maintenance
25
25
25
25
25
24
24
24
24
24
22
22
22
22
22
21
21
21
21
21
20
20
20
20
20
19
19
19
19
19
Instrument Repairman
Water Pump Serviceman
Maintenance Mechanic
Pipe Fitter, Maintenance
Electrician, Maintenance
Other Maintenance
Technical Management & Services
tag
sen
66 63 58 55 53 51 Laboratory Technician
66 63 58 55 53 51 Technical Management & Services
Administrative & Support
74 71 65 62 59 58 Administrative & Support Services
-------
Reverse Osmosis
Operating and maintenance labor for this treatment process
was developed through the extrapolation of data for reverse
osmosis treatment of acid mine drainage (4) . The figures
extrapolated were based on 1.67 mgd feedwater with total
dissolved solids of 500 ppm and total acidity of 1667 ppm.
Corrective
Maintenance
Preventive
Maintenance
and
Operations
Total Operating
and Maintenance
Labor
1.9 mgd 1750 man-hrs/yr 3750 man-hrs/yr 5500 inan-hrs/yr
2.0
2.1
2.2
2.4
2.5
1800
1850
1900
1950
2000
3800
3850
3900
3950
4000
5600
5700
5800
5900
6000
The following Table VI indicates how this labor was dis-
tributed across personnel for the various volumes of flow.
It should be noted that corrective maintenance for reverse
osmosis represents one-third of total labor; for most other
treatment processes corrective maintenance represents about
15% of the combined labor.
Deep Well Injection
Operations and maintenance labor for deep well injection
was derived through the general formula, which was reduced
to
man-hours/year = .00066 G
where G is gallons per day. Labor for deep well was com-
puted to be:
0.19 mgd « 125 man-hours/year
0.20 - 132
0.21 » 139
0.22 - 145
0.24 - 159
0.25 = 165
(4) Cyrus Wm. Rice and Company, 1969, ibid
110
-------
TABLE VI
REVERSE OSMOSIS
MAN-HOURS/YEAR
2.5 2.4 2.2 2.1 2.0 1.9
mgd mgd mgd mgd mgd mgd
Operation
1600 1580 1560 1540 1520 1500 Waste Treatment Plant Operator
1600 1580 1560 1540 1520 1500 Waste Treatment Plant Attendant
800 790 780 770 760 750 Waste Treatment Plant Worker
Maintenance
200 195 190 185 180 175 Instrument Repairman
800 780 760 740 720 700 Water Pump Serviceman
600 585 570 555 540 525 Maintenance Mechanic
200 195 190 185 180 175 Pipe Fitter, Maintenance
200 195 190 185 180 175 Electrician, Maintenance
Other Maintenance
Technical Management & Services
384 378 371 365 358 352 Laboratory Technician
576 566 557 547 538 528 Technical Management & Services
Administrative & Support
540 531 522 513 504 495 Administrative & Support Services
-------
The following Table VII indicates how this labor was dis-
tributed across personnel for the various volumes of
throughput.
Projected Manpower Requirements
Manpower requirements for the inorganic chemical industry
were compiled by summing the requirements for individual
treatment processes. The manpower requirements are ex-
pressed in man-hours per year for all categories of per-
sonnel. In addition, the three operator classifications
are expressed in man-hours per day, based on 365-day op-
eration of the waste treatment facility. For many of the
personnel it should be assumed that a requirement will not
exist on a day-to-day basis, but rather that a requirement
will occur sporadically in much larger units of time. For
example/ maintenance personnel will generally contribute a
large block of time in a single unit and then not be called
upon again for some time. For maintenance personnel, as
well as administrative and technical support personnel,
man-hours per year is more meaningful than man-hours per
day.
Tables VIII through XII summarize manpower requirements on
a treatment level basis for the years 1969 through 1974.
To simplify compilation of the total number of people in-
volved in waste treatment operations, and because there is
no reliable way to predict exactly how a plant will choose
to delegate specific personnel types, the manpower data for
all three operations classifications have been combined to
reflect total operator manpower on a daily basis. The fig-
ures included for each personnel class will serve to iden-
tify the proportional division appropriate for the three
classifications of operator.
Number of Qualified Operators Required
It is the concensus of wastewater treatment experts that
there should always be a qualified individual on hand
during the operation of a waste treatment facility to
monitor and verify the effectiveness of waste treatment.
In order to provide such coverage, it will be necessary
to train and qualify more people than would normally be
required to actually operate and maintain the treatment
system. The backup capability has been neglected in past
years, and continued neglect will almost certainly result
in less-than-effective wastewater treatment in the future.
It has been quite common, particularly in industries op-
erating continuously or on multiple shifts, to have problems
112
-------
TABLE VII
DEEP WELL INJECTION
MAN-HOURS/YEAR
Operation
42 41 37 35 34 32 Waste Treatment Plant Operator
70 68 62 59 56 53 Waste Treatment Plant Attendant
28 27 25 24 22 21 Waste Treatment Plant Worker
Maintenance
322222 Instrument Repairman
10 10 9 8 8 8 Water Pump Serviceman
8 7 7 66 6 Maintenance Mechanic
3 2 2 2 2 2 Pipe Fitter, Maintenance
3 22 2 22 Electrician, Maintenance
Other Maintenance
Technical Management & Services
10 10 9 9 88 Laboratory Technician
16 15 14 13 13 12 Technical Management & Services
Administrative & Support
15 14 13 13 12 11 Administrative & Support Services
-------
TABLE VIII
LARGE PLANT
LEVEL I TREATMENT-27% REMOVAL
EQUALIZATION, CHEMICAL ADDITION, LAGOON
1969
1970
1971
1972
1973
1974
H-
H
319
.87
669
1.83
709
1.94
59
86
71
65
59
45
178
154
344
.94
720
1.97
760
2.08
63
90
75
69
63
45
190
166
378
1.04
788
2.16
829
2,27
69
96
81
75
69
46
207
182
403
1.10
840
2.30
880
2.41
74
101
86
80
74
46
219
194
429
1.18
892
2.44
931
2.55
78
106
91
85
78
48
232
206
446
1.22
926
2.54
965
2.64
81
109
94
88
81
49
240
214
Man-Hrs/Yr.
Man-Hrs/Day
Man-Hrs/Yr.
Man-Hrs/Day
Man-Hrs/Yr.
Man-Hrs/Day
Man-Hrs/Yr.
n
n
H
n
n
n
n
187
201
219
232
246
255
Operation
Waste Treatment Plant Operator
Waste Treatment Plant Attendant
Waste Treatment Plant Worker
Maintenance
Instrument Repairman
Water Pump Serviceman
Maintenance Mechanic
Pipe Fitter, Maintenance
Electrician, Maintenance
Other Maintenance
Technical Management & Services
Laboratory Technician
Technical Management & Services
Administrative & Support
Administrative & Support Services
-------
TABLE IX
LARGE PLANT
LEVEL II TREATMENT-100% REMOVAL
EQUALIZATION, CHEMICAL ADDITION, SEDIMENTATION
FILTRATION, REVERSE OSMOSIS, DEEP WELL INJECTION
1969
1970
1971
1972
1973
1974
cn
810
7.70
909
10.71
3614
9.90
406
946
754
403
406
977
1145
2829
7.75
4025
11.03
3743
10.25
421
976
779
418
421
1007
1180
3028
8.30
4280
11.73
4011
10.99
447
1017
815
444
447
1072
1246
3123
8.56
4439
12.16
4180
11.45
465
1051
844
462
465
1113
1292
3210
8.79
4568
12.52
4342
11.90
484
1083
870
481
484
1150
1331
3271
8.96
4659
12.76
4445
12.18
494
1110
893
491
494
1176
1362
Man-Hrs/Yr.
Man-Hrs/Day
Man-Hrs/Yr.
Man-Hrs/Day
Man-Hrs/Yr.
Man-Hrs/Day
Man-Hrs/Yr.
11
ir
ti
il
M
ii
1193
1229
1304
1352
1396
1427
Operation
Waste Treatment Plant Operator
Waste Treatment Plant Attendant
Waste Treatment Plant Worker
Maintenance
Instrument Repairman
Water Pump Serviceman
Maintenance Mechanic
Pipe Fitter, Maintenance
Electrician, Maintenance
Other Maintenance
Technical Management & Services
Laboratory Technician
Technical Management & Services
Administrative & Support
Administrative & Support Services
-------
TABLE X
SMALL PLANT
LEVEL I TREATMENT-27% REMOVAL
EQUALIZATION, CHEMICAL ADDITION, LAGOON
TOTAL EFFLUENT ASSUMED DISCHARGED TO MUNICIPAL SEWERS
1969
64
1970
1971
1972
1973
1974
141 122 129
.31 .33 .35
233 250 264
.64 .68 .72
236 253 267
.65 .69 .73
132
136
.36
.37
270
.74
273
.75
139 Man-Hrs/Yr,
.38 Man-Hrs/Day
277 284 Man-Hrs/Yr.
.76 .78 Man-Hrs/Day
280 287 Man-Hrs/Yr.
.77 .79 Man-Hrs/Day
Operation
Waste Treatment Plant Operator
Waste Treatment Plant Attendant
Waste Treatment Plant Worker
Maintenance
21
26
24
23
21
10
58
54
22
27
25
24
22
10
62
58
23
28
26
25
23
10
65
61
24
29
27
26
24
10
67
63
24
29
27
26
24
10
69
65
25
30
28
27
25
10
70
66
Man-Hrs/Yr.
n
n
II
n
n
ii
n
Instrument Repairman
Water Pump Serviceman
Maintenance Mechanic
Pipe Fitter, Maintenance
Electrician, Maintenance
Other Maintenance
Technical Management & Services
Laboratory Technician
Technical Management & Services
68
72
73
75
77
Administrative & Support
Administrative & Support Services
-------
TABLE XI
NUMBER OF OPERATOR PERSONNEL
ASSIGNED TO WASTE TREATMENT
LARGE PLANT
Treatment Level I
Assigned OP/Plant I/
No. of Plants
Total Assigned OP
LARGE PLANT
Treatment Level II
Assigned OP/Plant
No. of Plants
Total Assigned OP
SMALL PLANT
Treatment Level I
Assigned OP/Plant
No. of Plants
Total Assigned OP
LARGE PLANT
Treatment Level I
Assigned OP/Plant
No. of Plants
Total Assigned Op
LARGE PLANT
Treatment Level II
Assigned OP/Plant
No. of Plants
Total Assigned OP
SMALL PLANT
Treatment Level I
Assigned OP/Plant
No. of Plants
Total Assigned OP
1969
OP* A** w***
.87 1.83 1.94
Z= 4.64 rah/day
1
464
464
7.07 10.71 9.90
28.31
4
464
1856
.31 .64 .65
1.60
1
2272
2271
1972^
Oper Atnt Wrkr
1.10 2.30 2.41
E. - 5.81
1
476
476
8.56 12.16 11.45
32.17
5
476
2380
.36 .74 .75
1.85
1
2334
2334
1970.
Oper Atnt Wrkr
.94 1.97 2.08
C - 4.99
1
466
466
7.75 11.03 10.25
29. 03
4
466
1864
.33 .68 .69
1.70
1
2288
2288
1973
Oper Atnt Wrkr
1.18 2.44 2.55
£ • 6.17
1
481
481
8.79 12.52 11.90
33.21
5
481
2405
.37 .76 .77
1.90
1
2361
2361
1971
Oper Atnt
1.04 2.16
£ - 5.47
1
471
471
8.30 11.73
31.02
4
471
1884
.35 .72
. 1.80
1
2309
2309
1974
Oper Atnt
1.22 2.54
E. - 6.
1
487
487
8.96 12.76
33.90
5
487
2435
.38 .78
1.95
1
2389
2389
Wrkr
2.27
10.99
.73
Wrkr
2.64
40
12.18
.79
* Waste Treatment Plant Operator
** Waste Treatment Plant Attendant
*** Waste Treatment Plant Worker
I/ Based on aggregate of all three operator classifications:(man-equivalent)
117
-------
arise with waste treatment and have no qualified person
available to correct the situation. By providing backup
personnel, there would always be a qualified person to
handle critical situations when regularly assigned operator
personnel are absent due to sickness, vacations, or varia-
tions in shift assignments.
Since the number of shifts operated each day has a definite
impact on the number of trained Waste Treatment Plant Op-
erators required for backup coverage, appropriate shift
factors must be used. A shift factor of 5.0 to 5.2 (5) is
normally used in industrial and military applications to
estimate the number of persons required for continuous
three-shift operations. Multiplying this factor by the
number of people required per shift (one Waste Treatment
Plant Operator in this case) results in the number of
workers in that classification necessary to compensate for
vacations, sickness, and 40-hour work-weeks in a continuous
operation. When the daily manpower requirements exceed 24
man-hours, the shift factor is not applied to the excess;
backup is calculated on a one-to-one ratio for the residual.
For continuous operations on less than a three-shift basis,
it is normally appropriate to provide a minimum of one back-
up person in addition to those required on a daily basis.
This approach to compensating for the shift operations of
the chemical industries results in the following Table XII
(using 5.0 as the shift factor):
TABLE XII
TOTAL NUMBER OF TRAINED ASSIGNED WASTE
OPERATORS REQUIRED FOR TREATMENT PLANT
EACH WASTE TREATMENT OPERATORS £/
FACILITY 12345
-for 3 Shifts 55566
-for <3 Shifts 23456
Derived by dividing total operations man-
hours per day by eight hours per day per
employee, then rounding to next higher
whole number.
(5) Manpower and Organization Programming, Airways and Com-
munications Service Manual 26-1, 1 May 1957.
118
-------
According to a recent survey (6), about 64% of chemical
plants operate 24 hours per day, 365 days per year. The
remainder are divided among one and two-shift operations on
either a five or seven-day week. For the purposes of this
report, the 36% remainder is assumed to work on something
less than a three-shift basis, but on a seven-day week.
The following Table XIII was developed from all of the
considerations previously discussed.
(6) Toward a Clean Environment, A 1967 survey of the members
of the Manufacturing Chemists Association, MCA, 1967.
119
-------
TABLE XIII
NUMBER OF TRAINED WASTEWATER TREATMENT
PLANT OPERATORS REQUIRED
1969 1970 1971 1972 1973 1974
LARGE PLANTS
Treatment Level I
27% Removal
No. Tnd Op for 3 shifts
No. of 3-shift plants
Total - 3 shift
No. Tnd Op for < 3 shifts
No. of <3 shift plants
Total - <3 shift
No. Tnd Op Req for Ind.
LARGE PLANTS
Treatment Level II
10 0 % Remoya1
No. Tnd Op for 3 shifts
No. of 3-shift plants
Total - 3 shift
No. Tnd Op for <3 shifts
No. of <3 shift plants
Total - < 3 shift
No. Tnd Op Req for Ind.
SMALL PLANTS
Treatment Level I
Discharge to Sewers
No. Tnd Op for 3 shifts
No. of 3-shift plants
Total - 3 shift
No. Tnd Op for < 3 shifts
No. of < 3 shift plants
Total - <3 shift
No. Tnd Op Req for Ind.
55555
297 298 301 305 308
1485 1490 1505 1525 1540
2
167
334
2
168
336
2
170
340
2
171
342
2
173
346
5
312
1560
2
175
350
1819 1826 1845 1867 1886 1910
6
297
1782
5
167
835
6
298
1788
5
168
840
6
301
1806
5
170
150
6
305
1830
6
171
1026
6
308
1848
6
173
1038
6
312
1872
6
175
1050
2617 2628 2656 2850 2886 2922
555555
1454 1464 1478 1494 1511 1529
7270 7320 7390 7470 7555 7645
222222
818 824 831 840 850 860
1636 1648 1662 1680 1700 1720
8906 8968 9052 9150 9255 9365
120
-------
It must be noted in connection with the above numbers,
that they are based upon 100% of the indicated size plant
utilizing the treatment level shown. There is no estimate
of the fraction of large plants utilizing either treatment
level, except for 1969 where other considerations indicate
that on the average all large plants employ Treatment Level
I.
121
-------
APPENDIX A
INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM
Instructions
Dictionary
Form
122
-------
INDUSTRIAL WASTE TREATMENT DATA FORM
INSTRUCTIONS
The Industrial Waste Treatment Practices Data Form is to be
filled out in strict accordance with these instructions/ in
order that the data be of maximum utility. It must be born
in mind that the data will be read and processed by machine
and that entries must therefore be made in the numbered
fields in the proper locations and in the precise terms
specified. In order to avoid unnecessary copying, all en-
tries should be printed in block letters and large figures,
preferably in red or black ink. These instructions are
given for the indicated sections of each data card in order
as they appear on the form.
DOCUMENT TO DATA CENTER BY
Date Name
REVISION TO DATA CENTER BY
Date Name
INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM
| CARD 1 | GENERAL INFORMATION
The information on this card identifies the plant and the
firm and is data of a permanent nature, not likely to
change. The name of the individual sending the completed
form or a revised form to the Data Center and the date of
forwarding should be entered as indicated? The number of
sheets comprising the form should be entered, as well as
the number of the revision being made.
PLANT NO. | I I I I |
1 2
A serial number, beginning with 00001, is to be assigned to
each plant for which data are acquired. Under some circum-
stances, it may be preferable to treat portions of a large
plant as a separate plant for the purposes of this form.
INITIAL FORM NO. II I I I I I
6 7 8 9 10 11
A serial number, beginning with 000001, is to be assigned
123
-------
to each form filled out. The number of the first form
filled out for the plant in question is to be entered here
in every case.
INITIAL? | | | |
Yes No
Indicate by mark (X) whether or not the form being filled
out is the first for the plant in question. If other than
an initial form is being completed, skip to Card 2, unless
a revised form is being submitted.
INDUSTRY S.I.C. NO.
12 13 14 15
Describe the industry within which the plant in question
falls and enter the 4-digit Standard Industrial Classifica-
tion (S.I.C.) number for this industry as found in the
Standard Industrial Classification Manual/ Bureau of the
Budget, latest edition.
FIRM PLANT
Enter the name of the firm owning the plant in question
(this may be a governmental entity or a subsidiary of
another firm) and the official name of the plant.
YEAR PLANT CONSTRUCTED [
16 17 18 19
Enter the year of the initial construction at the plant
site without regard to subsequent modifications.
STATE CODE [
20 21
Enter the name of the state or other territory in which the
plant is located and the 2-digit code taken from the Dic-
tionary.
CITY AND/OR COUNTY CODE I I I I I I
22 23 24 25 26
Enter the name of the city and/or county in which the plant
is located. Enter the 5-digit code from the Dictionary if
124
-------
such a code is listed; codes will be assigned by the Data
Center as specific locations appear on completed forms and
thus none will initially be listed. Source of this code
will be the Zip Code as found in the United States Post
Office Directory.
STATISTICAL AREA CODE | \ \ \
27 28 29
Enter the name of the Standard Metropolitan Statistical Area
(if any) in which the plant is located. Enter the code num-
ber which is the rank number of that area as found in
Statistical Abstracts of the United States, Section 34,
Bureau of the Census,88th Edition (1967).
ECONOMIC AREA CODE [_
30 31
Enter the name (if any) of the economic area in which the
plant is located and enter the 2-digit code number taken
from the Dictionary.
WATER RESOURCE REGION CODE j |
"~" 32 33
Enter the name of the Water Resource Region, as designated
by the Office of Water Resources Research for Type I
Surveys, in which the plant is located and the 2-digit code
number taken from the Dictionary.
Manor Minor
RECEIVING STREAM CODE | T I I I I
34 35 36 37
Enter the name of the stream or other body of water in which
plant effluents do or would discharge and the 4-digit code
taken from the Dictionary; the first two digits designate
the major river basin and the last two the minor river basin
in which the receiving stream lies. The codes correspond to
the STORET system.
Month Year
DATE OF DATA ACQUISITION | | | I I 1
38 39 40 41
BASE YEAR I I ill
42 43 44 45
125
-------
Enter the month and year that data being tabulated were
acquired and enter the year upon which costs are based.
All cost data are to be converted to the base year shown,
using the Engineering News Record Construction Cost Index
or other suitable cost indicator series.
SINGLE PLANT FIRM 1 | MULTIPLANT FIRM | |
46 47
Indicate by mark (X) whether the plant in question is the
only plant which the firm operates or is one of two or more
plants.
SIZE OF FIRM:
GROSS SALES ($1000 PER YEAR) I i I I I I I I
48 49 50 51 52 53 54
Enter the gross sales of the firm owning the plant in ques-
tion in thousands of dollars per year.
SUBSIDIARY OF | |
55
Enter the name of the parent firm of the firm owning the
plant and indicate by mark (X) if the firm is a subsidiary
of another.
SIZE OF FIRM IN THE INDUSTRY (% OF MARKET) I I I I
56 57 58
Enter the percentage of the market that the firm owning the
plant has in the indicated S.I.C. industry. Enter 000 if
the firm has no substantial market position; leave blank if
unknown.
SIZE OF FIRM IN THE INDUSTRY: LARGE | | MEDIUM
59
SMALL r~|
Indicate by mark (X) the relative size of the firm"owning
the plant as compared to other firms in the industry.
126
-------
OWNERSHIP OF FIRM: PUBLICLY TRADED STOCK
CLOSELY HELD f"I
Indicate by mark (X) whether the firm's stock is publicly
traded (on an exchange or over-the-counter) or is closely
held.
DEFENSE-ORIENTED ||
PUBLICLY REGULATED FIRM
Indicate by mark (X) if the firm is publicly regulated (such
as a common-carrier or utility) and if the firm produces
substantially for national defense (such as aircraft or
ordnance).
REVISION DATE
REV.
J__ ] END OF CARD
78 79
CARD 2\ BASES FOR TREATMENT DECISIONS
The information on this card relates to the bases upon which
decisions were made to institute (or not to initiate) pollu-
tion abatement measures at the plant in question.
| SAME AS CARD 1 |
1 II
DATA FORM NO. | | \ \ \ \\
12 13 14 15 16 17
Enter the serial number of the form being completed, which
may or may not be the same as the Initial Form No. on Card
1.
DATA BY
Name
Person Source
CODE ii ir~r~i
18 19 20 21
Month Year
DATE I I III I
22 23 24 25
Enter the name of the individual completing the form and
the 2-part code from the Dictionary, which classifies the
individual and his source of data. Enter the month and
year in which the form is completed.
127
-------
BASIS OF TREATMENT STANDARDS
COMMON LAW | |
26
STATUTE LAW [
27
PUBLIC OPINION
WITHIN FIRM | | COURTS: FEDERAL | | STATE | | LOCAL
29 30 ^1
ORDER
STATE
ORDER
PRECEDENT | | AGENCIES: FEDERAL
34 _ ~3!
INTERSTATE | | LOCAL [ | REGULATIONS | |
J8 ^^
CONFERENCE | 1 HEARSAY ["" I
^2
__
| 1
Tl
Indicate by mark (X) the primary basis upon which the treat-
ment standards to be attained were determined. Note that
this is the basis upon which the required effluent quality
was decided, not the motive force in initiating treatment
action. For example, a plant may treat too rigid standards
in deference to public opinion in a case where the law or a
regulatory agency would be more lenient; a plant might also
agree to higher treatment standards in conference with a
regulatory agency than the letter of the law required. The
controlling basis is to be indicated.
ACTION INITIATION WITHIN THE FIRM:
CORPORATE CODE
PLANT CODE
43 44 45
46 47 48
Enter here the corporate or plant initiator of treatment
action, i.e., who started the activity which led to the
treatment action and enter the appropriate code from the
Dictionary.
BASIS OF ACTION DECISION:
PUBLIC OPINION F"|
OTHER
LAW
LEGAL ACTION
ECONOMIC INCENTIVE
CODE I I I I
53 54 55
Indicate by mark (X) the principle reason for the decision
to institute the treatment practices or describe the reason
and enter the appropriate 3-digit code from the Dictionary.
128
-------
BASIS OF TREATMENT DECISION:
LEAST COST: TOTAL r~] OPERATING ["""""1 CAPITAL | |
ECONOMIC RETURN | ' | WATER CONSERVATION [ |
59 6Q
MINIMUM COMPLIANCE | | ULTIMATE TREATMENT | |
61 62
OTHER CODE | __ I | ~|
63 64 65
Indicate by mark (X) the principle reason for the decision
to utilize the chosen treatment practice or describe the
reason and enter the appropriate 3-digit code from the Dic-
tionary .
RESPONSIBILITY FOR ACTION DECISION:
CORPORATE CODE | | | |
66 6768
PLANT CODE
69 70 71
Enter the corporate or plant source of responsibility for
the decision to initiate a treatment action, i.e., who ac-
tually decided to take the action. Of interest here is the
lowest management level to which such responsibility was
delegated. Enter the appropriate 3-digit code from the
Dictionary.
RESPONSIBILITY FOR TREATMENT DECISION:
CORPORATE CODE | I I "
72 73 7'4"
PLANT CODE | | | ""
75 76 77
Enter the corporate or plant source of responsibility for
the decision as to the specific treatment utilized, i.e.,
who actually decided upon one treatment method in pref-
erence to other alternatives. Enter the appropriate code
from the Dictionary.
SAME AS CARD 1 | END OF CARD |2~|
"75 79
129
-------
I CARD 3 [ PLANT PRODUCTION INFORMATION I
The information on this card is concerned with the primary
products produced by the plant for sale and with the normal
production schedule.
PRODUCTS: I I I I I | I I | |
18 21 27 30 36 39
I i II J J L
45 48 5457 63 66
Enter the principle products of the plant in terms as de-
scriptive, yet inclusive, as possible; use additional Cards
3 if the space is not adequate. Enter the appropriate
codes, if any, from the Dictionary; codes will be assigned
by the Data Center as specific products appear on completed
forms.
PRODUCTION CAPACITY:
Code 10X Unit Code 10X Unit
r—ICZ] through ill. I rn rn
23 24 25 26 27 67 68 69 70 71
Enter the yearly production capacity for each product in
appropriate physical units to three significant figures,
and indicate the magnitude by the power of ten multiplier.
Enter the code for the physical unit taken from the Dic-
tionary.
NUMBER OF S.I.C. REPRESENTED ABOVE
72 73
From the product listings, determine the number of Standard
Industrial Categories represented within the plant.
PRODUCTION SCHEDULE HRS. PER MO. [
74 75 76
Enter the number of hours per month during which the plant
normally operates production facilities on the basis of 730
hours per average month.
REMARKS: Describe here any significant peculiarities of
this plant's production processes, product mix,
etc.
130
-------
NO. OF CARDS 3|\ \ SAME AS CARD 2 | END OF CARD
77 78 79
Enter in field number 77 the number of Cards 3 completed
for this form.
CARD $ PLANT PRODUCTION INFORMATION II
The information on this card relates to production pro-
cesses, plant size and age, level of production technology,
and raw materials. Use additional Cards 4 only if the
space is inadequate for an item.
PRIMARY WASTE-PRODUCING PRODUCTION PROCESSES:
18
41
Enter the six principle waste-producing production processes
in terms as descriptive, yet inclusive, as the space will
allow. Enter the appropriate codes, if any, from the Dic-
tionary; codes will be assigned by the Data Center as
specific processes appear on completed forms.
SIZE OF PLANT:
10*
EMPLOYMENT | | | ""| | |
42 43 44 45 10X
VALUE ADDED (DOLLARS/YR) | | \ ~| | ~~~\
46 47 48 49
Enter the total employment within the plant, including man-
agement and administrative employees, and indicate the
magnitude by the power of ten multiplier.
(ACRES)
1 1
50
.Amount
CODE | | |
54 55 56
1 1
51 52 53
10* Unit
C **jf P Q
3 * J Q
PRODUCTION
Enter the total plant area in acres and the yearly produc-
tion of the plant in appropriate physical units to three
significant figures and indicate the magnitude using the
power of ten multiplier. Enter the code for the physical
unit taken from the Dictionary.
131
-------
SIZE IN THE INDUSTRY: SMALL || MEDIUM || LARGE ||
59 60 61
Indicate by mark (X) the relative size of the plant in
comparison to others within the industry.
AGE OF PLANT:
AGE IN YEARS | | | YEARS SINCE MAJOR MODIFICATION | | |
62 63 64 65
Enter the age of the plant in years and the number of years
since a major modification, in terms of the production
facilities.
LEVEL OF TECHNOLOGY:
OLD || AVERAGE [| ADVANCED
66 67
TYPICAL || UNIQUE ||
69 7a
Indicate by mark (X) whether the production technology used
in the plant is old, average, or advanced in comparison to
other plants in the industry and whether the technology is
typical or unique for that size plant in the industry.
RAW MATERIALS USED: | | | | [
71 72 75 76
Enter the principle raw materials used in the production
processes using the appropriate codes from the Dictionary.
NO. OF CARDS 4[~"| | SAME AS CARD 3 | END OF CARD | T"|
TT ^78 79
Enter in the field number 77 the number of Cards 4 completed
for this form.
132
-------
COST
PRIMARY MAJOR (C/10QO GAL USED)
PURPOSE SOURCE TOTAL TREATMENT
PRINCIPLE
TREATMENT
USE
(104qd)
18 19 20 21
"i.n
22 23
24 25
TOTAL Codes
COOLING
TOTAL
PROCESS I II
33 34 35 36 37 38 39 40
TOTAL
OTHER
Codes ________
I I I I 111, I
27 28 29 30 31 32
I I I I I III
42 43 44 45 46 47
48 49 50 51 52
I-D COD
53 54 55 56
57 58 59 60 61 62
Tabulate the indicated information for each major, separate-
ly identifiable water use within the plant and summarize as
totals or weighted average the information indicated for
cooling, process, and all other purposes. Note that costs
are to be in cents per 1000 gallons used to tenths of a
cent, i.e., the total costs of using water or the total
treatment costs divided by the total used (not the total
taken in unless reuse or recirculation is zero). Enter
the codes taken from the Dictionary for the major sources
for each use and for the major treatments for each use.
1QX
TOTAL WATER INTAKE
L_L
63 64 65
Enter the total volume of water taken into the plant from
all sources to three significant figures and indicate the
magnitude using the power of ten multiplier.
TOTAL WATER USE
(104gd)
10X
676 8 69
Enter the total volume of water used in the plant for all
purposes and indicate the magnitude using the power of ten
multiplier. The total water use is defined as the total
volume of water through all individual uses, i.e., intake
times the number of reuses.
133
-------
PROCESS WATER QUALITY:
SATISFACTORY || MARGINAL || UNSATISFACTORY
u_ u__, __
Indicate by mark (X) the general acceptability of process
water at the point of use (with the treatment being accord
ed) and describe the general quality in the space provided.
PROCESS WATER QUALITY REQUIREMENTS:
CODES
74 75 76 77
Describe the general quality of water needed for major pro-
cess uses and enter the codes taken from the Dictionary for
the 4 most critical quality parameters.
SAME AS CARD 4 END OF CARD
78 79
[CARD 6 | CHARACTERISTICS OF WASTE STREAMS
The information on this card (of which there may be several
per form) relates to the nature and volume of the various
waste streams generated by the plant operations.
WASTE STREAM NO. | j | OF | | | WASTE STREAMS
18 19 20 21
The major, separately identifiable waste streams are to be
numbered from 01 and a Card 5 completed for each. Enter
the corresponding serial number for the waste stream being
reported and the total number of such streams.
134
-------
TOTAL PLANT EFFLUENT I CALCULATED AS WEIGHTED AVERAGE
22
An additional Card 5 is to be completed when there are more
than one waste stream, describing the total of all waste
streams as a weighted average. In this case, indicate by
mark (X) in field number 22.
_10X
FLOW : gpd I II I ~
23 24 25 26
Enter the flow of the waste stream in gallons per day to 4
significant figures and indicate the magnitude by the power
of ten multiplier.
l.-ll. SPECIFIC PARAMETERS
28 70
Enter the average concentrations of the indicated items in
the waste stream in milligrams per liter; calculate as
weighted averages in the case of a calculated total effluent
stream.
± 10*
12. OTHERS _mg/l. 1 __ I _ I 1 l"~] P I CODE
71 72 73 TT""^ 75
Enter the total concentration of all other materials as item
12 to 3 significant figures and the magnitude by the sign
and power of ten multiplier. Enter the best code from the
Dictionary, i.e., the code that most nearly describes these
"other" materials in total.
REMARKS:
Describe in this space any aspects of the waste stream which
are unique and not adequately treated above.
| | |
Tl ^7
NO. OF CARPS 6| | | SAME AS CARD 5 | END OF CARD
Enter in field number 77 the number of Cards 6 completed for
this form.
135
-------
I CARD 7 1 WASTE TREATMENT AND/OR REDUCTION PRACTICES
Information on this card (of which there may be several per
form) relates to specific, separately identifiable and de-
scribable waste treatment and/or reduction practices used
in the plant.
PRACTICE NO. OF PRACTICES IN USE IN PLANT
18 19 20 21
Each practice is to be numbered from 01 and a Card 6 com-
pleted for each. Enter the serial number of the practice
being reported and the total number of such practices in
the plant.
PRACTICE INSTITUTED IN CONNECTION WITH ABATEMENT OF POLLU-
TION FROM WASTE STREAM NOS. | | | | | | | [ | | | |
22
Indicate the numbers of the waste streams as given on Cards
6 for which the reported practice was instituted.
DATA ON THIS CARD IS FOR A COMPLETE TREATMENT PLANT | |
^0
Indicate by mark (X) if the data on the card is for a com-
plete treatment plant. If the data given apply only to the
unit treatments listed, leave this space blank.
UNIT TREATMENTS:
31 45
Enter the unit treatments and their codes from the Diction-
ary which comprise the treatment plant or which are being
reported as parts of a treatment plant or practice.
INSTALLATION DATES: INITIAL 19 [
46 47
LAST MODIFIED 18 II
48 49
Enter the year in which the practice was first installed or
initiated and the year of the last significant modification,
136
-------
SIZE AND/OR LOADINGS: [
50 61
Indicate the size and/or loading of the treatment in appro-
priate units to 3 significant figures and enter the unit's
code taken from the Dictionary.
10X
CAPITAL COST $ | | | "~
62 63 64 65
LAND VALUE $ | | | ~| | ~~\
66 67 68 69
OPERATING COSTS $/YR. r~T
TO 71 72 73
Indicate the costs in dollars for land and capital equipment
and operating costs in dollars per year to 3 significant
figures and indicate the absolute amounts by the power of
ten multiplier. Operating costs include all costs such as
labor, chemicals, utilities, etc., but exclude amortization
and depreciation.
EFFICIENCY, % ill ON BASIS OF _ CODE
74 75
Indicate the percentage efficiency of the reported prac-
tices, the basis of efficiency measurement, and enter the
code from the Dictionary describing that basis.
|~ | | SAME AS CARD 6 | END OF CARD
77 78 79
Enter in field number 77 the number of Cards 7 completed for
this form.
NO. OF CARDS 7
| CARD 8 | CHARACTERISTICS OF SLUDGES
The information on this card (of which there may be several
per form) describes the sludges produced in the plant,
treatment and disposal methods, and sludge handling costs.
137
-------
SLUDGE SOURCE NO. I | | OF
^^^__^ 18 19
| I | SLUDGE SOURCES IN PLANT
20 21
The major, separately identifiable sources of sludge in the
plant are to be numbered from 01 and a Card 7 completed for
each.
TOTAL OF SLUDGES IN PLANT \ CALCULATED AS AN AVERAGE
22
An additional Card 7 is to be completed which describes the
total of the sludges produced in the plant as a calculated
weighted average; in this case indicate by mark (X) in field
number 22.
10*
QUANTITY Ib/day | i I I I f I
23 24 25 26 27
Indicate the quantity of sludge produced in pounds of dry
solids per day to 4 significant figures and indicate the
magnitude by a power of ten multiplier.
DESCRIPTION OF SLUDGE:
CODE I II I
28 29 30 31
Describe the sludge and enter the appropriate descriptive
code from the Dictionary.
TREATMENT OF SLUDGE:
CODE II 111
32 33 34 35
Describe the in-plant treatment of sludge and enter the ap-
propriate descriptive code from the Dictionary.
138
-------
DISPOSAL OF SLUDGE:
CODE
36 37 38 39
Describe the sludge disposal method utilized and enter the
appropriate descriptive code from the Dictionary.
10*
CAPITAL COST $ I I I "~
40 41 42 43
LAND VALUE _ $ | | | "|
44 45 46 41
OPERATING COSTS _ $/YR. | | | ""
48 49 50
Indicate the costs in dollars for land and capital equipment
and operating costs in dollars per year to 3 significant
figures and indicate the absolute amounts by the power of
ten multiplier. Operating costs include all costs such as
labor, chemicals, utilities, transportation, etc. , but ex-
clude amortization and depreciation.
ULTIMATE DISPOSAL ) | SATISFACTORY | |
_ 52 5T"^
MARGINAL I 1 UNSATISFACTORY I H
' -g \ ' L- u u. '
54 55
Indicate by mark (X) if the sludge disposal method is ulti-
mate and similarly an appraisal of the degree to which the
entire sludge handling method reported is considered satis-
factory in general.
NO. OF CARDS 8 SAME AS CARD 7 END OF CARD
77 78 79 80
Enter in field number 77 the number of Cards 8 completed for
this form.
| CARD 9 | APERTURE CARDS
The first Card 9 is to contain a microfilm of all sheets
completed for inclusion in a single form. Additional Cards
9 may be used for this purpose, if a single microfilm will
not accommodate all sheets of a long form. In the latter
139
-------
case, print "TREATMENT PRACTICES DATA FORM" in fields 18
thru 46 and insert "001" for the code in fields 50-52.
Additional Cards 9 should be used for the microfilm storage
of other documents of interest such as process flowsheets,
treatment plant diagrams or flowsheets, detailed descriptive
material not accommodated on other cards, etc. Print a des-
cription of the documents to be filmed on the card in fields
18 thru 46 and insert an aperture code taken from the Dic-
tionary. It is preferred that different types of documents
not be combined on a single card.
APERTURE CODE j | | ""] NO. OF CARDS 9 f" |
50 51 52 53
Enter the aperture code from the Dictionary and indicate
the number of Cards 9 completed for this form.
SAME AS CARD 8 END OF CARD
78 79
| CARD 10 | MANPOWER UTILIZATION IN WASTE TREATMENT
The information on this card is concerned with the manpower
utilized to implement waste treatment practices in the
plant. Included here are the administrative functions re-
lating to negotiations with regulatory agencies, applica-
tions for discharge permits, etc., as well as the operating
and maintenance labor, technical help, and engineer inputs
to design, construction, and consulting. Use separate Cards
10 for individuals who have different functions, levels of
education, trades or professions, employment status, or work
areas.
FUNCTION:
Administration | | Analysis | | Operation
18 19 20
Maintenance | | Supervision | | Operator
, 2\ VI
Technician I | Laborer | | ENGINEERING:Process Design
24 25 26
Plant Design | | Consultant
140
-------
Indicate by mark (X) the function(s) which describes that
of the individual(s) reported on a single Card 10. More
than one field may be checked; for example, a laborer in
maintenance would be indicated by X's in fields 25 and 21,
or a technician in an analytical laboratory by X's in
fields 19 and 24. Include on a single Card 10 only in-
dividuals who have identical functions? use additional
Cards 10 for other functions.
OTHER CODE
29 30 31
Describe specialized functions which cannot be adequately
described as above and enter the appropriate 3-digit code
from the Dictionary.
EDUCATION AND/OR EXPERIENCE:
COLLEGE: B.S. || M.S. || PH.D. || 1 YR. | |
w ^ *J*j J ni «3 3
2 YRS. | 1 3 YRS. | 1 JUNIOR COLLEGE |~ |
^6"^ 37 3=8:
HIGH SCHOOL | | TECHNICAL SCHOOL | |
39 40
GRADE SCHOOL ["|
HHL
Indicate by a mark (X) the highest level of education of the
individual(s) reported on this Card 10. Do not check more
than one field.
YEARS WORKING EXPERIENCE | | |
42 43
YRS. IN SPECIALTY | I I
44 45
Enter the years of total working experience and the years
experience in the reported function for an individual on a
single Card 10. If more than one individual is reported on
a single Card 10, use the average figures in each case.
TRADE OR PROFESSION CODE
46 47 48
Describe the trade or profession of the individual(s) re-
ported on this Card 10 and enter the appropriate 3-digit
code from the Dictionary.
141
-------
WORK LEVELS AND COSTS:
NO. OF PERSONS
49 50
MAN-HOURS PER MONTH IIII
51 52 53 54
COSTS PER MAN-HOUR: WAGES $ | | | | |
55 56 57 58
TOTAL $ I|
59 60 61 62
Enter the number of persons reported on this Card 10 and
the total number of man-hours per month devoted to the
reported function by this individual(s). Enter the wages
received by the individual per hour and the total employ-
ment cost to the employer per hour; if more than one in-
dividual is reported on a single Card 10, use the average
figures in each case.
EMPLOYMENT STATUS:
FULL-TIME EMPLOYEE | | PART-TIME EMPLOYEE | |
63 64
OUTSIDE
% OF EMPLOYED TIME DEVOTED TO WASTE TREATMENT _ | | | %
_ 66 67
UNION MEMBER | | EXEMPT EMPLOYEE [ |
68 63""^
NON-EXEMPT EMPLOYEE f" I
70
Indicate by mark (X) whether the individual is a full-time
or part-time employee of the firm or is employed outside of
the firm. Indicate the percent of employed time devoted to
activities relating to waste treatment in the plant, in the
broad sense described above. Indicate by mark (X) if the
reported individual is a union member and whether or not he
is exempt from the provisions of the Wages and Hours Act.
WORK AREA:
COMPANY GENERAL | [ PLANT GENERAL | |
71 72
WASTE TREATMENT PLANT
Indicate by mark (X) whether the work level reported on this
Card 10 may be considered to be on behalf of the entire
142
-------
firm, the specific plant, or to waste treatment specifical-
ly. If the work reported on this Card 10 can be considered
to apply to a single waste treatment process, describe it
and enter the appropriate 3-digit code from the Dictionary.
REMARKS:
Describe here any peculiarities of the reported situation
not adequately described above.
NO. OF CARDS 10| I I SAME AS CARD 9 ~1 END OF CARD f~TO
1 ] I I J nun.— i __ I I •
77 78 79 80
Enter in field number 77 the number of Cards 10 completed
for this form.
143
-------
INDUSTRIAL WASTE TREATMENT DATA FORM
DICTIONARY
If any entry cannot be adequately described by a code number
in the Dictionary, the code fields are to be left blank;
s.uch codes will be assigned by the Data Center. However,
all information pertaining to the question should be re-
corded in the space provided for use by the Code Center.
In no case should a code be used which is not in the
Dictionary.
CARD 1 | | II | Standard Industrial Category
12 13 14 15
26 PAPER AND ALLIED PRODUCTS
261 Pulp Mills
2611 Pulp mills
262 Paper Mills, Except Building Paper Mills
2621 Paper mills, except building paper mills
263 Paperboard Mills
2631 Paperboard mills
264 Converted Paper and Paperboard Products, Except
Containers and Boxes
2641 Paper coating and glazing
2642 Envelopes
2643 Bags, except textile bags
2644 Wallpaper
2645 Die cut paper and paperboard; and cardboard
2646 Pressed and molded pulp goods
2647 Sanitary paper products
2649 Converted paper and paperboard products, not
elsewhere classified
265 Paperboard Containers and Boxes
2651 Folding paperboard boxes
2652 Set-up paperboard boxes
2653 Corrugated and solid fiber boxes
2654 Sanitary food containers
2655 Fiber cans, tubes, drums, and similar products
266 Building Paper and Building Board Mills
2661 Building paper and building board mills
28 CHEMICALS AND ALLIED PRODUCTS
281 Industrial Inorganic and Organic Chemicals
2812 Alkalies., and chlorine
2813 Industrial gases
2815 Dyes, dye (cyclic) intermediates, organic
pigments (lakes and toners) and cyclic
(coal tar) crudes
144
-------
2816 Inorganic pigments
2818 Industrial organic chemicals, not elsewhere
classified
2819 Industrial inorganic chemicals, not elsewhere
classified
282 Plastics Materials and Synthetic Resins, Synthetic
Rubber, Synthetic and Other Man-Made Fibers, Ex-
cept Glass
2821 Plastics materials, synthetic resins, and
nonvulcanizable elastomers
2822 Synthetic rubber (vulcanizable elastomers)
2823 Cellulosic man-made fibers
2824 Synthetic organic fibers, except cellulosic
283 Drugs
2831 Biological products
2833 Medicinal chemicals and botanical products
2834 Pharmaceutical preparations
284 Soap, Detergents, and Cleaning Preparations,
Perfumes, Cosmetics, and Other Toilet Prepara-
tions
2841 Soap and other detergents, except specialty
cleaners
2842 Specialty cleaning, polishing, and sanita-
tion preparations, except soap and deter-
gents
2843 Surface active agents, finishing agents,
sulfonated oils and assistants
2844 Perfumes, cosmetics, and other toilet prep-
arations
285 Paints, Varnishes, Lacquers, Enamels, and Allied
Products
2851 Paints, varnishes, lacquers, enamels and
allied products
286 Gum and Wood Chemicals
2861 Gum and wood chemicals
287 Agricultural Chemicals
2871 Fertilizers
2872 Fertilizers, mixing only
2879 Agricultural pesticides, and other agricul-
tural chemicals, not elsewhere classified
289 Miscellaneous Chemical Products
2891 Adhesives and gelatin
2892 Explosives
2893 Printing ink
2895 Carbon black
2899 Chemicals and chemical preparations, not
elsewhere classified
29 PETROLEUM REFINING AND RELATED INDUSTRIES
291 Petroleum Refining
2911 Petroleum refining
145
-------
295 Paving and Roofing Materials
2951 Paving mixtures and blocks
2952 Asphalt felts and coatings
299 Miscellaneous Products of Petroleum and Coal
2992 Lubricating oils and greases
2999 Products of petroleum and coal, not else-
where classified
33 PRIMARY METAL INDUSTRIES
331 Blast Furnaces, Steel Works, and Rolling and
Finishing Mills
3312 Blast furnaces (including coke ovens), steel
works, and rolling mills
3313 Electrometallurgical products
3315 Steel wire drawing and steel nails and spikes
3316 Cold rolled steel, sheet, strip, and bars
3317 Steel pipe and tubes
332 Iron and Steel Foundries
3321 Gray iron foundries
3322 Malleable iron foundries
3323 Steel foundries
333 Primary Smelting and Refining of Nonferrous Metals
3331 Primary smelting and refining of copper
3332 Primary smelting and refining of lead
3333 Primary smelting and refining of zinc
3334 Primary production of aluminum
3339 Primary smelting and refining of nonferrous
metals, not elsewhere classified
334 Secondary Smelting and Refining of Nonferrous
Metals
3341 Secondary smelting and refining of nonferrous
metals
335 Rolling, Drawing and Extruding of Nonferrous Metals
3351 Rolling, drawing, and extruding of copper
3352 Rolling, drawing, and extruding of aluminum
3356 Rolling, drawing, and extruding of nonferrous
metals, except copper and aluminum
3357 Drawing and insulating of nonferrous wire
336 Nonferrous Foundries
3361 Aluminum castings
3362 Brass, bronze, copper, copper base alloy
castings
3369 Nonferrous castings, not elsewhere classified
339 Miscellaneous Primary Metal Products
3391 Iron and steel forgings
3392 Nonferrous forgings
3399 Primary metal products, not elsewhere classi-
fied
146
-------
CARD 1
State Codes
01 Alabama
02 Alaska
03 Arizona
04 Arkansas
05 California
06 Colorado
07 Connecticut
08 Delaware
09 District of Columbia
10 Florida
11 Georgia
12 Hawaii
13 Idaho
14 Illinois
15 Indiana
16 Iowa
17 Kansas
18 Kentucky
19 Louisiana
20 Maine
21 Maryland
22 Massachusetts
23 Michigan
24 Minnesota
25 Mississippi
26 Montana
28 Nebraska
29 Nevada
30 New Hampshire
31 New Jersey
32 New Mexico
33 New York
34 North Carolina
35 North Dakota
36 Ohio
37 Oklahoma
38 Oregon
39 Pennsylvania
40 Rhode Island
41 South Carolina
42 South Dakota
43 Tennessee
44 Texas
45 Utah
46 Vermont
47 Virginia
48 Washington
49 West Virginia
50 Wisconsin
51 Wyoming
52 Puerto Rico
53 American Samoa
54 Canal Zone
55 Guam
56 U.S. Virgin Islands
57 Pacific Islands
Trust Territories
CARD 1
CITY AND/OR COUNTY
CODE
I -I J I
22 23 24 25^6
This code will correspond to the post office ZIP code for the
plant location, e.g., Crafton, Pennsylvania 15205
22 23 24 25 26
CARD 1
STATISTICAL AREA
CODE || |
27 28 29
147
-------
City
City
045 Akron, Ohio 043
093 Albany, N.Y. 007
059 Albuquerque, N. Mex. 026
116 Allentown, Pa. 084
088 Amarillo, Tex. 060
123 Anaheim, Calif. 047
024 Atlanta, Ga. 098
067 Austin, Tex. 027
006 Baltimore, Md. Ill
080 Baton Rouge, La. 118
102 Beaumont, Tex. 095
114 Berkeley, Calif. 117
036 Birmingham, Ala. 035
013 Boston, Mass. 003
079 Bridgeport, Conn. 031
020 Buffalo, N.Y. 094
119 Cambridge, Mass. 096
103 Camden, N.J. 022
109 Canton, Ohio 044
058 Charlotte, N.C. Oil
092 Chattanooga, Tenn. 025
002 Chicago, 111. 062
021 Cincinnati, Ohio 089
008 Cleveland, Ohio 073
104 Columbus, Ga. 125
028 Columbus, Ohio 081
074 Corpus Christi, Tex. 015
014 Dallas, Tex. 001
049 Dayton, Ohio (X)
110 Dearborn, Mich. (x)
023 Denver, Colo. (X)
055 Des Moines, Iowa (x)
005 Detroit, Mich. (X)
122 Duluth, Minn. 030
120 Elizabeth, N.J. 108
046 El Paso, Tex. 126
087 Erie, Pa. 041
086 Evansvilie, Ind. 033
061 Flint, Mich. 037
078 Fort Wayne, Ind. 042
034 Fort Worth, Tex. 105
090 Fresno, Calif. 085
070 Gary, Ind. 124
101 Glendale, Calif. 004
071 Grand Rapids, Mich. 029
099 Greensboro, N.C. 016
112 Hammond, Ind. 032
077 Hartford, Conn. 106
Honolulu, Hawaii
Houston, Texas
Indianapolis, Ind.
Jackson, Miss.
Jacksonville, Fla.
Jersey City, N.J.
Kansas City, Kans.
Kansas City, Mo.
Knoxville Tenn.
Lansing, Mich.
Lincoln, Nebr.
Little Rock, Ark.
Long Beach, Calif.
Los Angeles, Calif.
Louisville, Ky.
Lubbock, Tex.
Madison, Wis.
Memphi s, Tenn.
Miami, Fla.
Milwaukee, Wis.
Minneapolis, Minn.
Mobile, Ala.
Montgomery, Ala.
Nashville, Tenn.
New Bedford, Mass.
New Haven, Conn.
New Orleans, La.
New York, N.Y
Bronx Borough
Brooklyn Borough
Manhattan Borough
Queens Borough
Richmond Borough
Newark, N.J.
Newport News, Va.
Niagara Falls, N.Y.
Norfolk, Va.
Oakland, Calif.
Oklahoma City, Okla,
Omaha, Nebr.
Pasadena, Calif.
Paterson, N.J.
Peoria, 111.
Philadelphia, Pa.
Phoenix, Ariz.
Pittsburgh, Pa.
Portland, Oreg.
Portsmouth, Va.
148
-------
056 Providence, R.I.
052 Richmond, Va.
038 Rochester, N.Y,
09£ Rockford, 111.
063 Sacramento, Calif.
010 St. Louis, Mo.
040 St. Paul, Minn.
069 St. Petersburg, Fla.
065 Salt Lake City, Utah
017 San Antonio, Tex.
018 San Diego, Calif.
012 San Francisco, Calif,
057 San Jose, Calif.
130 Santa Ana, Calif.
082 Savannah, Ga.
113 Scranton, Pa.
019 Seattle, Wash.
076 Shreveport, La.
091 South Bend, Ind.
068 Spokane, Wash.
072 Springfield, Mass.
053 Syracuse, N.Y.
083 Tacoma, Wash.
048 Tampa, Fla.
039 Toledo, Ohio
100 Topeka, Kans.
128 Torrance, Calif.
107 Trenton, N.J.
154 Tucson, Ariz.
050 Tulsa, Okla.
129 Utica, N.Y.
009 Washington, D.C.
121 Waterbury, Conn.
051 Wichita, Kans.
127 Wichita Falls, Tex,
115 Winston-Salem, N.C,
066 Worcester, Mass.
064 Yonkers, N.Y.
075 Youngstown, Ohio
See STATISTICAL ABSTRACTS OF THE UNITED STATES, Section 34,
Bureau of the Census, 88th Edition (1967). The code number
will be the rank number of the area.
CARD 1
30 31
Economic Area Codes
01 New England Metropolitan State Economic Area
02 Labor Surplus Areas
03 Appalachia
CARD 1 | | I Water Resources Region Codes
32 33
01 Alaska
02 Arkansas-White-Red
03 California
04 Columbia - N. Pacific
05 Great Basin
06 Great Lakes
07 Hawaii
08 Lower Colorado
09 Lower Mississippi
10 Missouri
11 North Atlantic
12 Ohio
13 Puerto Rico-Virgin Islands
14 Rio Grande
15 Sooris-Red-Rainy
16 South Atlantic - Gulf
17 Tennessee
18 Texas - Gulf
19 Upper Colorado
20 Upper Mississippi
149
-------
Major Minor
CARD 1 1.1 1 I I 1 Receiving Stream Codes
34 35 36 37
01 NE - Northeast
01 Quinnipiac River & Western Connecticut Coastal
02 Housatonic River
03 Pawcatuck River & Eastern Connecticut Coastal
04 Connecticut River
05 Thames River
06 Narrangansett Bay
07
08 Massachusetts Coastal
09 Merrimac River
10 Piscategua River & New Hampshire Coastal
11
12 Saco River & South Main Coastal
13
14 Presumpscot River & Casco Bay
15 Androscoggin River
16 Kennebec & Sheepscot Rivers
17 Penobscot River
18 North Maine Coastal
19 St. Croix River
20 St. Johns River
21 Lake Memphremagog
22
23
24 Lake Champlain
25 St. Lawrence
26 Lake Ontario Shore - Oswego River to
St. Lawrence River
27 Niagara River
28 Genesee River
29 Oswego River
30 Mohawk River
31 Upper Hudson
32 Middle Hudson
33 Lower Hudson - New York Metropolitan Area
34 New Jersey Coast
35 Lake Erie Shore & Minor Tributaries
36 Lake Ontario Shore - Genesee River to
Oswego River
37 Lake Ontario Shore - Niagara River to
Genesee River
38 St. Regis River
02 NA - North Atlantic
03 Delaware River Basin - Zone 1
04 Delaware River Basin - Lehigh
150
-------
05 Delaware River Basin - Schuylkill
06 Delaware River Basin - Zone 2
07 Delaware River Basin - Zone 3
08 Delaware River Basin - Zone 4
09 Susquehanna River - North Branch
10 Susquehanna River - West Branch
11 Susquehanna River - Juniata
12 Susquehanna River - Main Stem
13 Upper Chesapeake Bay & Maryland-Delaware Coast
14 Potomac River
15 Rappahannock & York Rivers - Virginia Coast
16 James River
03 SE - Southeast
01 Chowan River
02 Roanoke River
03 Tar River
04 Neuse River
05 North Carolina Coastal Area
06 Cape Fear River
07 Yadkin-Pee Dee River
08 Pee Dee River - Lower Pee Dee River
09 Catawha-Wateree River
10 Congaree River
11 Santee-Cooper River
12 Edisto-Combahee River
13 Savannah River
14 Ogeechee River
15 Ocomee River
16 Ocmulgee River
17 Altamaha River
18 Satilla River
19 St. Marys-Nassau River
20 St. Johns River
21 Suwanee River
22 Ochlockonee-St. Marks River
23 Withalcoochee River
24 Tampa Bay Area
25 Pease River
26 Kissimmee River
27 Florida East Coastal Area
28 Lower Florida Area
29 Flint River
30 Chattachoochee River
31 Apalachicola River
32 Choctawhatchee River
33 Perdido-Escambia River
34 Tallapoosa River
35 Coosa River
36 Cahaba River
37 Alabama River
151
-------
38 Upper Tombigbee River
39 Warrior River
40 Lower Tombigbee River
41 Mobile Bay Area
42 Pasacagoula River
43 Pearl River
04 TR - Tennessee River
01 Clinch
02 Holston
03 French Broad
04 Little Tennessee
05 Hi was see
06 Elk
0 7 Duck
08 Main Stem, Tennessee River & Minor Tributaries
05 OR - Ohio River
01 Allegheny
02 Monongahela
30 Beaver
04 Muskingum
05 Little Kanawaha
06 Hocking
07 Kanawha
08 Gayandot
09 Big Sandy
10 Scioto
11 Little Miami
12 Licking
13 Miami
14 Kentucky
15 Salt
16 Green
17 Wabash
18 East Fork White River
19 West Fork White River
20 Cumberland
21 Ohio Main Stem fi Minor Tributaries
22 French Creek
23 Clarion River
06 LE - Lake Erie
01 Maumee
02 Sandusky
03 Cuyahoga
04 Lake Erie Shore - Maumee River to Sandusky
River
05 Lake Erie Shore - Sandusky River to Cuyahoga
River
152
-------
06 Lake Erie Shore - Cuyahoga River to N.Y.
State Line
07 UM - Upper Mississippi
01 Red River of the North
02 Rainy
03 Upper Portion Upper Mississippi River
04 Minnesota
05 St. Croix
06 Lower Portion Upper Mississippi River
07 Wisconsin
08 Mississippi-Wapsipinicon & Tributaries
09 Rock
10 Mississippi-Iowa-Cedar
11 Mississippi-Des Moines-Skunk
12 Mississippi-Salt
13 Chicago-Calumet
15 Kankakee
16 Fox
17 Illinois
18 Mississippi-St. Louis Area
19 Meramec
20 Kaskaskia
21 Big Muddy
22 Mississippi-Cape Girardeau Area
08 WL - Western Great Lakes
23 Lake Superior
24 Green Bay Western Shore
25 Pox-Wolf
26 Lake Michigan Western Shore
(Includes North Suburbs of Chicago which drain
to Lake)
27 Lake Michigan-Lake Huron North Shore
28 Lake Michigan Northeastern Shore
29 Muskegon River
30 Grand River
31 Kalamazoo
32 St. Joseph River
33 Lake Huron Western Shore
34 Saginaw River
35 Lake St. Clair & St. Clair River
36 Lake Erie Western Shore-Detroit River
37 Lake Huron-North Shore
49 Calumet-Burns Ditch Complex
09 MR - Missouri River
01 Upper Missouri
(Main Stem & Tributaries to oelow mouth of
Milk River)
153
-------
02 Yellowstone
03 Missouri-Souris
(Main Stem & Minor Tributaries from mouth of
Milk River to Spring Creek including Devils
Lake & Souris River)
04 Central Missouri
(Main Stem & Tributaries from above mouth of
Spring Creek to Niobrara River)
05 Niobrara
06 James
07 Big Sioux
08 Lower Platte
(Platte River from its origin at North Platte,
Nebraska, to its mouth)
09 North Platte
10 South Platte
11 Kansas
12 Lower Missouri
(Main Stem & Minor Tributaries from Niobrara
River to mouth)
13 Grand-Chariton
14 Osage-Gasconade
10 SM - Southwest-Lower Mississippi
01 Upper Arkansas River above Kansas-Colorado
State Line
02 Arkansas River-Kansas-Colorado State Line to
Tulsa
03 Verdigris River
04 Grand (Nesho) River
05 White River
06 Lower Mississippi River-Cairo to Helena,
Arkansas
07 Cimarron River
(New Mexico-Colorado-Kansas & Oklahoma)
08 North Canadian River
09 Arkansas River-Tulsa to Van Buren
10 Arkansas River-Van Buren to Mouth
11 Lower Mississippi River-Yazoo River
12 South Canadian River-above Texas-Oklahoma
State Line
13 South Canadian River-below Texas-Oklahoma
State Line
14 Washita River
15 Upper Red River-above Denison
16 Lower Red River-below Denison
17 Ouachita River
18 Lower Mississippi River-Big Black River
19 Atchafalaya River
20 Calcasieu River
154
-------
21 Lower Mississippi River-Natchez to Gulf
11 CR -v Colorado River
01 Lower Colorado River Basin
02 Middle Colorado-San Juan River Basin
03 Upper Colorado River
04 Gila River
05 Little Colorado River
06 Green River Basin
12 WG - Western Gulf
01 Sabin River
02 Neches River
03 Trinity & San Jacinto
04 Brazos
05 Colorado
06 Guadelup e, Lavaca/ & San Antonio Basin
07 Nueces River
08 Pecos (Upper)
09 Rio Grande (Upper) above Pecos River
10 Rio Grande (Lower) below Pecos River
13 PN - Pacific Northwest
01 Kootenai
02 Clark Fork-Pend Oreille River
03 Spokane
04 Yakima
05 Coluinbia River Basin above Yakima River
06 Upper Snake River
07 Central Snake River
08 Middle & Lower Snake River
09 Willamette River
10 Columbia River below Yakima River
11 Puget Sound
12 Washington Coast
13 Oregon Coast
14 Southern Oregon Lakes
14 CL - California
01 Klamath River
02 North Coastal
03 San Francisco Bay Region
04 Central Coastal
05 Santa Clara River
06 Los Angeles
07 Santa Ana River
08 San Diego
09 Sacramento River
10 San Joaquin River
11 Kings & Kern Rivers & Tulare Lake
155
-------
15 GB - Great Basin
01 Northwestern Lahontan
02 Humboldt River
03 Central Nevada
04 Owens River
05 Mojave
06 Colorado River Basin Region of California
07 Great Salt Lake
08 Sevier River
16 AL - Alaska
01 Southeast Alaska
02 North Pacific Ocean
03 Bering Sea
04 Huskokwim River
05 Yokon River
06 Arctic Ocean
07 Noatak-Kobuk Rivers
17 HA - Hawaii
01 Hawaii County (Hawaii Island)
02 Honolulu County (Oahu Island)
03 Kauai County (Kauai, Niihau, and small islands)
04 Maui - Kalawao Counties
(Maui, Molokai, Lanai & Kahoolawe, and small
islands)
18 PR - Puerto Rico
19 VI - Virgin Islands
Person Source
CARD 2
18 19
20 21
CODES FOR INDIVIDUALS COMPLETING
FORMS
PERSON
01 FWPCA Personnel
02 Consultant
03 Plant Personnel
04 Corporate Personnel
05 Plant Pollution Engineer
06 State Pollution Personnel
07 Environmental Control
Personnel
08 Plant Chemist
09 Legal Counsel
SOURCE OF DATA
01 Plant Interview
02 Corporate Interview
03 Plant Files
04 Corporate Files
05 Consultant Files
06 FWPCA Files
07 Literature References
08 Trade Organization
09 State Wastewater Permit
156
-------
CARD 2 | I I "~| CODES FOR CORPORATE ACTION INITIATION
43 44 45
001 Corporate Management
002 Corporate Legal Counsel
003 Corporate Public Relations Department
004 Corporate Pollution Department or Specialist
005 Corporate Engineering Department
006 Corporate Environmental Control Department
007 Corporate Pollution Consultant
008 Corporate Production Department
CARD 2 | I | ~ CODES FOR PLANT ACTION INITIATION
46 47^48
001 Plant Management
002 Plant Pollution Department or Specialist
003 Plant Production Department
004 Plant Labor Representatives
005 Treatment Plant Manager
006 Plant Maintenance or Utilities Departments
007 Plant Engineering Department
008 Plant Pollution Consultant
CARD 2 IIII CODES FOR BASIS OF ACTION DECISION
53 54 55
001 Insufficient Water Supply
002 Increase Production
003 Present Treatment Results in Equipment Failure
004 Public Relations in Community
005 Conservation Program
006 Cooperation with Local Industry
007 Product Recovery for Sale
008 Changes in Plant Layout
CARD 2 I\ CODES FOR ADDITIONAL BASES OF TREATMENT
63 64 65 DECISIONS
001 Land Available for Treatment Practice
002 Generally Accepted Method for Waste Treatment
003 Providing Water Acceptable for Recycle
004 Within Pollution Control Budget
005 Tax Allowance
006 Expected Process Life
007 Consultants Recommendations
008 Least Manpower Requirements
009 Estimated Future Pollution Requirements
157
-------
CARD 2 | I I "~1 CODES FOR CORPORATE ACTION DECISION
66 67 68 RESPONSIBILITY
001 Corporate Management
002 Corporate Legal Counsel
003 Corporate Public Relations Department
004 Corporate Pollution Department or Specialist
005 Corporate Engineering Department
CARD 2 | | | \ CODES FOR PLANT ACTION DECISION
69 70 71 RESPONSIBILITY
001 Plant Management
002 Plant Pollution Department or Specialist
003 Plant Production Department
004 Plant Public Relations Department
005 Treatment Plant Manager
006 Plant Maintenance or Utilities Departments
007 Plant Engineering Department
CARD 2 | I in CODES FOR CORPORATE TREATMENT DECISION
72 73 74
001 Corporate Management
002 Corporate Pollution Department or Specialist
003 Corporate Engineering Department
004 Consultant Reporting to Corporate Level
005 Contractor Reporting to Corporate Level
006 Vendor Reporting to Corporate Level
CARD 2 | | | J CODES FOR PLANT TREATMENT DECISION
75 76 77
001 Plant Management
002 Plant Pollution Department or Specialist
003 Plant Production Department
004 Plant Engineering Department
005 Plant Maintenance or Utilities Departments
006 Treatment Plant Manager
007 Consultant Reporting to Plant Level
008 Contractor Reporting to Plant Level
009 Vendor Reporting to Plant Level
158
-------
CARD 3
1
1 1
1 1 1 1
18 21 27 30
1 1 1 1
1 1 1
36 39 45 48
1
1 1
1 1 1
54 57 63 66
0001 Chlorine
0002 Sodium Carbonate
0003 Sodium Sulfate
0004 Lithium Carbonate
0005 Potassium Chloride,
Agricultural
0006 Potassium Sulfate
0007 Bromine
0008 Borax Decahydrate
0009 Sodium Sulfate,
Desiccated
0010 Potassium Chloride,
Chemical Grade
0011 Borax Pentahydrate
0012 Boric Acid
0013 Anhydrous Borax
0014 Sodium Pentaborate
0015 50% Sodium Hydroxide
0016 73% Sodium Hydroxide
0017 Alumina
0018 Anhydrous Ammonia
0019 Nitric Acid
0020 Ammonium Nitrate
0021 Sodium Chloride
0022 98% Sulfuric Acid
0023 Calcium Phosphate,
Animal Food
0024 Phosphoric Acid
0025 Hydrochloric Acid
0026 Paint
0027 Titanium Dioxide
0028 Merchant Sodium
0029 Zinc Oxide
0030 Hydrofluoric Acid
0031 Calcium Sulfate
0032 Ammonium Sulfate
0033 Oxygen
0034 Nitrogen
0035 Argon
0036 Urea
0037 Nitrogen Solutions
0038 Urea (Prilled)
0039 Aluminum Sulfate
0040
0041
0042
0043
0044
0045
0046
0047
0048
0049
0050
0051
0052
0053
0054
0055
0056
0057
0058
0059
0060
0061
0062
0063
0064
0065
0066
0067
0068
0069
0070
0071
0072
0073
0074
0075
0076
0077
0078
0079
0080
0081
0082
0083
PRODUCT CODES
Caustic Potash
Caustic Soda
Barites
Calcium Carbonate
Iron Oxide Pigments
Calcium Carbide
Hydrofluoric Acid
Hydrogen Peroxide
Lime
Phosphorus
Sodium Metal
Sodium Bicarbonate
Sodium Bichromate
Potassium Bichromate
Sodium Silicate
Sodium Sulfite
Sodium Tripoly
Phosphate
Aluminum Chloride
Varnish
Lacquer
Ammonium Phosphate
Diammonium Phosphate
Superphosphates
Phosphate Rock
Triple Super Phosphate
Potash
Lead Arsenate
Sulfur
Carbon Bisulfide
Hydrogen Cyanide
Fluorine
Lime-Sulfurs
Bordeaux Mixture
Mercuric Chloride
Sodium Chlorate
Sodium Arsenite
Ammonium Sulfamate
Nitrocellulose
TNT
Smokeless Powder
Ammonium Nitrate
Nitroglycerin
Dynamite
159
-------
0084 Sodium Perborate
0085 Manganese Dioxide
0086 Magnesium Oxide
0087 Calcium Oxide
CARD 3
1 Lbs per Year
2 Tons per Year
3 Gallons per Year
4 Barrels per Year
PRODUCTION CAPACITY CODES
5 Cubic Feet per Year
6 Pieces per Year
7 KWH per Year
CARD 4
WASTE-PRODUCING PROCESS CODES
18
41
0001 Electrolysis 0014
0002 Diaphragm Cell 0015
0003 Mercury Cell 0016
0004 Calcination 0017
0005 Solvey Process 0018
0006 Pressure Liguification 0019
0007 Thermal Reduction 0020
0008 Wet Grinding 0021
0009 Digestion 0022
0010 Crystallization 0023
0011 Oxidation 0024
0012 Electrothermic 0025
0013 Deacon Process
Kellogg Process
Hargreaves Reaction
Absorption
Thermal Decarbonation
Hydrolysis
Solar Evaporation
Mining
Well Brine
Fusing
Chamber Process
Contact Process
Mixing Process
CARD 4
PLANT PRODUCTION UNITS CODES
1 Lbs per Year
2 Tons per Year
3 Gallons per Year
4 Barrels per Year
5 Cubic Feet per Year
6 Pieces per Year
7 KWH per Year
CARD 4 [
RAW MATERIAL CODES
01
02
03
04
05
71
76
Minerals
Forest Products
Natural Gas
Petroleum
Inorganic Chemicals
06 Organic Chemicals
07 Ores
08 Metals
09 Animal Products
10 Agricultural Products
160
-------
11 Manufactured Goods
12 Petrochemicals
13 Ethylene
14 Sulfuric Acid
15 Limestone
16 Coke
17 Bauxite
18 Soda Ash
19 Starch
20 Rutile
21 Chlorine
22 Sodium
23 Phosphate Rock
24 Fluorspar
25 Mineral Trona
26 Ammonia
27 Air
28 Glycerin
29 Nitric Acid
30 Wood Flour
31 Cotton Linters
32 Lead Oxide
33 Sand
34 Well Brine
35 Salt Water
36 Rock Salt
37 Chromium Iron Oxide
38 Quicklime
39 Franklinite
40 Ilmenite
41 Natural Clays
42 Chalk
CARD 5 I I I i I I I I I
"•"^f^T^^^v^^*^ ^ ^ ^5 A O C
18 19 20
33 34 35
001 Company Surface Sources
002 Company Wells
003 Purchased from Municipal
Waterworks
004 Sewage Plant Effluent
005 Cooling Water
48 49 50
WATER SOURCES
CODES
006 Previously Recirculated
Cooling Water
007 Process Water
008 Previously Recirculated
Process Water
009 Sea Water
010 Lake
CARD 5
27 28 29
42 43
001 None
002 Sedimentation
003 Filtration
004 Sedimentation &
Filtration
005 Softening
006 Sedimentation &
Softening
007 Filtration & Softening
008 Sedimentation, Filtra-
tion, & Softening
009 Demineralization
010 Chlorination
Oil Coagulation
012 Coagulation & Filtration
013 Aeration
014. Deae ration
57 58 59
WATER TREATMENT
CODES
015 Oil Removal
016 Corrosion Inhibition
017 Scale Inhibition
018 Algae Control
019 Neutralization
020 Sedimentation, Filtra-
tion, & Chlorination
021 Sedimentation &
Chlorination
022 Filtration & Chlorina-
tion
023 Color Removal
024 Activated Carbon
Filtration
025 Iron & Manganese
Removal
161
-------
CARD 5 [
7T
1 USPHS Drinking Water
Standards
2 Any Available Water
3 No Color
PROCESS WATER QUALITY
REQUIREMENTS CODES
4 Low Turbidity
5 Low Hardness
6 Deionized Water
7 Controlled Temperature
CARD 6 |~1 CODES FOR "OTHER" MATERIALS IN WASTE STREAMS
'6
1 Taste and Odor Compounds
2 Color
3 Turbidity
4 Heavy Metals
5 Toxic Compounds
6 Residual Process
Materials
7 Inorganic Chemicals
8 Organic Chemicals
9 Treatment Chemicals
CARD 7 [
UNIT TREATMENT CODES
31
45
001
002
003
004
005
006
007
008
009
010
Oil
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026
027
028
None
Sedimentation Basin
Filtration
Sedimentation & Filtration
Softening
Sedimentation & Softening
Filtration & Softening
Sedimentation, Filtration, & Softening
Deminerali zation
Chlorination
Coagulation
Coagulation & Filtration
Aeration
Deaeration
Oil Removal
Corrosion Inhibition
Scale Inhibition
Algae Control
Neutralization
Sedimentation, Filtration, & Chlorination
Sedimentation & Chlorination
Iron Removal Filter
Color Removal
Activated Carbon Filtration
Iron & Manganese Removal
Equalization
Screening
Pre-Aeration
162
-------
029 Flotation
030 Oil Separators
031 Primary Chemical Coagulation
032 Chemical Treatment
033 Nutrient Addition
034 Stabilization Basins
035 Trickling Filter
036 Activated Sludge
037 Aerated Lagoon
038 Dentrification
039 Aerobic or Anaerobic Digestion of Solids
040 Thickening
041 Lagooning or Drying Bed
042 Centrifugation
043 Vacuum Filtration
044 Dry Combustion
045 Wet Combustion
046 Land Disposal
047 Biological Sedimentation
048 Final Chemical Coagulation & Sedimentation
049 Sand Filtration
050 Diatomite Filtration
051 Chlorination
052 Evaporation
053 Freezing
054 Distillation
055 Eutectic Freezing
056 Adsorption
057 Electrodialysis
058 Ion Exchange
059 Solvent Extraction
060 Reverse Osmosis
061 Foaming
062 Electrochemical Treatment
063 Deepwell Disposal
064 Ocean Discharge
065 Chain Type Scale Scrapers
066 De-Phenolizer
067 Contract Hauling
070 Cooling Towers
071 Collection System
CARD 7
SIZE AND/OR LOADING CODES
1 Acres Plant Area
2 Square Feet Plant Area
3 Cubic Feet Plant Volume
4 Height in Feet
5 Depth in Feet
6 Diameter in Feet
7 Overflow Rate, Ft/Min
8 Retention Time, Min
163
-------
9 LB/LB MLSS
A Sedimentation Index, Min
B Lb/Ft3/Day
C Lb/Ft2/Day
D Gal/Ft2/Day
E Gal/Ft3/Day
CARD 8 | f I I
28 29 30 31
CODES FOR SLUDGE DESCRIPTIONS
0001 Water Treatment Sludge 0006
0002 Thickener Underflow
0003 Primary Sludge 0007
0004 Final Clarifier Sludge, 0008
Activated Sludge
0005 Digestor Sludge 0009
Final Clarifier Sludge/
Trickling Filter
Filter Backwash
Lime Neutralization
Sludge
Chemical Treatment
Sludge
CARD 8 | | || | CODES FOR SLUDGE TREATMENT
32 33 34 35
0001 Thickening
0002 Filtration
0003 Lagooning
0004 Elutriation
0005 Digestor Sludge
0006 Centrifuging
0007 Digestion
0008 Wet Air Oxidation
0009 Flotation
CARD 8 I _ I I _ T
36 37 38 39
0001 Incineration
0002 Contract Hauling
0003 Landfill
0004 Disposal at Sea
CODES FOR SLUDGE DISPOSAL MEANS
0005 Sinter Plant
0006 Sale
0007 Reuse in Plant
CARD 9
APERTURE CARD CODES
50 51 52
001 Treatment Practices Data Form
002 Process Flowsheets
003 Waste Treatment Flowsheets
CARD 10 | I I
29 30 31
001
CODES FOR SPECIALIZED FUNCTIONS
Corporate Head of
Pollution Control
002 Plant Head of Pollution
Control
003 Plant Utilities Chief
004 Plant Maintenance Chief
005 Plant Engineer
006 Plant Superintendent
164
-------
007 Plant Chief Chemist
008 Corporate Officer
CARD 10
46 47 48
I | TRADE AND PROFESSION CODES
001 Electrician
002 Instrument Technician
003 Pipe Fitter
004 Chemist
005 Sanitary Engineer
006 Chemical Engineer
007 Civil Engineer
008 Electrical Engineer
009 Certified Waste Treat-
ment Plant Operator
CARD 10 [
CODES FOR SPECIFIC PROCESSES
7475 76
Use the unit treatment codes listed for Card 7
31 45
165
-------
DOCUMENT TO DATA CENTER_
REVISION TO DATA CENTER
DATE
by_
by
NAME
sh._
Rev.
of
DATE
NAME
INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM
|_CA_RC[ 1 I GENERAL INFORMATION
PLANT NO. I I I I I I INITIAL FORM NO. | j [ 1
12345 6789
INDUSTRY
FIRM PLANT
YEAR PLANT CONSTRUCTED I I 1 I 1 STATE
16 17 18 19
CITY AND/OR COUNTY
STATISTICAL AREA
ECONOMIC AREA
WATER RESOURCE REGION
RECEIVING STREAM
Month Year
DATE OF DATA ACQUISITION [ | ] |~ | |
38 39 40 41
| 1 INITIJ
10 11
S.I.C. NO. [
12
CODE
CODE | |
22 23
CODE |
CODE
CODE
Major
CODE [ 1
34 35
BASE YEAR |_
42
\L? | ILJ
Yes No
1 1 1
13 14 15
I 1 1
20 21
1 1 1
24 25 26
1 1 1
27 28 29
1 1 1
30 31
1 1 1
32 33
Minor
Mil
36 37
i 1 1
43 44 45
SINGLE PLANT FIRM | |
MULTIPLANT FIRM
SIZE OF FIRM: GROSS SALES ($1000 PER YEAR)
SUBSIDIARY OF
48 49 50 51 52 53
59
SIZE OF FIRM IN THE INDUSTRY (PERCENT OF THE MARKET)
SIZE OF FIRM IN THE INDUSTRY: LARGE ||
OWNERSHIP OF FIRM: PUBLICLY TRADED STOCK
DEFENSE-ORIENTED
REV.
PUBLICLY REGULATED FIRM ["""""1
REVISION DATE
™_ 56 57 58~
MEDIUM | | SMALL | |
60 61
CLOSELY HELD I I
78 79
END OF CARD
TIT
166
-------
INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM
| CARD 2 I BASES FOR TREATMENT DECISIONS
I SAME AS CARPI |
1 11
DATA FORM NO. I _ I _ II I l~~
12 13 14 15 16 17
Person Source
DATA BY
CODE
NAME
BASIS OF TREATMENT STANDARDS:
COMMON LAW | | STATUTE LAW
18 19
Month
Year
20 21
DATE II I I .1
22 23 24 25
27
PUBLIC OPINION | | WITHIN FIRM
^8
LOCAL """
COURTS: FEDERAL |~" I STATE f~ 1 LOCAL ("""I ORDER [~~~] PRECEDENT | ^
AGENCIES: FEDERAL | | STATE [~ | INTERSTATE [~~~| LOCAL I""""!
REGULATIONS | 1 ORDER | | CONFERENCE | | HEARSAY {" |
£ |
ACTION INITIATION WITHIN THE FIRM:
CORPORATE
PLANT
CODE ' .,' I '
"43 44 45
CODE I
46 47 48
BASIS OF ACTION DECISION:
PUBLIC OPINION r~~1 LAW I""""! LEGAL ACTION [""""1 ECONOMIC INCENTIVE [~~1
OTHER
CODE
53 54 55
BASIS OF TREATMENT DECISION:
LEAST COST: TOTAL [~"~] OPERATING [~~| CAPITAL \~~\ ECONOMIC RETURN
WATER CONSERVATION | ~~\ MINIMUM COMPLIANCE |
OTHER
RESPONSIBILITY FOR ACTION DECISION:
CORPORATE
PLANT
RESPONSIBILITY FOR TREATMENT DECISION:
CORPORATE
PLANT
] ULTIMATE TRE
CODE
CODE
CODE
CODE
CODE
ATMENT | ]
1 1 j 1
63 64 65
1 1 1 I
66 67 68
Ll II
69 70 71
1 1 1 1
72 73 74
1 1 1 1
75 76 77
SAME AS CARD 1
END OF CARD
167
-------
INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM
CARD 3 | PLANT PRODUCTION INFORMATION I
SAME AS CARD 2
Product
Code
Production Capacity
1
18
1
27
1
36
i
45
1
54
1
1 1
19 20
Code
i
28 29
Code
1
37 38
Code
|
46 47
Code
1
55 56
Code
1
L.
21
Jo
^
3d
|
48
1
57
1
63 64 65 66
NUMBER OF S.I.C. REPRESENTED ABOVE_
PRODUCTION SCHEDULE
REMARKS:
Amount
I ,,', '
22 23 24
Amount
I '""'
31 32 33
Amount
40 41 V2
Amount
I M I I I
49 50 51
Amount
I I.LI
58 59 60
Amount
10* Unit
^^?
10X Unit
^q?
1QX unit
^?^
IP* Unit
^?^
10X Unit
^^
10X Unit
LJ_
67 68 69
HRS. PER MO.
74 75 76
NO. OF CARDS 3
SAME AS CARD 2
END OF CARD
168
-------
INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM
CARD 4 I PLANT PRODUCTION INFORMATION II
[ SAME AS CARD 3 |
1 17
PRINCIPAL WASTE-PRODUCING PRODUCTION PROCESSES:
Code
.
18 19 20 21
Code
I ' ,'' ""I
26 27 28 29
Code
I ,,LJ,, L,J
34 35 35 37
SIZE OF PLANT:
10
Code
'I' ' '
22 23 24 25
Code
30 31 32 33
Code
I I I I "1.
38 39 40 41
EMPLOYMENT | II ~| | j
42 43 44 45
10
VALUE ADDED (SAR.) I I I "
46 47 48
Amount x Unit
PLANT AREA I I I I I PRODUCTION | I I ~l
(Acres) 50 51 52 53 54 55 56
SIZE IN INDUSTRY:
SMALL
MEDIUM ||
LARGE ||
AGE OF PLANT:
AGE IN YEARS | II
62 63
LEVEL OF TECHNOLOGY:
OLD
YEARS SINCE MAJOR MODIFICATION LI I
64 65
AVERAGE f~~] ADVANCED | | TYPICAL
^T 6!T
UNIQUE
RAW MATERIALS USED:
Code
^ln
71 72
Code
73 74
Code
75
NO. OF CARDS 4
SAME AS CARD 3 |
"75 7!P
END OF CARD
169
-------
INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM
CARD 5 WATER USES
WATER USE IN PLANT:
PRIMARY
PURPOSE
MAJOR
SOURCE
| SAME AS CARD 4~ |
1 17
COST (C/1000 GAL. USED) PRINCIPLE
TOTAL _ TREATMENT TREATMENT USE (104GAL. )
TOTAL COOLING
TOTAL PROCESS
TOTAL OTHER
Code
l', 1,1 I , I
18 19 20 21 22
Code
Code
>ci? w-^ WS3
Code
I .'1. '
,.,.
ao 31 32
Code
'
48 49 50 51 52
TOTAL WATER INTAKE
_ ____
Ul~l ' ',.
53^ 54 55
Code
„„ „
57 58 59
,„,,
60 61
63 64
10*
TOTAL WATER USE
PROCESS WATER QUALITY:
COMPLETELY SATISFACTORY I""""!
MARGINAL
|~~]
, . .
67 68 69 70
UNSATISFACTORY [_ 1
PROCESS WATER QUALITY REQUIREMENTS:
CODES
| SAME AS CARD 4 |
^Tg 79
END OF CARD
.
80
170
-------
INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM
I CARD 6 I CHARACTERISTICS OF WASTE STREAMS
SAME AS CARD 5
11
WASTE STREAM NO.
OF
18 19
TOTAL PLANT EFFLUENT CALCULATED AS WEIGHTED AVERAGE
| | WASTE STREAMS IN PLANT
20 21
FLOW
1. OIL
2. BIOCHEMICAL OXYGEN DEMAND
3. CHEMICAL OXYGEN DEMAND
4. TOTAL ORGANIC CARBON
5. SUSPENDED SOLIDS
6. TEMPERATURE
7. ALKALINITY
8. ACIDITY
9. TOTAL DISSOLVED SOLIDS
10. NITROGEN
11. PHOSPHOROUS
12. OTHERS mg/1 f | |
71 72 73
REMARKS:
gpd i i
23
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
mg/1
±
II 1 [
74
10X
1 1 II 1
24 25 26 27
1 1 1 I I
28 29 30 31
1 1 1 1 1
32 33 34 35
1 1 1 1 1
36 37 38 39
1 1 1 1 I
40 41 42 43
1 1 1 1 1
44 45 46 47
°F| | | |
48 49 50
1 ~1 1 1 1
51 52 53 54
till!
55 56 57 58
1 1 1 1 1
59 60 61 62
1 1 1 1 I
63 64 65 66
1 1 t 1 1
67 68 69 70
10*
75 T^
NO. OF CARDS 6 f J | SAME AS CARD 5 |
7? 78 79
END
OF CARD [T1
TIT
171
-------
INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM
CARD 7 | WASTE TREATMENT AND/OR REDUCTION PRACTICES
I SAME AS CARD 6
PRACTICE NO. 1 I
18 19
1
OP
PRACTICES IN USE IN PLANT
20 21
PRACTICE INSTITUTED IN CONNECTION WITH ABATEMENT OF POLLUTION FROM WASTE
STREAM NOS:
22 23~^ 24 25 26 27 28 29
DATA ON THIS CARD IS FOR A COMPLETE TREATMENT PLANT
1. UNIT TREATMENT_
2. UNIT TREATMENT_
3. UNIT TREATMENT
4. UNIT TREATMENT^
5. UNIT TREATMENT
INSTALLATION DATES: INITIAL, 19 | I I
46 47
SIZE AND/OR LOADINGS:
CAPITAL COST_
LAND VALUE
OPERATING COSTS
EFFICIENCY, % 111 ON BASIS OF
74 75
I ..I.J., I
31 32 33
I , I I, '
34 35 36
37 38 39
42
43 44 45
LAST MODIFIED, 19 j | |
48 49
Unit
WiS?
Unit
54 55 56
58 59
* L
62 63 64
$ 'II
66 67 68
unit
5?
10X
V
10X
$/YR.
NO. OF CARDS 7
| SAME AS CARD 6 |
-737y-
70 71 72
CODE
END OF CARD
172
-------
INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM
| CARD 8 I CHARACTERISTICS OF SLUDGES
SAME AS CARD 7
IT
SLUDGE SOURCE NO.
18 19
TOTAL OF SLUDGES IN PLANT
QUANTITY
DESCRIPTION OF SLUDGE:
OF
SLUDGE SOURCES IN PLANT
LBS. PER DAY I J
CALCULATED AS AN AVERAGE
IP*
\~~]
27
_
23 24 25 26
TREATMENT OF SLUDGE:
CODE |~~T
28 29 30 31
DISPOSAL OF SLUDGE:
CODE
,,. ,
32 33 34 35
CAPITAL COST
LAND VALUE
OPERATING COSTS
CODE
n,, LTI
36 37 38
40 41
$CZI
_VYR C
44 45
ULTIMATE DISPOSAL | | SATISFACTORY
MARGINAL
NO. OF CARDS 8
SAME AS CARD 7
4B 49
UNSATISFACTORY [~~]
END OF CARD
173
-------
INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM
CARD 9 I APERTURE CARDS
SAME AS CARD 8
FIRST CARD 9
T R E ATMENTPRACTICESDATAFOR
] NO. OF CARDS 9 |"""1
ADD. CARDS 8
| ALL. CARDS 9
APERTURE CODE
50 51 52
IB 46
APERTURE CODE | ~| NO. OF CARDS 9 |~~|
50 51 52 77
IB 46
APERTURE CODE I
50 51 52
] NO. OF CARDS 9 |"~~1
___________
APERTURE CODE f ^"1 NO. OF CARDS 9
50 51 52
_____
|~~~1
17
46
IB 46
APERTURE CODE | ~] NO. OF CARDS 9
50 51 52
46
APERTURE CODE
50 51 52
] NO. OF CARDS 9 [""""1
| SAME AS CARD 8 | END OF CARD r~y\
ifl 79 BlT
174
-------
CARD 10
FUNCTION:
INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM
MANPOWER UTILIZATION IN WASTE TREATMENT
AS CARD 9
ADMINISTRATION [""""1
SUPERVISION | |
ENGINEERING: PROCESS
OTHER
ANALYSIS |~ 1
19
OPERATOR | |
T3~^
DESIGN r~|
| OPERATION r~~1
TECHNICIAN | \
PLANT DESIGN r~~|
MAINTENANCE [~~~]
LABORER I"""")
CONSULTANT [~~|
CODE | | I |
EDUCATION AND/OR EXPERIENCE:
COLLEGE: B.S. [""""I M.S. ["""I
3 YRS. r~~~l JR. COLLEGE | ^
GRADE SCHOOL \~~]
YRS. IN SPECIALTY [
44 45
WORK LEVELS AND COSTS:
NO. OF PERSONS I
PH.D. | | 1 T
HIGH SCHOOL [~~|
YEARS WORKING EXPERIENCE
TRADE OR PROFESSION
MAN-HOURS PER MONTH
I I I I I TOTAL
29 30
2 YRS.
TECHNICAL SCHOOL |~~1
42 43
CODE [_
^* 50 __^_^
COSTS PER MAN-HOUR: WAGES $ II I
EMPLOYMENT STATUS:
FULL-TIME EMPLOYEE j | PART-TIME EMPLOYEE | |
% OF EMPLOYED TIME DEVOTED TO WASTE TREATMENT
UNION MEMBER II EXEMPT EMPLOYEE | |
PLANT GENERAL
46 47 48
..I., I,. L. J
51 52 53 54
irrn
59 60
61 62
OUTSIDE
WORK AREA:
COMPANY GENERAL | |
SPECIFIC PROCESS
66 67
NON-EXEMPT EMPLOYEE
WASTE TREATMENT PLANT
CODE I
I. I
74 75 76
REMARKS:
NO. OF CARDS' 10
SAME AS CARD 9
END OF CARD
78
175
-------
APPENDIX B
INORGANIC CHEMICAL INDUSTRY SURVEY DATA
176
-------
TABLE I
Plant
Number
00013
00016
00017
00018
00026
00027
00030
00033
00034
00037
00040
00042
00050
00051
00052
00053
00054
00055
00056
00057
00058
00059
00060
00061
00062
00063
00064
Critical
Pollutant
SO4
Acidity
Acidity
—
Acidity
-
SS
Cl
SS
Cl
Oil
-
Temp.
SS
SS
SS
BOD
BOD
SS
-
-
SS
BOD
—
-
BOD
Acidity
Efficiency
99
99
99.5
98
73
95
95
90
45
99.8
0
90
50
99
0
70
Capital Operating Capital
Cost Per Cost Per Cost Per
1000 GPD 1000 GPD Ton/Year
Operating
Cost Per
Ton/Year
Wastewater
GPD/Ton/
Year
1736.11
2083.33
1666.67
6.92
-
300.00
1.04
2.66
3.62
57.80
1.28
260.41
2.17
1.06
1.29
411.37
20.83
83.33
1500.00
152.17
583.33
116.66
12.00
0.00
5.00
387.10
307.69
0.00
1.67
0.10
1.28
140.27
-
5.55
600.00
1.04
166.66
36.66
1.00
0.00
2.50
32.26
116.92
0.00
0.35
22.00
1.42
4.15
1.74
8.82
1.44
0.44
87.50
7.00
6.00
0.00
10.00
0.41
0.31
0.00
0.01
-
—
—
10.40
0.19
—
—
-
—
2.00
0.21
1.42
-
5.88
0.58
-------
APPENDIX C
INORGANIC CHEMICAL INDUSTRY
PRODUCT PROFILES
Individual Product Profiles
Flowchart of a Standard Medium-Pressure Air-Separation
Plant
Flowchart for Diaphragm Caustic Soda and Chlorine Cell
Flowchart for 60% Nitric Acid from Ammonia
Typical Flowchart for Sulfur-Burning Contact Plant
Flowchart for Smokeless Powder
Flowchart for Mixing of Paint
Flowchart for Titanium Dioxide
Sources of Data:
Chemical Profiles
Oil, Paint and Drug Reporter
"Future Inorganic Chemical Growth Patterns"
R. N. Rickles, Noyes Development
Chemical Week
Bureau of the Census
TVA
178
-------
SIC 2812 (ALKALIES AND CHLORINE)
Caustic Potash
Producer Capacity —<
Allied, Syracuse, N.Y. 30,000
Diamond, Delaware City, Del. 12,500
Diamond, Muscle Shoals, Ala. 22,000
Dow, Pittsburg, Calif. 10,000
FMC, South Charleston, W. Va. 10,000
Hooker, Niagara Falls, N.Y. 36,000
IMC, Niagara Falls, N.Y. 22,000
Monsanto, Anniston, Ala. 25,000
Monsanto, East St. Louis, 111. 29,000
Pennsalt, Calvert City, Ky. 5,000
PPG, Corpus Christi, Tex. 5,000
PPG, New Martinsville, W. Va. 10,000
Total 216,500
i/ 1000's of tons/year (90% basis)
Production; 1969: 180,000 tons (90% basis)
1974: 216,000 tons (90% basis)
Uses; Soaps and detergents (including use as tetra-
potassium pyrophosphate), potassium carbonate
and other potassium chemicals.
Processes; By the electrolysis of potassium chloride
Waste Problems; No major change is expected.
See chlorine.
Caustic^ Soda
Producer Capacity -/
Alcoa 450
Allied 1/200
Diamond 2,030
Dow 7,800
FMC 850
GAF 525
Goodrich 575
Hooker 1,780
179
-------
Caustic Soda (cont.)
Producer Capacity 4
Kaiser 600
Monsanto 350
Olin 1,870
Pennsalt 1,100
PPG Industries 2,860
Shell 275
Stauffer 913
Vulcan 330
Weyerhaeuser 300
Wyandotte 1,870
Others 1,070
Total 26,748
_!/ tons/day
Production; 1969: 8,500,000 tons/year
1974: 11,500,000 tons/year
Uses; Chemicals, pulp and paper, aluminum, rayon,
textiles, petroleum refining, soap and detergents,
cellophane.
Processes; Caustic soda is manufactured primarily
from salt in electrolytic cells. A full discussion
is included under chlorine.
Waste Problems: See chlorine.
Chlorine
Producer Capacity —f
Alcoa 415
Allied 1,100
Diamond 1,850
Dow 7,050
DuPont 180
Ethyl 625
FMC 765
Frontier 415
GAF 475
Goodrich 520
Hooker 1,800
180
-------
Chlorine (cont.)
Producer Capacity —'
IMC 180
Kaiser 500
Monsanto 310
Olin 1,700
Pennsalt 1,000
PPG Industries 2,600
Shell 200
Stauffer 700
Vulcan 300
Wyandotte 1,700
Other 1/300
Total 25,685
I/ tons/day
Production: 1969: 8.6 million tons/year
1974: 12.0 million tons/year
Uses: Organic chemicals, inorganic chemicals, paper
Industry, cyclic intermediates, sanitation, anti-
freeze, chlorofluoro carbons, plastics.
Processes: Chlorine and caustic soda are produced
by the electrolysis of brine. As an alternative,
caustic potash may be produced by the electrolysis
of potash. Other sources of chlorine are from the
manufacture of hydrochloric acid and sodium.
Neither method is important.
Two basic methods are involved. The production is
divided between the diaphragm and mercury cells and
there is no expected change in the distribution.
In a typical diaphragm cell, the nearly saturated
brine solution at 60-70°C is fed to the anolyte
which flows through the diaphragm to the catholyte
where the caustic is formed. Chlorine is formed at
the anode.
In the mercury cell, mercury flowing along the
bottom of a steel trough forms the cathode. The
anodes are horizontal graphite plates. Brine at
290 gms/liter is fed to the cell. A sodium
amalgam is formed with the mercury at the cathode
and is decomposed external to the cell by the
addition of water. Hydrogen is produced as a by-
product of this latter action.
181
-------
FIGURE 1
ELECTROLYTIC
CELL
BRINE
HEATER
.CHEMICALS
BRINE•
00
MULTIPLE
EVAPORATORS
WEAK
CAUSTIC
STORAGE
•
SEPARATOR
"•TU
HYDROGEN OUT
SOME HgO OUT
CAUSTIC NOT SPECIALLY
PURIFIED
FILTER
WASH
SALT TO
BR INE
CONC.
CAUSTIC
STORAGE
REFRIGERATION MACH.^
CAUSTIC FOR
SPECIAL PURIFICATION
t CRYSTALLIZER
CENTRIFUGAL
EXPANSION
DRUM
LIQUEFIED
CHLORINE
Y
LIQUID
CAUSTIC
SALES
DRUMS FLAKES
FOR SALE
FINAL EVAPORATION
FLOWCHART FOR DIAPHRAGM CAUSTIC SODA AND CHLORINE CELL
This flow chart is selectively reproduced in content and configuration from Figure 13.7
in the book by R. Norris Shreve, Chemical Process Industries, Third Edition, New
York, Me Grow- Hill Book Company, 1967, p. 236
-------
Brine purification is necessary to produce a high
grade caustic in the diaphragm process. Calcium,
iron magnesium and sulfate ions are precipitated.
In the diaphragm process, the cell liquor, contain-
ing 50% of the sodium chloride, is concentrated.
The salt precipitates and is reused following wash-
ing. Special purification of the caustic may be
necessary and this usually produces considerable
sludge.
It is necessary to dry the chlorine, and this is
accomplished by contact with a concentrated
sulfuric stream.
The mercury cell produces, without all of the major
purification problems, a high purity caustic and
chlorine. This eliminates the major waste problems
except those arising from chlorine drying.
No significant change is expected in this process.
Waste Problems; The waste problem common to both
systems is the waste sulfuric acid stream which
amounts to about 1,000,000 gpd/100 tons/day of
chlorine. Such a stream (1,000,000 gpd) would
contain about 2000 pounds of sulfuric acid and 200
pounds of chlorine. Regeneration of this stream
is quite possible by evaporation and steam
stripping of the chlorine. This would permit use
of the chlorine for sterilization purposes.
Other wastes arise from the discharge of waste
brine as a slipstream. This may amount to 1-5%
of total brine throughput. Improved brine puri-
fication techniques could reduce these practices.
The waste brine could be utilized in a small
mercury cell to produce chlorine or for the
regeneration of ion exchange systems. The waste
brine from a mercury cell contains some mercury
which requires physical separation for removal.
Economics usually justifies removal.
The sludges collected from the purification of
brine also create a problem, and current techniques
involve land disposal or discharge to a water
body. No major processing changes are anticipated.
183
-------
Soda Ash
_ Producer _ Capacity
Allied, Baton Rouge, La. (S) 785,000
Allied, Green River, Wyo. (N) 550,000
Allied, Syracuse, N.Y. (S) 1,000,000
American Potash, Trona, Calif. (N) 160,000
Diamond Shamrock, Painesville, 0. (S) 800,000
Dow, Freeport, Tex. (S) 75,000
FMC, Green River, Wyo. (N) 1,250,000
Olin, Lake Charles, La. (S) 3,750,000
Olin, Saltville, Va. (S) 400,000
PPG, Barberton, O. (S) 600,000
PPG, Corpus Christi, Tex. (S) 240,000
Stauffer, Green River, Wyo. (N) 800,000
Stauffer, Westend, Calif. (N) 160,000
Wyandotte, Wyandotte, Mich. (S) 800,000
Total 7,995,000
tons/year (S) synthetic; (N) natural
Production; 1969: 7,000,000 tons
1974: 9,000,000 tons
Uses; Glass, chemicals, pulp and paper, soap and
detergents, aluminum, water treatment.
Processes: About 30% of the current production of
soda ash is obtained naturally through the mining
of trona (sodium sesquicarbonate) . Some amount is
recovered through the calcination of natural
alkali brines in California. Neither technique
produces significant quantities of waste. The
mining operation does produce the usual solid waste
problems and any brine operation produces a waste
brine solution. The location of these areas makes
their impact upon the environment relatively
insignificant.
The Solvay process uses brine, limestone and coke
or gas as the raw material. Brine is purified as
previously noted (see chlorine) . Ammonia is
dissolved in the purified brine and this solution
is carbonated with carbon dioxide produce by the
184
-------
decarbonation of limestone by calcining the stone
mixed with coke. This produces a moist sodium
bicarbonate which is calcined to soda ash. The
ammonia is recovered from the filtrate (sodium
bicarbonate unit) by addition of quick lime to the
system. The ammonia and carbon dioxide are
recovered and recycled.
The recovery of ammonia produces a waste stream
(1-2000 gals/ton) which contains ammonia (2-4 kgms
of (NH4)2 S04 per ton of 58% soda ash) and sub-
stantial amounts of calcium chloride (0.3 tons/ton
of 58% Na2) and some calcium sulfate and calcium
carbonate. While some calcium chloride is
recovered by distillation, this practice is not
sufficiently prevalent to prevent it from being a
major pollution problem.
Since calcination involves dust control, there is
the likelihood of a discharge containing a large
concentration of suspended solids from a scrubber
or where water is used for conveying fly ash.
It is expected that more natural soda ash will be
utilized, but no major changes in the manufacture
of soda ash by the Solvay process are anticipated.
185
-------
SIC 2813 (INDUSTRIAL GASES, EXCEPT FOR ORGANIC GASES)
Nitrogen
Producers: The number of nitrogen and oxygen produc-
ing plants is quite large and capacities of either
individual plants or companies are not available.
These plan to be generally located in areas of high
user demand.
Major producers are:
Air Products and Chemicals - 20% of market
Airco - 20% of market
Big Three Industrial Gas
Burdett Oxygen
Chemetron - National Cylinder Gas
Union Carbide - Linde Division - 40% of market
Production; 1969: 130,000 million cubic feet
1974: 370,000 million cubic feet
Uses: Chemical and drug production, steel and metal
production, electronics, aerospace, cryogenics.
Processes; Both oxygen and nitrogen are produced
primarily through the medium pressure liquification
and rectification of air. The process can produce
a variety of products including high purity oxygen
and nitrogen and low purity oxygen. The process
naturally has many variations, but it is expected
that there will be no substantial changes in the
method of production.
Waste Problems; The major problem associated with
this process is related to the discharge, with the
cooling waters, of waste compressor oils. The
quantity of such oils may vary greatly from plant
to plant depending on compressor type, size, and
age. In-plant control is not only possible, but
feasible. This is best done by skimming in the
sumps.
Oxygen
Producers: See nitrogen.
186
-------
NITROGEN
FIGURE 2
00
EXCHANGERS
LOW-PRESSURE
COLUMN
SUBCOOLER
COMPRESSOR
^VAPORIZER
AUXILIARY
VAPORIZER
HIGH
PRESSURE
COLUMN
SEPARATOR
C0g SCRUBBER
EXPANDER
FLOWCHART OF A STANDARD MEDIUM-PRESSURE AIR-SEPARATION PLANT
This flow chart is selectively reproduced in content and configuration from Figure 7.7 fn
the book by R. Norris Shreve, Chemical Process Industries^ Third Edition, New York,
Me Grow - Hill Book Company, 1967, p. 109
-------
Production: High Purity (99.5-100%)
1969: 260,000 million cubic feet
1974: 520,000 million cubic feet
Low Purity
1969: 1,900,000 tons
1974: 3,800,000 tons
Uses: Chemical production, steel production, medi-
cal.
Processes; See nitrogen.
Waste Problems; See nitrogen.
188
-------
SIC 2816 (INORGANIC PIGMENTS)
Barites
Producers; Produced by:
Chemical Products Corporation, Cartersville, Ga.
Chicago Copper and Chemical Corporation, Blue
Island, 111.
The Great Western Sugar Corporation, Johnstown,
Colo.
Holland-Suco Color Corporation, Huntington, W. Va.
FMC, Modesto, Calif.
Mallinckrodt Chemical, St. Louis, Mo.
Ozark Smelting and Mining, Coffeyville, Kan.
PPG, New Martinsville, W. Va.
Capacities are not available.
Production: 1969: 950,000 tons
1974: 1,300,000 tons
Uses; White pigment.
Processes; Barites is recovered as a mineral which
may be converted to a soluble salt, such as the
chloride or the sulfide, by thermal reduction. The
sulfate is then produced by the addition of a
sulfate such as sodium sulfate. The resulting
filtrate is a solution of the resulting chloride
(usually sodium) on an equivalent mole basis.
Thus, the discharge will be a brine solution. No
major process change may be expected in the near
future and no process improvement is considered
likely.
Calcium Carbonate
Producers: Produced by:
Allied, Baton Rouge, La.
Allied, Green River, Wyo.
Allied, Syracuse, N.Y.
American Potash, Trona, Calif.
Diamond Shamrock, Painesville, 0.
Dow, Freeport, Tex.
FMC, Green -River, Wyo.
189
-------
Olin, Lake Charles, La.
Olin, Saltville, Va.
PPG, Barberton, 0.
PPG, Corpus Christi, Tex.
Stauffer, Green River, Wyo.
Stauffer, Westend, Calif.
Wyandotte, Wyandotte, Mich.
Capacities are not available.
Production: 1969: 180,000 tons (estimated)
1974: 240,000 tons
Uses; Pigment, filler, neutralization, soaps, abra-
sives, agriculture.
Processes: Whiting is used as a filler and pigment.
It is prepared by wet grinding and levigating
natural chalk. This process produces a waste which
contains large amounts of suspended solids.
Artificial whiting arises through the reaction of
calcium chloride with sodium carbonate forming a
milk of lime suspension. The filtrate from this
suspension is high in suspended solids. Use of
polyelectrolytes will increase recovery of this
product.
Iron Oxide Pigments
Producers; Not available
Production;
1969: Natural Brown Iron Oxides 13,000 tons
Umbers 5,000 tons
Red Iron Oxides 35,000 tons
S ienna 1,000 tons
Yellow Ocher 5,000 tons
Sienna 1,000 tons
Subtotal 60,000 tons
Manufactured Black 4,000 tons
Brown 5,000 tons
Red 32,000 tons
Yellow 24,000 tons
Subtotal 65,000 tons
Total 125,000 tons
190
-------
1974: 160,000 tons
Processes and Waste Problems: These products are made
in dry thermal processes or are produced from natural
clays, etc. Therefore, except for waste slurries
and equipment washouts, no serious waste problems
exist. The discharge of highly colored turbid solu-
tions from clay-mining sites is most serious
locally.
Titanium Dioxide
Producer
American Potash, Hamilton, Miss, (C)
Cabot, Ashtabula, O. (C)
Cyanamid, Piney River, Va. (S)
Cyanamid, Savannah, Ga. (C,S)
DuPont, Antioch, Calif. (C)
DuPont, Baltimore, Md. (S)
DuPont, Edge Moor1, Del. (C,S)
DuPont, New Johnsonville, Tenn. (C)
Glidden, Baltimore, Md. (S)
National Lead, Sayreville, N. J. (C,S)
National Lead, St. Louis, Mo. (S)
New Jersey Zinc, Gloucester City,
N. J. (S)
PPG, Natrium, W. Va. (C)
S. Williams
Total
Capacity —
30,000
20,000
18,000
92,000
27,000
40,000
100,000
68,000
56,000
173,000
108,000
46,000
18,000
25,000
821,000
I/ tons/year (C) chloride process;
Production;
~
(S) sulfate process
1969:
1974:
650,000 tons
800,000 tons
Uses; Varnish and lacquer, paint, floor coverings,
rubber, coated fabrics, printing ink.
Processes; Titanium dioxide is produced by either of
two processes. The older process is the digestion
of ilmenite ore in sulfuric acid. The heat of the
reaction evaporates the water. Water is added
dissolving the titanium and iron sulfates. The
ferric ions are reduced with scrap and the solution
is clarified. Fifty percent of the iron is re-
191
-------
FIGURE 3
10
GROUND
ILMENITE
ORE
TO STACK OR PRECIPITATOR
~l i OIL-FIKED KILN
•T ' •* i_n_ii . DISPERSING
) AGENTS
(REAGENT
FOR pH
CONTROL
HYDROLIZING AND
PRECIPITATING
FILTRATE
TO H2S04
AND FeS04
RECOVERY
(I) DIGESTION
(2) DISSOLVING
(3) REDUCING
TITANIUM
HYDRATE
FREPULPER
PEBBLE
MILL
SEPARATOR
1 ^
itifftftttfffwtftftfltfffff}
THICKENER
REPULPER
a—L-
RESIDUE
TO
POSSIBLE
VACUUM
FILTERS
RECOVERY
WATER
REDUCING
GENTS
_ VACUUM
\ EVAPORATO
CRYSTALLIZER
STEAM ROTARY
DRYER^
CENTRIFUGAL
WASH
WATER
FILTRATE TO
SETTLING
FOR Ti02
RECOVERY
STORAGE 8
SHIPMENT
FERROUS
SULFATE
SEPTA HYDRATE
AIR SEPARATION-
PULVERIZER
CLARIFYING FILTER
FLOWCHART FOR TITANIUM DIOXIDE
This flow chart is selectively reproduced in content and configuration from Figure 24.9
in the book by R. Norris Shreve, Chemical Process Industries, Third Edition, New York,
Me Grow-Hill Book Company, 1967, p. 438
-------
FIGURE 4
1
\
1
1
i
, MIXER
!
' ,
PLATFORM
SCALE
CD
CD
CD
TINTING
a
THINNING
TANK
LABELING
MACHINE
Q
FILLING, i MACHINE
nnnnnn
D
BELT CONVEYOR
GRINDING MILLS
FLOWCHART FOR MIXING OF PAINT
This flow chart is selectively reproduced in content and configuration from Figure 24.1 in
the book by R. Norris Shreve, Chemical Process Infantries, Third Edition, New York,
Me Grow -Hill Book Company, 1967, p. 428
-------
moved by crystallization of ferrous sulfate. The
titanyl sulfate is hydrolyzed and crystallized and
filtered and washed.
The newer chloride process involves the oxidation
in a flame of titanium chloride produced by the
chlorination, in the presence of coke of rutile
ore or slag. Chlorine is recovered. The chloride
process is expected to become the more standard
one if supplies of rutile and slag hold out.
Waste Problems; The sulfate process generates
considerable quantities of wastewater effluents.
The principal sources are the wash waters from
the washing of the titania and the overflow from
the thickeners earlier in the process. Both steps
are necessary but it seems likely that some
reuse of the wash waters can be provided for.
Zinc Oxide
Producers; Major producers are:
American Zinc
Eagle Picher
New Jersey Zinc
St. Joseph Lead
Capacities are not available.
Production: 1969: 195,000 tons
1974: 220,000 tons
Processes; The American process produces zinc oxide
directly from ore franklinite. The ore is mixed
with coal and heated. The zinc oxide is reduced
to zinc which is then oxidized to zinc oxide in
cyclones and bag filters without wet wastes.
The French process involves the vaporization of zinc
in a retort with indirect heat and carbon monoxide
gas. The zinc and carbon monoxide are oxidized to
carbon dioxide and zinc oxide. The process is dry.
The Electrothermic process is similar to the
American process except that the furnace is
electrically heated.
194
-------
Aluminum Sulfate
Producers
Allied
American Cyanamid
DuPont
Essex
Monsanto
Olin
Stauffer
Production; 1969: 1,090,107 tons
1974: 1,250,000 tons
Uses; Water treatment, paper sizing, dye industry.
Production; Aluminum sulfate, while commonly called
alum, Is" not a true alum. True alums are a double
sulfate of aluminum or chromium and a monovalent
metal or radical.
Aluminum sulfate is made by the reaction of 60 Be1
sulfuric acid with bauxite following grinding.
The liquor is treated by the addition of barium
sulfide to remove iron and is then clarified and
solidified. Production means are not likely to
change in the near future.
Waste Problems: The major wastes are slurries of
solids collected in the thickener decanters.
These solids can easily be collected and con-
trolled. No major change in the amount of wastes
is expected.
195
-------
Ammonium Nitrate
AMMONIUM NITRATE PLANTS
UNITED STATES
Company
Agway, Inc.
Allied Chemical Corp
American Cyanamid Co,
Apache Powder Co.
Arkla Chemical
Armour Agricultural
Chemical Company
Calumet Nitrogen Co.
Carolina Nitrogen Co.
Central Nitrogen Co.
Cherokee Nitrogen Co.
Chevron Chemical Co.
Columbia Nitrogen Co.
Cominco American, Inc.
Commercial Solvents
Corporation
Escambia Chemical
Corporation
Farmers Chemical
Association
Farmland Industries
Fel-Tex/ Inc.
Gulf Oil Corp.
Hawkeye Chemical Co.
Hercules, Inc.
Location
Olean, N.Y.
Geismar, La.
Hopewell, Va.
Omaha, Nebr.
South Point, O.
Hannibal, Mo.
Benson, Ariz.
Helena, Ark.
Cherokee, Ala.
Crystal City, Mo.
Hammond, Ind.
Wilmington, N.C.
Terre Haute, Ind.
Pryor, Okla.
Fort Madison, Iowa
Kennewick, Wash.
Richmond, Calif.
Augusta, Ga.
Beatrice, Nebr.
Marion, 111.
Sterlington, La.
Pace, Fla.
Tyner, Tenn.
Lawrence, Kans.
Fremont, Nebr.
Henderson, Ky.
Pittsburg, Kans.
Vicksburg, Miss.
Clinton, Iowa
Donora, Pa.
Hercules, Calif.
Louisiana, Mo.
Capacity-
1966
(thousand
tons)
105
385
400
98
235
140
30
150
128
111
55
161
134
45
70
61
55
208
200
148
100
180
208
34
105
360
43
153
• • •
140
425
196
-------
Ammonium Nitrate (cont.)
Company
Location
Illinois Nitrogen, Inc.
Kaiser Chemical Co.
Ketona Chemical Corp.
Mississippi Chemical
Corporation
Mobil Chemical Co.
Monsanto Co.
Nipak, Inc.
Nitram, Inc.
Nitrin, Inc.
Northern Chemical
Industries
Olin Mathieson
Chemical Co.
Phillips Chemical Co.
St. Paul Ammonia Corp,
Smith Chemical Co.
Solar Nitrogen
Chemicals Co.
Terra Chemicals
International
Texaco, Inc.
Union Oil of Calif.
U.S. Indus tri al
Chemicals Co.
U.S. Steel Corp.
Valley Nitrogen
Producers
Wycon Chemical Co.
Source: TVA
Marseilles, 111.
Bainbridge, Ga.
North Bend, Ohio
Savannah, Ga.
Tampa, Fla.
Ketona, Ala.
Yazoo City, Miss.
Beaumont, Tex.
El Dorado, Ark.
Luling, La.
Kerens, Tex.
Tampa, Fla.
Cordova, 111.
Searsport, Maine
E. Alton, 111.
Beatrice, Nebr.
Etter, Tex.
Kennewick, Wash.
Pine Bend, Minn.
Douglas, Ga.
Joplin, Mo.
Lima, Ohio
Port Neal, Iowa
Lockport, 111.
Brea, Calif.
Tuscola, 111.
Geneva, Utah
El Centre, Calif.
Helm, Calif.
Cheyenne, Wyo.
Total
Capacity-
1966
(thousand
tons)
132
50
95
198
54
39
296
200
280
290
56
140
110
25
50
11
240
20
88
110
75
145
95
60
88
90
88
35
37
7,874
197
-------
AMMONIUM NITRATE PLANT LOCATIONS
FIGURE 5
H
£
X
A NEW PLANT
-------
Production; 1969: 5,200,000 tons
1974: 6,300,000 tons
Uses; Fertilizer, explosives.
Processes; While some ammonium nitrate is manu-
factured by the old batch method, the vast
majority is manufactured by one of a variety of
continuous processes. All processes involve
the direct contact of preheated ammonia and
nitric acid, separation of the gaseous water,
and prilling or flaking by melting. While
various modifications are continuously being
brought into use, no basic changes are expected.
Waste Problems; Washdown produces substantial
amounts of nitrogen rich wastewaters. Additional
amounts are associated with scrubber blowdowns
and from cooling water. Improved plant mainten-
ance would assist in controlling this problem.
Ammonium Sulfate
Producers; A detailed list is not available because
of the large number of by-product producers, but
producers include:
Alabama By-Products Interlake Steel
Allied Chemical Olin
American Cyanamid Phillips
Bethlehem Steel Shell
C. F. & I Steel Simplot
Chevron Sinclair
Columbia Nitrogen Sunray
DuPont U. S. Pipe
Graver U. S. Steel
Inland Steel
Production; 1969: 2,715,000 tons
1974: 3,000,000 tons
Uses: Fertilizer
199
-------
Processes; About 35% of the production is associated
with the direct reaction of ammonium salts such as
the carbonate with sulfuric acid. Some is made by
the use of gypsum in place of the sulfuric acid.
Major discharges involve solid slurries of by-
product materials.
Major amounts of ammonium sulfate are made during
the recovery of ammonia from coke oven gas. About
40% of the total production is involved with the
actual recovery of by-product ammonia from a
variety of other processes. A plant in California
is being built based on the reaction of gypsum and
ammonia. To summarize, most of the ammonium sul-
fate produced in this country is a result of
attempts to control atmospheric pollution. No
change in production pattern is expected to occur.
Waste Problems; As indicated above, no major waste
problem exists.
Calcium Carbide
Producer Capacity —
Airco, Calvert City, Ky. 300,000
Airco, Keokuk, Iowa 36,000
Airco, Louisville, Ky. 150,000
Midwest Carbide, Keokuk, Iowa 50,000
Midwest Carbide, Pryor, Okla. 30,000
Pacific Carbide, Portland, Ore. 20,000
Union Carbide, Ashtabula, Ohio 228,000
Union Carbide, Niagara Falls, N. Y. 210,000
Union Carbide, Portland, Ore. 32,000
Union Carbide, Sheffield, Ala. 60,000
Total 1,116,000
_!/ tons/year
Production: 1969: 920,000 tons
1974: 900,000 tons
Use_s: Production of acetylene.
Processes; Calcium carbide is prepared from quicklime
and carbon (usually coke, petroleum coke or anthra-
200
-------
cite) at 2000-2200°C in a furnace related to the
familiar arc furnace. No major process change is
expected but the use of carbide-based acetylene is
expected to be reduced in the future.
Waste Problems: Since the process is not a wet
process, the only major discharges are associated
with wastewaters used to scrub furnace and kiln
effluents.
Hydrochloric Acid
Producers: Most HC1 is produced as a by-product from
the production of carbon tetrachloride and other
chlorinated hydrocarbons, PVC, ethylene oxide, and
phenol. (See "Projected Wastewater Treatment Costs
in the Organic Chemicals Industry," Department of
the Interior.) Major producers of anhydrous HC1
are:
Detrex Morton
Diamond Shamrock Shell
Dow Stauffer
Hooker Vulcan
Montrose
Major producers of aqueous HC1 are:
Allied Hooker Pennsalt
Ark la Mob ay PCA
Baker Monsanto Reichhold
Cabot Mont Shell
Detrex Morton Stauffer
Diamond Shamrock Olin Velsicol
Dow PPG Vulcan
DuPont Pearsall Wyandotte
GAF
Production; 1969: 1,800,000 tons
1974: 2,200,000 tons
Uses; Oil well activation, chemical production, steel
pTckling, monosodium glutamate and starch hydrolysis,
metal cleaning.
201
-------
Processes: The major portion of HCl currently produced
(85%) is a by-product of the chlorination of hydro-
carbons. However, it is expected that the amount of
by-product HCl available will be greatly decreased
in the future for several reasons. These include:
1. The practice of oxychlorination is increasing
rapidly and this, in a balanced system, can
eliminate the presence of waste HCl.
2. Most vinyl chloride plants employ oxychlorina-
tion and do not produce major amounts of waste
acid.
3. A new process, based on a modification of the
old Deacon process, as developed by Kellogg,
is expected to produce large amounts of chlorine
(note impact on chlorine under #2812) and con-
sume substantial amounts of by-product acid.
There are sufficient amounts of waste acids avail-
able so that the short term supply will not be a
problem.
Three other sources of supply are as follows:
1. Direct burning of chlorine in a small excess of
hydrogen. This is followed by the adsorption
of HCl in water, followed by stripping to pro-
duce a high purity HCl.
2. The reaction of salt and sulfuric acid in a
high temperature furnace. Sodium sulfate is
formed as a by-product. Adsorption of the acid
in water takes place with removal of salt and
acid in a coke tower.
3. A Hargreaves-type operation which involves the
reaction of salt, sulfur dioxide, oxygen and
water to form sodium sulfate and acid. (This
process is used by only one plant.)
Waste Problems; In the salt acid reaction, the wash-
ing out of the coke tower produces a waste stream
of acid and salt. Improved furnace design would
cut down on the amount of carryover.
202
-------
In the salt-acid process, as in the Hargreaves
reaction, a stream of weak sulfuric amounting to
50-90 Ibs/ton 20° Be1 hydrochloric acid is pro-
duced.
Weak hydrochloric acid is also wasted from the
system.
Hydrofluoric Acid
Producer Capacity ±/
Alcoa, Point Comfort, Tex. 25,000
Allied, Baton Rouge, La. 15,000
Allied, Geismar, La. 15,000
Allied, Nitro, W. Va. 20,000
Allied, North Claymont, Del. 25,000
Allied, Port Chicago, Calif. 12,000
DuPont, Deepwater Point, N. J. 15,000
DuPont, Strang, Tex. 50,000
Essex, Paulsboro, N. J. 11,000
Harshaw, Cleveland, Ohio 10,000
Kaiser, Gramercy, La. 15,000
Olin, Joliet, 111. 12,000
Pennsalt, Calvert City, Ky. 18,000
Reynolds, Bauxite, Ark. 40,000
Stauffer, Houston, Tex. 18,000
Total 301,000
I/ tons/year
Production; 1969: 310,000 tons
1974: 420,000 tons
Uses; Fluorocarbons, aluminum, petroleum alkylation,
stainless steel pickling, AEG work.
Processes; HF is prepared by heating, in kilns, the
ore-fluorspar (CaF2) with sulfuric acid. The
gaseous HF is either absorbed in water or liquified,
employing refrigeration to obtain the anhydrous
product.
Waste Problemst Not significant except in washout
where fluoride concentrations can be a serious prob-
lem.
203
-------
Hydrogen Peroxide
Producer Capacity —'
Allied, Syracuse, N. Y. 4,000
DuPont, Memphis, Tenn. 25,000
FMC, Buffalo, N. Y. 6,000
FMC, South Charleston, W. Va. 8,000
FMC, Vancouver, Wash. 6,000
Pennsalt, Wyandotte, Mich. 1,750
Pittsburgh Plate, Barberton, Ohio 3,750
Shell, Norco, La. 17,000
Total 71,500
I/ tons/year
Production; 1969: 70,000 tons
1974: 100,000 tons
Uses; Textiles, paper and pulp, plasticizers, chemi-
cals.
Processes; Hydrogen peroxide is manufactured by one
electrolytic and two organic oxidation processes.
Sulfuric acid is electrolyzed to peracid (H2S20s)
which hydrolyzes to sulfuric acid and peroxide.
The organic processes center on 2-ethylanthraquinone
which is oxidized to produce peroxide and recycle-
able quinone and isopropyl alcohol. The latter are
oxidized at modest temperatures and pressures to
peroxide and acetone.
Waste Problems; The electrolytic process produces a
stream of dilute sulfuric acid. The organic based
processes will probably produce a waste stream from
the distillation column.
Lime
Producers; There are some 210 lime producing plants
located wherever there are significant limestone
deposits. This list is too exhaustive for display
here. Refer to "Minerals Yearbook," U. S. Bureau
of Mines, for a complete listing.
204
-------
Production: 1969:
1974:
Quicklime - 14,000,000 tons
Hydrated - 3,000,000 tons
Total - 19,000,000 tons
Uses; Agriculture, chemical manufacture, pulp manu-
facture, tanning, steel and cement manufacture,
water treatment, soap manufacturing, construction.
Processes: Thermal decarbonation of limestone or
calcium carbonate sludge usually in a shaft kiln
or a rotary kiln but also in a fluidized bed kiln.
Waste Problems; These generally arise if solids cap-
ture is by wet scrubbing. Conversion to a dry
capture system such as bag filters would eliminate
the problem.
Nitric Acid
Producers
Company
Agway
Allied
American Cyanamid
Ark la
Armour
Atlas
Celanese
Central Farmers
Central Nitrogen
Plant Location
Olean, N.Y.
Buffalo, N.Y.
Geismar, La.
Hopewell, Va.
La Platte, Nebr.
Newell, Pa.
South Point, 0.
Bound Brook, N.J.
Hannibal, Mo.
Willow Island, W. Va.
Helena, Ark.
Cherokee, Ala.
Crystal City, Mo.
Joplin, Mo.
Tamaqua, Pa.
Bay City, Tex.
Fremont, Nebr.
Terre Haute, Ind.
Estimated capacity
('68) (1,000 tons/
year)
Plant Co. Total
60
25
200
250
90
60
240
25
110
27
90
110
100
122
24
77
31
133
60
865
162
90
210
146
77
31
133
205
-------
Nitric Acid (cont.}
Company
Plant Location
Cherokee
Chevron
Collier
Columbia Nitrogen
Cominco
Commercial Sol-
vents
Cooperative Farm
Chems.
DuPont
El Paso
Escambia
Farmers' Chemical
Grace
Gulf
Hawkeye
Hercules
Estimated capacity
('68) (1,000 tons/
year)
Plant Co. Total
Prior, Okla.
Ft. Madison, La.
Kennewick, Wash,
Richmond/ Calif,
Brea, Calif.
Augusta, Ga.
Beatrice, Nebr.
Marion, 111.
Sterlington, La.
Lawrence, Kans.
Barksdale, Wis.
Belle, W. Va.
Birmingham, Ala.
DuPont, Wash.
Gibbstown, N.J.
Louviers, Colo.
Old Hickory, Tenn,
Orange, Tex.
Victoria, Tex.
Seneca, 111.
Wabash, Ind.
Odessa, Tex.
Pensacola, Fla.
Tyner, Tenn.
Wilmington, N. C.
Henderson, Ky.
Pittsburg, Kans.
Vicksburg, Miss.
Clinton, La.
Bessemer, Ala.
Hercules, Calif.
Kenvil, N.J.
Louisiana, Mo.
Parling, N.J.
Donora, Pa.
Illinois Nitrogen Marseilles, 111.
65
94
130
85
47
162
135
50
163
485
20
82
20
20
350
15
44
180
120
215
150
63
90
170
164
85
281
85
125
20
65
16
400
53
120
120
65
309
47
162
135
213
485
1,216
63
90
170
164
451
125
674
120
206
-------
FIGURE 6
AMMONIA
ABSORPTION
COLUMN
AIR
INTAKE
FILTER
CONDENSED STEAM
MAKE UP WATER
ABS. COL.
FEED TANK
VAPORIZER
AMMONIA
SOLENOID
VALVE
ABS. COL.
FEED PUMP
MIST
SEPARATOR
COOLING
WATER
COOLER
CONDENSER
GAS
, .MIXER
ISO PSI6
.l TEAM
COOLING
WATER
WASTE
HEAT
BOILER
COOLING
WATER
HN03 TO
STORAGE
COMPRESSOR
{ELECTRIC MOTOR)!
COOLING WATER
RETURN PUMP
EXPANDER
L_J
BLEACHING AIR
SOLENOID VALVE
TERMINAL BOX
r
FLOWCHART FOR 60% NITRIC ACID FROM AMMONIA
This flow chart is selectively reproduced in content and configuration from Figure 18.9
in the book by R. Norris Shrove, Chemical Process Industries, Third Edition, New
York, Me Grow -Hi II Book Company, 1967, p. 316
-------
Nitric Acid (cont.)
Company
Kaiser
Ketona
Miscoa
Mob ay
Mobil
Monsanto
Nipak
Nitram
Nitrin
Northern Chemi-
cal Industries
Olin Mathieson
Phillips Chemical
St. Paul Ammonia
Plant Location
Bainbridge, Ga.
North Bend, O.
Savannah, Ga.
Tampa, Fla.
Ketona, Ala.
Yazoo City, Miss.
New Martinsville,
W. Va.
Beaumont, Tex.
El Dorado, Ark.
Luling, La.
Pensacola, Fla.
Kerens, Tex.
Tampa, Fla.
Cordova, 111.
Searsport, Maine
Lake Charles, La.
Kennewick, Wash.
Beatrice, Nebr.
Etter, Tex.
Pasadena, Tex.
Pine Bend, Minn.
Estimated capacity
('68) (1,000 tons/
year)
Plant Co. Total
47
84
162
42
36
388
50
154
275
270
258
50
120
95
25
95
43
9
164
13
100
335
36
388
50
154
803
50
120
95
25
95
100
Production:
1969: 6,140,000 tons
1974: 7,000,000 tons
Uses; Fertilizers, chemicals, photoengravings,
explosives.
Processes: Nitric acid is produced by the catalytic
air oxidation of ammonia. Nitric oxide is absorbed
in water and oxidized. Higher strength nitric acid
is produced by breaking the azeotrope with either
sulfuric acid or magnesium nitrate. No significant
changes are expected in the production of nitric
acid.
208
-------
Waste Problems; Major problems are associated with
cooling -water blowdown and area washdown which may
contain troublesome amounts of nitric acid.
Phosphoric Acid
Producers
Location
Allied Chemical
American Agricul-
tural Chem.
American Cyanamid
American Potash
Arkla Chemical
Armour Agricul-
tural
Borden
Bunker Hill
Central Phos-
phates
Coastal Chemical
Consumers Co-
operative
Des Plaines
Chemical
El Paso Natural
Gas
Farmers Chemical
Freeport Sulfur
W. R. Grace
National Phos-
phate
IMC
New Jersey Zinc
Nipak
NW Cooperative
Mills
E. St. Louis, 111,
N. Claymont, Del.
Geismar, La.
Pierce, La.
Brewster, Fla.
Trona, Calif.
Helena, Ark.
Bartow, Fla.
Ft. Meade, Fla.
Piney Point, Fla.
Streator, 111.
Texas City, Tex.
Kellogg, Ida.
Plant City, Fla.
Pascagoula, Miss.
Pierce, Fla.
Morris, 111.
Conda, Ida.
Joplin, Mo.
Uncle Sam, La.
Bartow, Fla.
Joplin, Mo.
Taft, La.
Marseilles, 111.
Bonnie, Fla.
Depue, 111.
Tulsa, Okla.
Pine Bend, Minn.
Capacity (tons
100% P205/yr)
36,200
36,200
159,300
216,000
148,800
Not Available
50,000
85,000
188,000
165,000
24,000
60,000
24,500
200,000
175,900
200,000
50,000
100,000
55,000
540,000
415,000
35,000
207,000
103,500
500,000
150,000
21,000
32,000
209
-------
Phosphoric Acid (cont.)
Producers
Location
Occidental
Petroleum
Best Fertilizer
Olin Mathieson
Phosphate Chemi-
cals
F. S. Royster
Guano
J. R. Simplot
Mobil Chemical
Western Phos-
phates
Swift
Tennessee Corp.
TGS
U.S. Industrial
Chemicals
Valley Nitrogen
Western States
Chem.
Hamilton Co., Fla.
Lathrop, Calif.
Joliet, 111.
Pasadena, Tex.
Pasadena, Tex.
Mulberry, Fla.
Pocatello, Ida.
Nichols, Fla.
Garfield, Utah
Agricola, Fla.
E. Tampa, Fla.
Aurora, N. C.
Tuscola, 111.
Helm, Calif.
Capacity (tons
100% P2Q5/yr)
207,000
17,300
127,000
217,500
50,000
130,000
265,000
125,000
70,000
126,300
490,000
347,000
40,000
50,000
Point Chicago, Calif. 90,000
Total 5,807,500
Production:
1969: 4,926,000 tons (100% P2Os)
1974: 5,900,000 tons (100% P2O5)
Uses; Fertilizer, detergents, food.
Processes'; Phosphoric acid is produced by two methods.
One method involves the hydrolysis of phosphorous and
will be discussed under phosphorous. The most common
approach is responsible for some 80% of the total
production; this is from the acidulation of phosphate
rock* Usually the acidulation involves the use of
sulfuric acid. The acid is concentrated while the
by-product, gypsum, is filtered and washed.
210
-------
PHOSPHORIC ACID PLANT LOCATIONS
FIGURE 7
FURNACE PHOSPHORIC ACID
WET PROCESS PHOSPHORIC ACID
NEW WET PROCESS PHOSPHORIC ACID PLANT
-------
Alternative routes involve the use of nitric or
hydrochloric in place of sulfuric. This approach
is not likely to make any impact on acid production,
The swing towards production of a more usable by-
product in the form of the hemihydrate will have a
major impact upon waste treatment. On the other
hand, increasing pressure relative to air pollution
will increase the removal of fluorides and thereby
increase waste streams.
Waste Problems: Waste arises from at least four
sources in the process. The primary source is the
waste gypsum from the acidulation. This semi-solid
waste may contain quantities of phosphoric and
sulfuric acid. The development of techniques for
utilizing the waste product should greatly reduce
the magnitude of the problem.
The second source is the water from the scrubbers
which contain large amounts of acid fluorides.
By-product use would appear to be the answer here,
as well. Increasing amounts are utilized as a
source for fluoride chemicals.
This third waste source is the sludge of aluminum
and iron phosphate sludge produced by the post
precipitation of the acid. This may amount to
1-5% of production.
A fourth source involves the tailings from the rock
beneficiation. No change in these waste sources is
anticipated.
Phosphorus
Capacity
Producers Location (tons/year)
Continental Oil Pierce, Fla. 30,000
El Paso, George-
town, Ida. 21,000
FMC Pocatello, Idaho 142,000
Hooker Columbia, Tenn. 68,500
Mobil (V-C) Charleston, S. C. 10,000
Mobil (V-C) Mt. Pleasant, Tenn. 20,000
Mobil (V-C) Nichols, Fla. 6,000
212
-------
Phosphorus (cont.)
Capacity
Producers Location (tons/year)
Monsanto Columbia, Tenn. 110,000
Monsanto Soda Springs, Idaho 120,000
Stauffer Mt. Pleasant, Tenn. 80,000
Stauffer Silver Bow, Mont. 30,000
Stauffer Tarpon Springs, Fla. 12,500
TVA Wilson Dam, Ala. 110,000
Total 760,000
Production; 1969: 610,000 tons
1974: 740,000 tons
Uses: Sodium tripolyphosphate, phosphoric acid,
other sodium phosphates, calcium phosphates,
tetrapotassium pyrophosphate, sodium metaphosphate.
Processes; Phosphate rock is mixed with sand and coke,
sintered and introduced into an electric furnace.
After heating at elevated temperature, slag and
ferrophosphorous is drawn off. Phosphorous vapor is
drawn off and condensed. Phosphorous is oxidized to
P2C-5 which is cooled and hydrated, filtered and
purified.
Waste Problems; A stream containing a significant
amount of phosphorous (1% of production) is known as
"phossy" water. The phosphorous may be settled,
thickened and recycled. The filtration of the acid
also produces a waste sludge of acid which causes a
disposal problem. No major processing changes are
anticipated.
TKPP
Producer Location Capacity —/
FMC Carteret, N. J. 10,000
FMC Newark, Calif. 2,500
Hooker Jeffersonville, Ind. 5,000
Mobil (V-C) Fernald, Ohio 12,000
Monsanto Carondelet, Mo. 15,000
213
-------
TKPP (cont.)
Producer Location Capacity =/
Olin joliet, 111. 5,000
Stauffer Chicago Heights, 111. 7,500
Stauffer South Gate, Calif. 2,500
Total 59,500
I/ tons/year
Production; 1969: 48,500 tons
1974: 60,000 tons
Uses; Liquid detergent builder.
Processes; TKPP is prepared by the reaction of phos-
phoric acid and potassium carbonate to produce
dipotassium-phosphate which is calcined to TKPP.
Waste Problems; Not significant.
Sodium Metal
Producers Location Capacity —r
DuPont
Ethyl
National
Distillers
Memphis , Tenn .
Niagara Falls, N.Y.
Baton Rouge , La .
Houston, Tex.
Ash tabula, Ohio
Total
70
84
90
60
56
360"
I/ million Ibs/year
Production: 1969: 165,000 tons
1974: 200,000 tons
Uses; Tetraethyl and tetramethyl lead, potassium,
sodium peroxide, sodium cyanide.
Processes: Electrolysis of fused sodium chloride.
The crude sodium is filtered at 105-110°C.
214
-------
Waste Problems; Since the process is run dry, waste
problems are limited to washouts/ spills and filter
cake discharge.
Sodium Bicarbonate
Producer
Location
Church & Dwight Syracuse, N. Y.
Church & Dwight Green River, Wyo.
Diamond Painesville, Ohio
Saltville, Va.
Barberton, Ohio
Wyandotte, Mich.
Total
I/ tons/year
Olin
PPG
Wyandotte
Capacity —'
100,000
40,000
28,000
23,000
40,000
30,000
261,000
Production:
1969: 205,000 tons
1974: 235,000 tons
Uses: Food, chemicals, drugs, fire extinguishant,
soap and detergents, leather, textile, and paper.
Processes; Sodium bicarbonate is not made by refining
the crude sodium bicarbonate from the Solvay process.
A saturated solution of soda ash (natural or
synthetic) is prepared and is carbonated with CO2 in
a tower. The suspension is filtered, washed,
centrifuged and dried.
Waste Problems; Major problem is the blowdown of the
filter cake and filter cake washups. No significant
process changes are expected and no change in the
nature of pollutional problems seems likely.
Sodium Bichromate
Producer
Location
Allied
Diamond Shamrock
Diamond Shamrock
Hercules
Pittsburgh Plate
I/ tons/year
Baltimore, Md.
Kearny, N.J.
Painesville, Ohio
Glen Falls, N.Y.
Corpus Christi, Tex.
Total
Capacity =/
90,000
15,000
50,000
16,000
35,000
206,000
215
-------
Production; 1969: 150,000 tons
1974: 165,000 tons
Uses: Pigments, leather tanning, chromic acid, metal
treatment, textiles and dyes.
Processes: The raw material is a chromium iron oxide
containing about 50% Cr2O3. The ore is ground to
200 mesh, mixed with limestone and soda ash and
heated to 2200°F in a strongly oxidizing atmosphere.
The mass is leached with hot water to remove the
soluble sodium chromate. The solution is acidified
to convert the chromate to dichromate. The sodium
sulfate crystallizes out and the solution is sent
to crystallizers to recover the dichromate. No
process changes are expected.
Waste Problems: The solution coming off the
crystallizers contains about 0.1 ton of Na2S04 per
ton of sodium dichromate and minor amounts of
sodium dichromate and chromate. Use of ion exchange
and other concentrating systems could permit re-
covery from this system.
Sodium Chloride
Producers Capacity —'
Morton 6
International 4
Diamond Crystal 2.5
Leslie 1.5
Other salt companies 5
Total noncaptive capacity 19
Captive to chemical companies 22
Total salt and brine 41
I/ million tons/year
Production: 1969: 43,000,000 tons
1974: 57,000,000 tons
Uses; Production of chlorine, caustic, soda ash, other
chemicals, highway use, food, feed, water condition-
ing.
216
-------
Processes; Salt is obtained in three fashions: one
by solar evaporation of sea water or western lake
brines; another from well brine and a third by the
mining of rock salt. It is necessary to remove
calcium and magnesium chlorides, usually by under-
taking evaporative concentration followed by filtra-
tion of the precipitated salts of Mg and Ca. The
process may undergo some modification but major
changes are not likely.
Waste Problems; Wastewater results from two sources.
One is the deposits of calcium and magnesium salts
which are removed in the process. This slurry can
amount to 3-5% of the total process flow.
The second source is the slip stream removed to
control impurities in any recycling system such as
the Alberger method. Use of a concentrating or an
ion control system may be effective in controlling
this problem internally.
Sodium Silicate
Producer Capacity —
Allied 105,000
Amerace 25,000
Chemical Products 10,000
Diamond 230,000
DuPont 150,000
Grace 65,000
Philadelphia Quartz 225,000
Philadelphia Quartz (Calif.) 35,000
Pittsburgh Plate 60,000
Proctor & Gamble 20,000
Twin Chemical 15,000
Total 940,000
I/ tons/year
Production; 1969: 640,000 tons
1974: 750,000 tons
Uses: Catalysts and silica gels, soaps and detergents,
boxboard adhesives, pigments, water, paper and ore
treatment.
217
-------
Processes; Sodium silicates are prepared by fusing
sodium carbonate and silica sand in a glass melting
furnace at about 1300°C. If the product is to be
sold as a solution, it is dissolved by steam
injection. No process change is anticipated.
Waste Problems; None except washdown.
Sodium Sulfite
Producer
Location
Capacity =•
Allied
Allied
Koppers
Monsanto
Reichhold
Stauffer
El Segundo, Calif.
N. Claymont, Del.
Petrolia, Pa.
Monsanto, M4.
Tuscaloosa, Ala.
South Gate, Calif.
Total
5,000
10,000
25,000
62,500
145,000
3,000
250,500
I/ tons/year
Production:
1969: 230,000 tons
1974: 240,000 tons
Processes: Direct contact between SC-2 and soda ash
followed by boiling off of C02. Sesgihydrate is
precipitated. Another source is as a by-product in
the preparation of phenol by the fusion of sodium
benzene sulfonate with caustic (See "Waste Water
Treatment Costs in the Organic Chemical Industry,"
U. S. Department of the Interior).
Uses; Sulfite pulping, water treatment, photo grade.
Waste Problems; The waste solution contains a
saturated solution of sulfite which has an
immediate oxygen demand if released to the river.
Additional recycling and reuse is possible and,
if practiced, dumping may be eliminated.
218
-------
Sodium Sulfate
Producer Capacity —'
Allied (B) 45,000
American Cyanamid (0) 13,000
American Enka (R) 56,000
American Potash (N) 250,000
Beaunit (R) 42,000
Climax Chemical (M) 35,000
Diamond Shamrock (B) 50,000
DuPont (M) 30,000
FMC (R) 275,000
Hercules (B,M) 25,000
Huber (0) 8,000
Industrial Rayon (R) 36,000
Koppers (0) 15,000
Lithium Corporation (0) 15,000
Monsanto (0) 35,000
Morton Chemical (M) 120,000
Ozark-Mahoning (N) 200,000
Stauffer (N,O) 200,000
U. S. Borax (O) 30,000
Miscellaneous 25,000
Total 1,505,000
I/ tons/year
B-Bichromate; 0-Other; R-Rayon or Cellophane;
N-Natural; M-Mannheim or Hargreaves
Production; 1969: 1,500,000 tons/year
1974: 1,800,000 tons/year
Uses; Sulfate pulping, detergents, glass.
Processes; Much of the sodium sulfate is from by-
product sources discussed elsewhere. Glauber's
salt (Na2SO4.1OH2O) is made by dissolving salt cake
in mother liquor, adding of CaCl2 and lime. The
Mg, Ca and Fe are permitted to settle and the mud
washed. Crystallization takes place in pans and
anhydrous sodium sulfate is prepared by dehydrating
Glauber's salt. No new sources or processes are
anticipated.
Waste Problems; Disposal of the mud is the primary
problem and in-plant control would have little
impact on this problem.
219
-------
Sodium Tripolyphosphate
Producer
Allied
AAC
FMC
FMC
FMC
FMC
Hooker
Hooker
Hooker
Monsanto
Monsanto
Monsanto
Monsanto
Monsanto
Olin
Stauffer
Stauffer
Stauffer
Stauffer
Virginia-Carolina
Location
I/ tons/year
Production:
Capacity —f
1969:
1974:
N. Claymont, Del.
Carteret, N. J.
Carteret, N. J.
Green River, Wyo.
Lawrence, Kans.
Newark, Calif.
Adams, Mass.
Dallas, Tex.
Jeffersonville, Ind.
Augusta, Ga.
Carondelet, Mo.
Kearny, N. J.
Long Beach, Calif.
Trenton, Mich,
Joliet, 111.
Chicago, 111.
Chicago Heights, 111
Morrisville, Pa.
South Gate, Calif.
Fernald, Ohio
Total
1,200,000 tons
1,600,000 tons
30
40
150
50
75
50
25
25
75
25
100
75
25
75
140
40
25
75
50
50
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
1,200,000
Uses; Detergents.
Processes; The sodium phosphates are made primarily
from furnace acid and soda ash which are reacted
in a mix tank and dried in a rotary or spray drier
and dehydrated in a calciner. This is followed by
annealing and cooling in a tempering unit.
Water Problems: Scrubber waters and vessel washouts
are major sources of polluted wastewaters.
220
-------
SIC 2819 (INDUSTRIAL INORGANIC CHEMICALS)
Aluminum Chloride Anhydrous
Producer Capacity —
Allied, Elberta, N. Y. 9,000
Dow, Freeport, Texas 5,000
Hercules Alelor, Ravenna, Ohio 2,400
Pearsall, LaPorte, Texas 4,000
Pearsall, Phillipsburg, N. J. 6,000
Stauffer, Baton Rouge, La. 8,000
Stauffer, Elkton, Md. 8,000
Van de Mark, Lockport, N. Y. 2,500
Total 44,900
I/ tons/year
Production: 1969: 34,000 tons
1974: 44,000 tons
Uses; Ethylbenzene catalyst, dyestuffs, detergent
alkylate, ethyl chloride, Pharmaceuticals.
Processes; The reaction involves the direct contact
of chlorine vapor with molten aluminum. Chlorine
is fed below the surface of the aluminum and the
product sublimes and is collected by condensing.
No change is expected in processing methods.
Waste Problems: The major discharge is a chlorine
containing wastewater which could be utilized as a
treatment chemical. Recovery of the chlorine by
rectification is feasible.
Sulfuric Acid
New Plants Built Since 1966 Include The Following:
Producer Location Capacity
Acid, Inc. Bonnie, Fla. 2,000,000
Arkla Chemical Helena, Ark. 180,000
American Cyanamid Linden, N. J. 250,000
221
-------
Sulfuric Acid (cont.)
Producer
American Oil Co.
Allied
American Smelting &
Refining Co.
American Zinc
Borden Chemical
Bunker Hill
DuPont
Freeport Sulfur
W. R. Grace
Kennecott Copper
Mo. Lead Smelting
National Zinc
Olin
Sinclair
Stauffer
Stauffer
Tennessee Corp.
Texaco
Texas Gulf Sulfur
I/ tons/year
Location
Texas City, Tex.
Geismar, La.
Haydon, Ariz.
Monsanto, 111.
Columbus, Ohio
Plant City, Fla.
Kellogg, Idaho
Burnside, La.
Memphis, Tenn.
Uncle Sam, La.
Bartow, Fla.
Hayden, Ariz.
Salt Lake City, Utah
Iron Co. , Mo.
Bartlesville, Okla.
Shreveport, La.
Ft. Madison, Iowa
Houston, Texas
Martinez, Calif.
Augusta, Ga.
Port Arthur, Tex.
Lee Creek, N. C.
Total
Major merchant producers include:
Stauffer Chemical
Allied Chemical
DuPont
Capacity —'
150,000
720,000
250
146
64
385
100
540
75
1,725
385
270
505
75
100
125
540
720
360
135
92
1,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
,000
10,892,000
American Cyanamid
Tennessee Corporation
Production: 1969: 28,000,000 tons
1974: 34,000,000 tons
Uses; Fertilizer, chemical production, iron and steel
pickling, food, petroleum products, metallurgy/
Ti02 production, (NH4)2 604, alum, rayon.
Processes; Two processes have been used for the
production of sulfuric acid - the chamber process
and the contact process. Since no new chamber
processes have been built for perhaps 30 years, the
222
-------
LIGLRE 8
10
to
CO
AIR INTAKE
SILENCER
OR FILTER
EXIT GAS
STACK
98-99% .»
ACID TO
STORAGE
ABSORBING
TOWER
STEAM
MELTER -
SETTLER
CIRCULATING
TANK
I-.-OLEUM TO
STORAGE
5j
^•J OLEUM PUMP
VOLEUM COOLER
TYPICAL FLOWCHART FOR SULFUR-BURNING CONTACT PLANT
This flow chart is selectively reproduced in content and configuration from Figure 19.4
in the book by R. Norris Shreve, Chemical Process Industries, Third Edition, New York,
Me Grow-Hi II Book Company, 1967, p. 330
-------
following discussion will center on the contact
process. In this process, either sulfur or SC>2 may
be the starting point. If sulfur is the starting
point, it is melted and burnt with air to S02. The
S02 must be filtered and converted catalytically to
803. 803 is absorbed in strong sulfuric acid.
Present process changes are directed towards the
improvement in conversion and recovery because of
the air pollution problem.
Waste Problems; Primarily from vessel cleanout, and
slab washdown as well as discharge of cooling
waters.
224
-------
SIC 2851 (PAINTS AND ALLIED PRODUCTS)
Paints., and Allied Products
Producers: There are several hundred paint companies
with several thousand paint plants scattered through-
out the country. Paint production tends to be a
local product because of the high transportation
charges. However, Ohio, Illinois, New Jersey and
California are major paint-producing centers.
Among the leading concerns are the following:
DuPont
National Lead
Sherwin-Williams
Glidden
Moore
Devoe and Reynolds-Celanese
Production;
Paint and Varnishes, Total
Trade Sales
Paint and Varnish
Lacquer
Trade Sales, Total
Industrial Product Finishes
Paint and Varnish
Lacquer
Industrial Product
Finishes, Total
1969 (gal)
904,000,000
438,000,000
11,000,000
449,000,000
360,000,000
95,000,000
PPG
DeSoto
Mobil
Inmont
Cook
1974 (gal)
1,196,000,000
587,000,000
15,000,000
602,000,000
482,000,000
112,000,000
455,000,000 594,000,000
Processes; The manufacture of paints involves
primarily mixing in tanks although grinding mills,
sand mills, high-speed stone mills and high-speed
agitators are being increasingly used in these
systems. The process is batch type. Finally, color
may be added in a tinting and thinning tank before
packaging.
Varnish is a solution of a resin in a drying oil
or solvent (shellac). This is accomplished by
mixing; in some cases, by heating. Finally, the
final product is clarified by filtration or
225
-------
centrifugation followed by aging in large tanks
to precipitate grit particles.
There has been little change in the manufacture
of paints for a century or more and none is
expected.
Waste Problems: The major problems arise from tank
washings and dumpings. The presence of latex is
a specially difficult problem but collection and
recycle of the latex is completely possible as is
the multiple reuse of wash waters.
226
-------
SIC 2871 (FERTILIZERS)
Fertilizers
Producers; Fertilizers are generally made by a large
number of production facilities located throughout
the country. The basic ingredients include: potash,
ammonia, ammonium sulfate, ammonium nitrate/
ammonium phosphates, plus other phosphate products
all of which are prepared in a limited number of
large production facilities. Most of these have
already been discussed under SIC 2819 but several
including potash, super phosphate, triple super
and mixed fertilizers will be discussed in this
section.
CONCENTRATED SUPER-PHOSPHATE PLANTS
UNITED STATES
Company
American Cyanamid
Armour Agr. Chem. Co.
Borden Chem. Co.
Central Phosphates
Cities Service Oil
Coastal Chemical
Continental Oil
El Paso Natural Gas
Farmland Industries
W. R. Grace & Co.
Int. Minerals & Chem.
Kerr-McGee
Mobil Chemical
Occidental Agrilcul.
Phillips Chemical
F. s. Royster Guano
J. R. Simplot
Stauffer Chemical
Swift & Company
Tenn. Valley Authority
Texas Gulf Sulfur
I/ Idle facilities
2/ High-analysis 54%
Location
Brewster, Fla.
Ft. Meade, Fla.
Port Mantee, Fla.
Plant City, Fla.
Tampa, Fla.
Pascagoula, Miss.
Pierce, Fla.
Georgetown , Idaho
Lakeland, Fla.
Joplin, Mo.
Ridgewood, Fla.
Bonnie, Fla.
Baltimore, Md.
Nichols, Fla.
White Springs, Fla.
Pasadena, Tex.
Mulberry, Fla.
Pocatello, Idaho
Garfield, Utah
Tacoma, Washington
Agricola, Fla.
Muscle Shoals, Ala.
Lee Creek, N. C.
Total
material
Capacity
Cthou. tons)
180
113
33
155
165 I/
135 ±/
180
55
36
32
350
203
130
188
45
170
92
45
23
77
27
167
2/
±/
2,601
227
-------
AMMONIUM AND DIAMMONIUM PHOSPHATE PLANTS
UNITED STATES
Company
Location
AFC, Inc.
Allied Chemical
American Cyanamid
Arizona Agrochemical
Arkla Chemical
Armour Agri. Ghent,
Borden Chemical
Bunker Hill
Central Phosphates
Chevron Chemical
Cities Service Oil
Coastal Chemical
Colorado Fuel & Iron
Continental Oil
Des Plaines Chemical
Dominguez Fertilizer
El Paso Nat. Gas
Farmland Industries
Ford Motor
W. R. Grace
Hooker Chemical
Int. Min. & Chem.
Kaiser Steel
Mobil Chemical
Monsanto
Nat. Dist. & Chem.
N. J. Zinc
Nipak, Inc.
NW Coop. Mills
Occidental Agri.
Edison, Calif.
Geismar, La.
Brewster, Fla.
Chandler, Ariz.
Helena, Ark.
Bartow, Fla.
Cherokee, Ala.
Port Manatee, Fla.
Streator, 111.
Texas City, Tex.
Kellogg, Idaho
Plant City, Fla.
Ft. Madison, Iowa
Kennewick, Wash.
Richmond, Calif.
Tampa, Fla.
Pascagoula, Miss.
Pueblo, Colo.
Pierce, Fla.
Morris, 111.
Long Beach, Calif.
Soda Springs, Idaho
Lakeland, Fla.
Joplin, Mo.
Dearborn, Mich.
Henry, 111.
Joplin, Mo.
Ridgewood, Fla.
Marseilles, 111.
Taft, La.•
Bonnie, Fla.
Fontana, Calif.
Nichols, Fla.
Luling, La.
Danville, 111.
Depue, 111.
Kerens, Tex.
Tulsa, Okla.
Pine Bend, Minn.
White Springs, Fla.
Lathrop, Calif.
Plainview, Tex.
Capacity
(thousand
tons/year}
28
91
18
15
75
85
25
45
15
NK V
NK I/
NK I/
NK I/
179
127°
46
34
15
30
147
67 ,
10 !/
100
20
174
69
175
230
15
77
120
15
124
46
20
69
115
10
9
228
-------
AMMONIUM AND DIAMMONIUM PHOSPHATE PLANTS (cont.)
Company
Olin Mathieson Chem.
Phosphate Chemicals
F. S. Royster Guano
Shell Chemical
J. R. Simplot
Stauffer Chemical
Swift
Tennessee Farmers
Tennessee Valley Auth
Texas Gulf Sulfur
Union Oil of Calif.
Valley Nitrogen Prod.
Western States Chem.
Location
Pasadena, Tex.
Houston, Tex.
Mulberry, Fla.
Pittsburg, Calif.
Pocatello, Idaho
Garfield, Utah
Agricola, Fla.
Sheffield, Ala.
Muscle Shoals, Ala.
Lee Creek, N. C.
Brea, Calif.
Helm, Calif.
Capacity
(thousand
tons/year)
Nichols, Calif.
Total
I/ Nitric phosphate process
2/ Diammonium phosphate 21-53-0 analysis
200
69
41
12
91
80
69
NK
15
105
12
35
NK
2/
!/
y
i/
3,169
229
-------
AMMONIUM PHOSPHATE PLANT LOCATIONS
FIGURE 9
to
U)
o
A NEW PLANT
-------
PHOSPHATE ROCK MINES
UNITED STATES
Company
Location
American Cyanamid
Armour Agr. Chem.
Armour Agr. Chem. &
Freeport Sulfur
Borden Chemical
Cities Service
Continental Oil
W. R. Grace
Int. Min. & Chem.
Kerr-McGee, Inc.
Mobil Chemical
Occidental Agril.
Swift & Co.
Texas Gulf Sulfur
Armour Agril. Chem.
Hooker Chemical
Mobil Chemical
Monsanto
Presnell Phosphate
Stauffer Chemical
Tennessee Valley Auth.
Florida
Brewster
Amour
Lake Hancock
Ft. Meade
Teneroc
Ft. Meade
Pierce
Bonny Lake
Bonnie
Kingsford
Brewster
Ft. Meade
"White Springs
Watson
Silver City
North Carolina
Lee Creek
Tennessee
Columbia
Columbia
Mt. Pleasant
Columbia
Columbia
Mt. Pleasant
Knob Creek
Franklin
Capacity
(thousand
short tons)
3,650
1,500
2,000
1,500
2,000
6,500
1,550
6,000
2,000
1,500
5,700
3,000
2,325
3,000
90
750
200
1,000
700
600
200
Cominco Ltd.
El Paso Nat. Gas
Monsanto
Mountain Fuel Supply
New Idria Mining
& Chemical
George Relyea
J. R. Simplot
Wesjtern States
Garrison, Mont.
Phillipsburg, Mont.
Soda Springs, Idaho
Ballard, Idaho
Soda Springs, Idaho
Bakersfield, Calif.
Garr i son, Mont.
Fort Hall, Idaho
Soda Springs, Idaho
1,050
400
500
NK
NK
100
1,600
231
-------
PHOSPHATE ROCK MINES (cont.)
Company
Location
Stauffer Chemical
Hot Springs, Idaho
Montpelier, Idaho
Cherokee, Utah
Vernal, Utah
Leefe , Wyo.
Melrose, Mont.
Total United States
Capacity
(thousand
short tons)
200
400
200
350
600
51,165
232
-------
ESTIMATED NUMBER OF BULK BLEND PLANTS IN THE
UNITED STATES
State
Maine
New Hampshire
Vermont
Massachusetts
Rhode Island
Connecticut
NEW ENGLAND
New York
New Jersey
Pennsylvania
Delaware
Maryland
West Virginia
MIDDLE ATLANTIC
Virginia
North Carolina
South Carolina
Georgia
Florida
SOUTH ATLANTIC
Ohio
Indiana
Illinois
Michigan
Wisconsin
No. of
Plants
1966
3
1
3
5
5
_4
21
39
20
44
7
26
1
137
15
41
28
76
95
255
100
235
428
55
82
EAST NORTH CENTRAL 900
Minnesota
Iowa
Missouri
North Dakota
South Dakota
Nebraska
Kansas
WEST NORTH
CENTRAL
192
426
224
17
33
116
102
1,110
State
No. of
Plants
1966
Montana
Idaho
Wyoming
Colorado
New Mexico
Arizona
Utah
Nevada
MOUNTAIN
Washington
Oregon
California
PACIFIC
Kentucky
Tennessee
Alabama
Mississippi
EAST SOUTH CENTRAL 107
Arkansas
Louisiana
Oklahoma
Texas
WEST SOUTH CENTRAL 254
11
43
29
53
15
13
27
191
174
Total Continental
U.S. 3,149
Hawaii 4
TOTAL U.S.
3,153
233
-------
ESTIMATED NUMBER OF BULK BLEND FERTILIZER PLANTS
FIGURE 10
MIDDLE
ATLANTIC
HAWAII - 4
WEST NORTH
CENTRAL
ST NORTH
O I IMUHI
CENTRAL-
PACIFIC
MOUNTAIN
19
SOUTH"/3" SOUTH
CENTRAL-ATLANTIC
WEST SOUTH
CENTRAL
NEW
ENGLAND
TOTAL - 3, 153
-------
ESTIMATED NUMBER OF LIQUID MIX PLANTS IN THE
UNITED STATES
State
Maine
New Hampshire
Vermont
Massachusetts
Rhode Island
Connecticut
NEW ENGLAND
New York
New Jersey
Pennsylvania
Delaware
Maryland
West Virginia
MIDDLE ATLANTIC
Virginia
North Carolina
South Carolina
Georgia
Florida
SOUTH ATLANTIC
Ohio
Indiana
Illinois
Michigan
Wisconsin
No. of
Plants
1966
2
4
8
6
5
8
1
6
26
11
11
7
12
27_
68
29
129
154
12
15
EAST NORTH CENTRAL 339
Minnesota
Iowa
Missouri
North Dakota
South Dakota
Nebraska
Kansas
WEST NORTH
CENTRAL
41
85
63
5
7
49
125
375
NO. Of
Plants
State 1966
Kentucky
Tennessee
Alabama
Mississippi
EAST SOUTH CENTRAL
Arkansas
Louisiana
Oklahoma
Texas
WEST SOUTH CENTRAL
Montana
Idaho
Wyoming
Colorado
New Mexico
Arizona
Utah
Nevada
MOUNTAIN
Washington
Oregon
California
PACIFIC
Total Continental
U.S. 1
Hawaii
7
3
6
19^
35
19
15
24
67
125
4
24
5
16
1
19
1
_2
72
55
17
109
181
,229
2
TOTAL U.S.
1,231
235
-------
ESTIMATED NUMBER OF LIQUID MIXED FERTILIZER PLANTS
FIGURE 11
U)
CTi
MIDDLE
ATLANTIC
WEST tfORTH
CENTRAL X EAST NOR1
K L ^ CENTRA
PACIFIC
MOUNTAIN
i** •>
72
AST
SOUTH
CENTRAL
SOUTH
ATLANTIC
CENTRAL
NEW
ENGLAND
HAWAII - 2
TOTAL - 1,231
-------
Production; (100% APA)
Other
Normal Triple Ammonium Phosphatic
Super Super Phosphates Fertilizer
1969 913,000 1,390,000 1,651,000
1974 900,000 1,800,000 2,200,000
Processes: Superphosphate is solubilized phosphate
rock in which the rock is acidulized with sufficient
acid to convert the rock to monocalcium phosphate
and gypsum. No separation is made. The waste
products and processes except for the gypsum are
similar to those generated in the production of
phosphoric acid.
Concentrated superphosphate is produced by the
reaction of phosphoric acid with phosphate rock
producing Ca (H2P04)2- No gypsum is produced.
The reaction takes place in a rotating granulator.
The major waste products are the scrubber waters
from the granulator and subsequent cooler exhaust
gas scrubbers which contain some phosphoric and
considerable amounts of silico fluorides for which
a considerable market exists. The condensate from
the acid preheater can be used for scrubber water
to close loop the system. Normal super production
is being superseded by triple production.
Phosphate rock handling results in a heavily turbid
water flow. Solids settling is usually practiced.
Ammonium phosphate is produced by the direct contact
of phosphoric acid and ammonia. Vessel washout is
the major pollutional source.
Liquid mix and dry mix plants involve the blending
of fertilizer base materials such as superphosphate,
urea, ammonium nitrate, ammonium phosphate and
potash thereby producing the final product. Vessel
washout is the major pollutional problem.
Potash is produced from sedimentary deposits of
syluinite (a mixture of K Cl and Na Cl) and lang-
beinite (K2S04•2MgSO4)/ primarily. Langbeinite is
processed to produce potassium sulfate. The Trona,
237
-------
California/ salts are another important salt.
Solar evaporation at Great Salt Lake is also
practiced. The biggest single source of new potash
is the deep deposit in Saskatchewan, Canada which
will be developed by conventional and solution
mining.
Some of the potash is produced by fractional
crystallization but the syluinite deposits are
handled by either soap flotation or fractional
solution. In both processes, slimes and reject
salt solutions are present to create pollution
problems. The reject salt solutions may contain
small amounts of flotation agents such as starch
and amines. It is possible through the careful
use and selection of these agents to minimize
losses. Reuse and recovery of the slimes and salt
solutions may be practiced. Of course, since
great stretches of land are available, disposal is
not generally a problem. In Europe, the great
potash mines of the Alsace are one of the main
polluters of the Rhine. Recovery of the salt is
totally feasible. The present trend is towards
partial solution of KC1 as practiced in Canada
since this area will be the major source in
the next decade.
Complex fertilizer is prepared by reaction of
ammonia, phosphoric acid, nitric acid and phosphate
rock in acidulation tanks. The final slurry is
mixed with potassium chloride (potash). The
product may be spherodized, granulated or coated.
A dust collector is used to recover fines.
Generally, the entire system is kept dry for process
reasons but vessel and slab washdowns produce waste-
water problems. Fluorine in fume scrubbing water
may be a problem.
TVA has been successful in developing direct
ammination and acidulation processes aimed at pro-
ducing higher concentration fertilizers. Most of
these processes are carried out dry, but this is
not the universal practice and those processes
carried out in a wet state create steady waste
streams. The trend towards high analysis ferti-
lizer is expected to continue in the future.
238
-------
POTASH PLANTS
UNITED STATES AND CANADA
Company
Location
American Metal
Climax
Am. Potash & Chem,
U.S. Borax & Chem.
Agri. Minerals
Dow Chemical
N. Am. Cement
Int. Min. & Chem.
Calium Chemicals
Potash Corp. of Am,
U.S. Borax & Chem.
United States
Carlsbad, N. M.
Trona, Calif.
Carlsbad, N. M.
Carlsbad, N. M.
Wendover, Utah
Carlsbad, N. M.
Ogden, Utah
Carlsbad, N. M.
Carlsbad, N. M.
Moab, Utah
Carlsbad, N. M.
Davenport, Calif.
Midland, Mich.
Security, Md.
Total
Canada
Lanigan, Sask,
Delisle, Sask.
Saskatoon, Sask.
Esterhazy, Sask.
Belle Plaine, Sask.
Viscount, Sask.
Lake Patience, Sask.
Saskatoon, Sask,
Total
Total North America
1969 Capacity
(thou. tons)
600
235
450
450
66
300
270
350
620
350
550
10
4,251
600
600
600
2,460
360
720
430
900
6,670
10,921
239
-------
SIC 2879 (INORGANIC PESTICIDES)
Inorganic Pesticides
Producers: Data not available
Production: (tons/year) 1969 1974
Arsenic compounds 6,000 5,000
Sulfur 210,000 150,000
Processes and Waste Problems: In general, inorganic
compounds have been replaced by organic compounds.
The major inorganic pesticides are the following:
lead arsenate
sulfur
carbon bisulfide
hydrogen cyanide
fluorine
lime-sulfurs
Bordeaux mixture
mercury chlorides
sodium chlorate
sodium arsenite
ammonium sulfamate
This review does not consider the organophosphorous
compounds which are gaining major importance in the
industry. Neither will this review detail many of
the above listed chemicals because their use in this
particular application is minor compared to other
uses for them.
Lead arsenate is prepared from lead oxide which is
dissolved in acetic and nitric acid and arsenic
acid is added. Lead arsenate is removed by filtra-
tion. The mixture of nitric and acetic acid is
reused three times. Thus, 0.15 pounds of nitric
acid per pound of product and a similar amount of
acetic acid is discarded or must be treated and
recycled. It is obvious that recycle would result
in greatly reduced waste problems.
Sulfur is made by milling sulfur to 325 mesh,
emulsifying molten sulfur, heating mixtures of
240
-------
sulfur with bentonite and using flotation sulfur
obtained from the recovery of the element from
hydrogen sulfide from gases. Washout streams con-
taining fine sulfur particles can be recovered.
Lime-sulfur is prepared by boiling a mixture of
lime, sulfur and water to a dry mixture.
Bordeaux mixture is prepared by mixing copper
sulfate, lime and water. Both lime sulfur and
Bordeaux mixture are generally prepared in the
field and wastewater problems are not significant,
Mercury chlorides are prepared in the following
fashion. Mercuric chloride is prepared by the
direct reaction of mercury and chlorine and
mercurous chloride is made by reducing mercuric
chloride with mercury. Wastewater problems
result from vessel washout.
Considering the fading nature of the industry, no
process changes are expected.
241
-------
SIC 2892 (EXPLOSIVES)
Explosives
Producer; Data not available
Production; 1969: ($) 264,000,000
1974: ($) 322,000,000
(weight data not available)
Processes and Waste Problems; Nitrocellulose is
prepared first by boiling cotton linters in dilute
caustic and bleaching with chlorate. The cotton
is then dried and nitrification with nitric acid
and sulfuric acid takes place in a nitrator.
The charge is dropped into a centrifuge for drying.
Two waste problems exist. The kiering caustic
solution must be dumped from time to time and this
is a serious waste load. Regeneration of the
caustic solution by dialysis or other membrane
processes is possible but not practical.
The waste acid amounts to 0.5 pounds of sulfuric
and 0.35 pounds of nitric. Some of this acid is
sent for concentration, some is sold and the
remainder is discharged. Reuse of this acid should
be possible if careful measures are taken.
Naturally, washouts of vessels and slabs can also
produce major waste treatment problems.
Smokeless powder is washed and beaten to remove
free acid and destroy any unstable sulfate esters
that may have been formed. The final product is
colloidized by mixing with alcohol, ether,
diphenylamine and other modifying agents. Again,
the washing of the nitro cellulose produces a
waste containing sulfuric and nitric acid which can
be reclaimed in a fortifying plant.
TNT is produced by the three stage nitrification
of toluene followed by soda ash and sodium sulfate
washes. The wash water contains considerable
amounts of alkalies and sodium dinitrosulfanates.
242
-------
U>
DEHYDRATING
PRESS
FIGURE 12
WATER-WET
NITROCELLULOSE
12.5-12.7% N2
ETHYL
ALCOHOL
ETHYL
ETHER
BLENDING
TOWER
DIPHENYLAMINE
OR OTHER
STAB I LI Z ER
SMOKELESS
POWDER
TO PACKING
DOUBLE -ARM
MIXER
BLOCKING
PRESSES
WARM AIR HOT COLC
COIL COIL
WATER OUT
MIXED SOLVENTS
AND WATER
«• NOTE: ASTERISKS DENOTE EQUIPMENT CONNECTED TO SOLVENT RECOVERY SYSTEM
FLOWCHART FOR SMOKELESS POWDER
This flow chart is selectively reproduced in content and configuration from Figure 22.4
in the book by R. Morris Shreve, Chemical Process Industries, Third Edition, New York,
Me Graw-Hill Book Company, 1967, p. 390
-------
Ammonium nitrate - Fuel oil (AN) are produced by
mixing and shaping of the two ingredients. A
major waste source is from the washing of the
equipment/ thereby producing a waste stream con-
taining oil and a high nitrogen content.
Nitroglycerin and dynamite. Nitration of the
glycerin takes place in the presence of sulfuric
acid. The nitroglycerin is separated from the
spent acids and washed several times. The spent
acid is recycled and fortified. About 80 pounds
of sulfuric and 160 pounds of nitric are wasted
from the system per ton of nitroglycerine.
Dynamite is made by adsorbing nitroglycerine on
agents such as wood flour, ammonium nitrate or
sodium nitrate. Nonfreezing dynamite can be
made by the addition of ethylene glycol dinitrate
to lower the freezing point of nitroglycerine.
A typical waste from a dynamite-nitroglycerine
facility has the following composition: pH-7,
COD-350 ppm, TDS-10,800 ppmr SS-40, sodium-150,
ammonia-nitrogen-1270 ppm, nitrate nitrogen-550
ppm, sulfates-1000 ppm.
244
-------
APPENDIX D
QUALITATIVE PERSONNEL REQUIREMENTS FOR TREATMENT
PROCESSES - TASK ENUMERATIONS
Chemical Addition
Equalization
Oil Removal
Sedimentation
Filtration
Reverse Osmosis
Electrodialysis
Ion Exchange
Multiple Effect Evaporators
Deep Well Injection
Lagooning/Cooling Ponds/Solar Evaporation Ponds
Centrifugation
Cooling Towers
245
-------
CHEMICAL ADDITION
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
NJ
**
CTi
Operations
Monitors and verifies proper operation and con-
dition of the following units of equipment:
Dry volumetric feeders
Liquid displacement feeders
pH status and control instruments
Conductivity status and control instrumentation
Electric motors, relays, and circuit breakers/
switches
Centrifugal, reciprocating, and diaphragm pumps
Flow measuring devices
Iron, steel, glass, copper, plastic pipe and
fittings
Manual and automatic control valves
Steel, lined steel, and wood tanks, drums, and
vessels
Mixing and blending equipment (electrically
driven)
Belt, chain, and gear drive mechanisms
Reads and interprets status and control instru-
mentation :
pH recorders and meters
Conductivity recorders and meters
Flow recorders and meters
Level indicators
Pressure recorders and meters
Pilot lamps and voltage/current recorders
and meters
OP
2
2
2
2
2
2
2
1
2
2
2
2
2
2
2
2
I/Shift
11
-------
CHEMICAL ADDITION (cent.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
fo
Volume recorders and meters
Weight measuring devices
Maintains supplies for chemical feeding equipment
(refills, tanks and hoppers):
Measures, weighs, and mixes chemicals
Activates, controls units of equipment:
Adjusts and calibrates feed rate on dry
volumetric and liquid displacement feeders
Switches to standby or parallel pumps
Adjusts electrical motor speeds
Overrides automatic controls to correct in
specific situations
Adjusts manual valves to achieve specified
flow, pressure, or volume
Adjusts speed of mixing and blending equipment
Collects composite or grab samples for laboratory
analysis
OP
2
2
I/Shift
3
2
2
2
2
As Req
I/Shift
Preventive Maintenance Activities
Services dry chemical feeders:
Removes chemical dust accumulations from hoppers
and feed mechanism
Checks for loose bolts and defective parts
Cleans solution tanks of accumulated sediment
Lubricates drive mechanism and moving parts
2
2
2
2
wkly
dly
wkly
dly
-------
CHEMICAL ADDITION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
ro
**
oo
Checks for rust/corrosion
Checks rate of feed against known standard
Paints exposed parts
Services liquid displacement feeders:
Cleans sediment from trap and chemical storage
tanks
Checks for loose or defective parts
Lubricates moving parts and drive mechanisms
Checks pilot tubes and needle valves for
proper operation
Checks rate of feed against known standard
Paints exposed parts
Services status and control instrumentation:
Cleans and lubricates chart drive mechanisms
Cleans electrical sensors
Checks electrical contacts, connections, and
wiring
Checks pneumatic sensors for leaks
Checks zero or null setting on galvanometers
and on pen recorders
Checks mechanical linkage for corrosion, rust,
and freedom of movement
Cleans indicator covers and glass viewing
windows
Cleans recorder pens and checks for ink flow
Checks indicated valves against known standards
(checks calibration)
OP
1
3
1
2
2
2
2
2
2
2
2
wkly
wkly
yrly
2
2
2
2
3
1
wkly
dly
dly
dly
wkly
yrly
2/yr
mthly
wkly
wkly
wkly
wkly
mthly
dly
mthly
-------
CHEMICAL ADDITION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
N>
•U
Services electric motors and auxiliary equipment:
Inspects motors for signs of overheating
Checks for excessive vibration or hum
Checks wiring insulation
Checks for dirt or moisture
Checks drive coupling and motor mounts for
play/loose fittings
Checks for sticking brushes or excessive
arcing
Checks pilot lights and alarms
Checks points and contacts for pitting
Cleans and tightens electrical connections
Checks and lubricates bearings
Checks switches and circuit breakers for
proper functioning
Services centrifugal, reciprocating, and dia-
phragm pumps:
Checks solenoid oiler flow; adjusts as
necessary
Checks oil level in ball bearing housing;
fills as necessary
Checks grease cup; maintains proper pressure
Checks enclosed shaft bearings; refills oil
cup as necessary
Checks ball-thrust bearings; adds fresh grease
as necessary
Checks guide bearings; adds grease as
necessary
Drains and adds fresh lubricant to shaft
bearings
OP
2
2
2
2
2
2
2
2
1
1
2
2
2
2
2
dly
dly
wkly
dly
dly
dly
I/Shift
mthly
mthly
wkly
dly
wkly
dly
dly
dly
mthly
wkly
mthly
-------
CHEMICAL ADDITION (cent.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
to
Ul
o
Flushes bearing housing and adds fresh grease
Checks bearing temperatures; adjusts as
necessary
Checks stuffing boxes for leaks; tightens or
repacks as necessary
Checks water-seal systems for leaks; adjusts
pressure as necessary
Clean and paint pump casting
Check, clean, lubricate, and adjust float
switch system
Inspect check valves for leaks
Clean sediment and accumulated solids from
sumps
Check and clean strainers
Services flow measuring devices:
Cleans and flushes annular chambers
Cleans and flushes piezometer pressure taps
Cleans and dresses orifice plates
Cleans and paints exterior
Inspects interior for corrosion
Purges connecting lines and fittings
Services pipes and pipe fittjngs:
Checks for leaks in pipes and pipe fittings
Inspects for rust and corrosion
Cleans and paints pipes and fittings
Flushes dead-ends
Checks and cleans sediment traps
OP
ii
11
ii
2
2
2
2
1
2
2
1
1
4/yr
wkly
dly
dly
dly
wkly
dly
mthly
dly
2
2
2
1
2
2
1
1
1
2
1
mthly
mthly
2/yr
yrly
mthly
wkly
wkly
wkly
yrly
mthly
wkly
-------
CHEMICAL ADDITION (cent.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
NJ
(Jt
Checks and cleans wells and sumps
Mechanically cleans pipes with augers and
snakes
Services manual and automatic control valves:
Checks valves for leaks
Inspects for rust and corrosion
Checks actuating bellows for leaks
Checks linkages for free movement
Checks for complete opening and closing
Checks calibration
Lubricates control linkage
Adjusts packing
Cleans and paints exterior
Cleans solenoid actuating mechanisms
Services storage tanks, drums, and vessels:
Checks for leaks
Inspects for rust and corrosion
Cleans and paints interior and exterior
Removes accumulated deposits of sludge and
sediment
Services mixing and blending equipment:
Cleans deposits from paddles, arms, and
propellers
Inspects for rust and corrosion
Inspects mechanical drive functioning
Lubricates mechanical drive system
Paints and protects exposed surfaces
OP
1
2
1
1
1
1
1
2
2
1
wkly
yrly
2
2
2
2
2
3
2
2
1
2
dly
wkly
dly
dly
dly
mthly
wkly
wkly
yrly
dly
dly
wkly
yrly
wkly
wkly
wkly
wkly
wkly
yrly
-------
CHEMICAL ADDITION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
ui
to
Checks for homogeneity of mixed substances
Checks speed of mixing or blending
Services mechanical drive systems:
Checks tension of flat and V-belt drives
Checks and adjusts belt alignment
Checks belts for wear
Checks and adjusts chain drive slack
Lubricates chain drive systems
Checks lubricant levels in right-angle
gear drives
Checks lubricant levels in reduction gear
boxes
Drains and changes oil in sump systems
Cleans and inspects variable speed belt
drive systems
Lubricates thrust and frame bearings for
drive shafts
Checks oil seals for leaks
Lubricates pressure grease fittings
OP
ir
ii
ii
ii
ii
ii
2
2
2
2
2
2
2
2
2
2
2
2
dly
dly
dly
dly
wkly
wkly
wkly
wkly
wkly
mthly
wkly
wkly
dly
wkly
Corrective Maintenance Activities
Repairs and overhauls dry chemical feeders:
Troubleshoots and diagnoses malfunctions
Installs, removes, and replaces chemical
feeder units
Inspects and measures parts for wear and
defects
Mech Main
3
3
3
As Req
-------
CHEMICAL ADDITION (cont.}
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
m
U)
Checks and adjusts stroke rods
Cleans pockets of star feeder and scraper
Checks and cleans feeding gates
Checks feeder scale sensitivity and null
balance
Replaces worn or defective parts and bearings
Fits parts/ seals, and gaskets
Reassembles feeding unit
Tests and calibrates feed rate against known
standard
Cleans and paints all exposed surfaces
Repairs and overhauls liquid and solution chemical
feeders:
Troubleshoots and diagnoses malfunctions
Installs, removes f and replaces chemical feeder
units
Disassembles feeder units and reassembles
Inspects and measures parts for wear and
defects
Repairs linings and diaphragms
Measures and adjusts float valve settings
Fits parts, seals, and gaskets
Replaces worn or defective parts, seals, and
gaskets
Tests and calibrates feed rate against known
standard
Cleans and paints all exposed surfaces
Mech Main
11
it
H
II
n
11
11
3
3
3
3
3
3
3
3
1
As Req
3
3
3
3
3
3
3
1
M
It
Fl
II
II
II
-------
CHEMICAL ADDITION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
ro
in
Repairs and overhauls status and control
instrumentation:
Troubleshoots and diagnoses malfunctions in
status and control instrumentation
Installs, removes, replaces status and con-
trol instrumentation
Disassembles and reassembles status and
control instrumentation
Tests diaphragms, bourdon tubes, and bellows
for leaks or defects
Tests bimetallic strips and thermocouples for
defects
Tests electrical circuitry for shorts, open
circuits, and resistance
Cleans and adds mercury to manometers
Cleans and sets contact points
Cleans and checks knife edges
Cleans and lubricates jeweled bearings
Blows down pressure lines to remove restric-
tions or stoppages
Cleans and checks orifices and nozzles
Adjusts backlash in mechanical linkages
Calibrates indicators and recorder pen against
known standard
Replaces worn or defective parts, seals, and
bearings
Repairs and overhauls electric motors and
auxiliary equipment:
Diagnoses and troubleshoots electrical
malfunctions
Ins Repmn
3
3
3
3
3
3
3
3
3
3
3
3
3
As Req
Elec
-------
CHEMICAL ADDITION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
10
Ol
U1
Installs/ removes, replaces electric motors,
wiring, and control devices
Inspects and tests rotor and stator windings
for shorts or open circuits
Inspects commutator for wear, shorts, and
signs of excessive heat
Checks brushes for wear and proper spring
tension
Adjusts brushes to seat properly and prevent
sticking
Cleans, adjusts, and lubricates bearings
Checks thermal switches, circuit breakers,
and fuses
Cleans and polishes collector rings
Checks and tightens pigtails and mechanical
wire connections
Replaces or repairs defective parts in motors
and control devices
Adjusts rotor and shaft alignment
Reconditions or replaces contacts on relays
and switches
Replaces defective wiring and conduit
Inspects exposed equipment for defective
gaskets and seals
Measures voltage, current, and power consump-
tion
Checks motor speeds
Elec
n
II
3
3
3
3
3
3
3
3
3
3
3
3
3
3
As Req
-------
CHEMICAL ADDITION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
K)
Ul
O\
Repairs and overhauls centrifugal, reciprocating,
and diaphragm pumps:
Troubleshoots and diagnoses malfunctions in
pumps
Installs, removes, and replaces pumps
Disassembles and assembles pumps
Inspects and measures bearings and bearing
races for defects
Repacks ball-thurst bearings, roller bearings,
and guide bearings
Cleans and inspects pump interior
Checks stuffing box for free movement of gland
and excessive leakage
Repacks gland assembly and adjusts
Grinds and laps valves and valve seats
Inspects impellers for deposits, scaling, and
cavitation pits
Dynamically balances impellers
Checks and aligns drive system
Fits replacement parts
Repairs bent float rods, binding mechanical
fittings
Lubricates mechanical fittings
Cleans and paints exterior housing
Repairs and replaces pipes and pipe fittings:
Troubleshoots and diagnoses nature and location
of stoppages
Removes and replaces sections of pipe, pipe
fittings, and coolings
Pump Serv
it
Pipe Ftr
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
3
3
As Req
11
ti
it
11
n
it
n
11
ii
M
it
-------
CHEMICAL ADDITION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
10
U1
-0
Cuts and threads pipe
Cleans pipe using mechanical and hydraulically
propelled tools
Replaces gaskets and seals on flange type
joints
fiends pipe and tubing
Tests pipe systems for pressure capability and
leaks
May be required to repair and replace special
purpose pipe and fittings of the following types:
Glass
Glass or plastic lined steel
Plastic and PVC
Aluminum
Wood
Vitrified tile
Repairs and overhauls manual and automatic control
valves:
Troubleshoots and diagnoses malfunction in
manual and controlled valves
Installs, removes, and replaces valves
Assembles and disassembles valves and
control mechanisms
Inspects and measures valve clearances
Grinds, polishes, laps-in valves and valve
seats
Cleans and inspects valve actuating mechanisms
Adjusts backlash in valve actuating mechanisms
Pipe Ptr
ii
11
n
n
ii
n
Ins Repmn
n
3
3
3
3
As Req
3
3
3
3
3
3
3
3
3
3
3
3
3
II
n
it
n
n
n
As Req
n
ti
n
n
ii
-------
CHEMICAL ADDITION (cent.>
OCCUPATIONAL SKILL FREQUENCY
KREA LEVEL f
to
ui
m
Lubricates valve actuating mechanisms
Tests bellows and diaphragm actuators for
leaks
Calibrates valve position and control
actuator
Adjusts and replaces packing and seals
Tests valves for complete opening and
shut-off
Tests functioning of control actuators
(pneumatic, hydraulic, electrical,
mechanical)
Replaces worn oir defective valve and actuator
parts
Repairs and overhauls storage tanks r drums and
vessels:
Repairs leaks and defective portions of steel
storage facilities
Repairs leaks and defective portions of lined
steel storage facilities
Repairs leaks and defective portions of wood
storage facilities
Repairs leaks and defective portions of con-
crete storage facilities
Diagnoses cause of rust, corrosion, and leaks
Repairs and overhauls mixing and blending equip-
ment and mechanical appurtenances:
Troubleshoots and diagnoses malfunctions in
mechanical systems
Ins Repmn
Meeft Main
3
3
3
3
As Req
3
3
3
3
3
3
3
-------
CHEMICAL ADDITION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
(ji
VD
Installsr removes, and replaces arms, paddles,
and propellers
Disassembles and assembles mechanical drive
systems
Inspects and measures gear drives for wear
and defects
Inspects chain drives, replaces defective
links, adjusts tension
Checks and measures sprocket alignment
Inspects sprocket teeth for wear/ hooks, and
other defects
Inspects and measures screen and bar rakes for
wear and defects
Inspects and measures bearings and races for
wear and defects
Cleans and finishes moving parts to prevent
freezing or binding
Repacks bearings
Fits and replaces parts showing excessive wear
or defects
Inspects and replaces water and oil seals as
necessary
Dresses and reconditions scrapers, paddles, and
propellers
Cleans and paints exposed surfaces
Replaces drive belts, pulleys, and tensioning
devices
Mech Main
It
II
3
3
3
3
3
3
3
3
3
3
3
3
3
1
As Req
Note: Acids and alkalies used in this treatment
are extremely hazardous
-------
EQUALIZATION
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
-------
EQUALIZATION (cont.)
OCCUPATIONAL SKILL FREQUENCY
AREA LEVEL f
Collects composite or grab samples for laboratory
analysis
Checks flow time for individual tanks using dye
or salt solution
OP
2
2
As Req
K>
Preventive Maintenance Activities
Services status and control instrumentation:
Cleans and lubricates chart drive mechanisms
Cleans electrical sensors
Checks electrical contacts, connections, and
wiring
Checks pneumatic sensors for leaks
Checks zero or null setting on galvanometers and
pen recorders
Checks mechanical linkage for corrosion, rustr
and freedom of movement
Cleans indicator covers and glass viewing
windows
Cleans recorder pens and checks for ink flow
Checks indicated values against known standards
(checks calibration)
Services electric motors and auxiliary equipment:
Inspects motors for signs of overheating
Checks for excessive vibration or hum
Checks wiring insulation
Checks for dirt or moisture
See Chem Add
n
n
M
it
n
ti
II
-------
EQUALIZATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
a\
ro
Checks drive coupling and motor mounts for
play/loose fittings
Checks for sticking brushes or excessive arcing
Checks pilot lights and alarms
Checks points and contacts for pitting
Cleans and tightens electrical connections
Checks and lubricates bearings
Checks switches and circuit breakers for proper
functioning
Services centrifugal, reciprocating, and diaphragm
pumps:
Checks solenoid oiler flow; adjust as necessary
Checks oil level in ball bearing housing; fills
as necessary
Checks grease cup; maintains proper pressure
Checks enclosed shaft bearings; refills oil cup
as necessary
Checks ball-thrust bearings; adds fresh grease
as necessary
Checks guide bearings; adds grease as necessary
Drains and adds fresh lubricant to shaft bear-
ings
Flushes bearing housing and adds fresh grease
Checks bearing temperature; adjusts as necessary
Checks stuffing boxes for leaks; tightens or re-
packs as necessary
Checks water-seal systems for leaks; adjusts
pressure as necessary
Clean and paint purap casing
Check, clean, lubricate, and adjust float switch
system
See Chem Add
n
II
u
n
n
it
n
-------
EQUALIZATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
N>
o\
u>
Inspect check valves for leaks
Clean sediment and accumulated solids from sumps
Check and clean strainers
Services flow measuring devices:
Cleans and flushes annular chambers
Cleans and flushes piezometer pressure taps
Cleans and dresses orifice plates
Cleans and paints exterior
Inspects interior for corrosion
Purges connecting lines and fittings
Services pipes and pipe fittings:
Checks for leaks in pipes and pipe fittings
Inspects for rust and corrosion
Cleans and paints pipes and fittings
Flushes dead-ends
Checks and cleans sediment traps
Checks and cleans wells and sumps
Mechanically cleans pipes with augers and snakes
Services manual and automatic control valves:
Checks valves for leaks
Inspects for rust and corrosion
Checks actuating bellows for leaks
Checks linkages for free movement
Checks for complete opening and closing
Checks calibration
Lubricates control linkage
Adjusts packing
Cleans and paints exterior
See Chem Add
it
n
-------
EQUALIZATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Cleans solenoid actuating mechanisms
Services storage tanks, drums, and vessels:
Checks for leaks
Inspects for rust and corrosion
Cleans and paints interior and exterior
Removes accumulated deposits of sludge and
sediment
Services mechanical drive systems:
Checks tension of flat and V-belt drives
Checks and adjusts belt alignment
Checks belts for wear
Checks and adjusts chain drive slack
Lubricates chain drive systems
Checks lubricant levels in right-angle grear
drives
Checks lubricant levels in reduction gear boxes
Drains and changes oil in sump systems
Cleans and inspects variable speed belt drive
systems
Lubricates thrust and frame bearings for drive
shafts
Checks oil seals for leaks
Lubricates pressure grease fittings
See Chem Add
"
"
"
"
"
"
"
"
"
"
"
"
Corrective Maintenance Activities
Repairs and overhauls status and control instru-
mentation:
-------
EQUALIZATION (con t.}
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
Ch
CJ1
Troubleshoots and diagnoses malfunctions in
status and control instrumentation
Installs, removes, replaces status and control
instrumentation
Disassembles and reassembles status and control
instrumentation
Tests diaphragm, bourdon tubes, and bellows for
leaks or defects
Tests bimetallic strips and thermocouples for
defects
Tests electrical circuitry for shorts, open
circuits, and resistance
Cleans and adds mercury to manometers
Cleans and sets contact points
Cleans and checks knife edges
Cleans and lubricates jeweled bearings
Blows down pressure lines to remove restrictions
or stoppages
Cleans and checks orifices and nozzles
Adjusts backlash in mechanical linkages
Calibrates indicators and recorder pens against
known standard
Replaces worn or defective parts, seals, and
bearings
Repairs and overhauls electric motors and auxiliary
equipment:
Diagnoses and troubleshoots electrical malfunc-
tions
Installs, removes, replaces electric motors, wir-
ing, and control devices
See Chem Add
-------
EQUALIZATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Inspects and tests rotor and stator windings
for shorts or open circuits
Inspects commutator for wear, shorts, and
signs of excessive heat
Checks brushes for wear and proper spring
tension
Adjusts brushes to seat properly and prevent
sticking
Cleans, adjusts, and lubricates bearings
Checks thermal switches, circuit breakers,
and fuses
Cleans and polishes collector rings
Checks and tightens pigtails and mechanical
wire connections
Replaces or repairs defective parts in motors
and control devices
Adjusts rotor and shaft alignment
Reconditions or replaces contacts on relays
and switches
Replaces defective wiring and conduit
Inspects exposed equipment for defective
gaskets and seals
Measures voltage, current, and power consump-
tion
Checks motor speeds
Repairs and overhauls centrifugal, reciprocating,
and diaphragm pumps:
Troubleshoots and diagnoses malfunctions in
pumps
Installs, removes, and replaces pumps
See Chem Add
ir
11
"
"
ii
ii
-------
EQUALIZATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
Disassembles and assembles pumps
Inspects and measures bearings and bearing
races for defects
Repacks ball-thrust bearings, roller bear-
ings, and guide bearings
Cleans and inspects pump interior
Checks stuffing box for free movement of
gland and excessive leakage
Repacks gland assembly and adjusts
Grinds and laps valves and valve seats
Inspects impellers for deposits, scaling,
and cavitation pits
Dynamically balances impellers
Checks and aligns drive system
Fits replacement parts
Repairs bent float rods, binding mechanical
fittings
Lubricates mechanical fittings
Cleans and paints exterior housing
Repairs and replaces pipes and pipe fittings:
Troubleshoots and diagnoses nature and location
of stoppages
Removes and replaces sections of pipe, pipe
fittings, and couplings
Cuts and threads pipe
Cleans pipe using mechanical and hydraulically
propelled tools
Replaces gaskets and seals on flange type joints
Bends pipe and tubing
See Chem Add
it
it
-------
OCCUPATIONAL SKILL FREQUENCY
EQUALIZATION (cont.) AREA LEVEL f
Tests pipe systems for pressure capability
and leaks See Chem Add
May be required to repair and replace special
purpose pipe and fittings of the following
types:
Glass
Glass or plastic lined steel "
Plastic and PVC
Aluminum "
Wood "
Vitrified tile "
Repairs and overhauls manual and automatic control
£* valves:
oo Troubleshoots and diagnoses malfunctions in
manual and controlled valves "
Installs, removes, and replaces valves "
Assembles and disassembles valves and control
mechanisms "
Inspects and measures valve clearances "
Grinds, polishes, laps-in valves and valve
seats
Cleans and inspects valve actuating mechanisms "
Adjusts backlash in valve actuating mechanisms "
Lubricates valve actuating mechanisms "
Tests bellows and diaphragm actuators for leaks "
Calibrates valve position and control actuator "
Adjusts and replaces packing and seals "
Tests valves for complete opening and shut-off "
-------
EQUALIZATION (cont. )
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
Tests functioning of control actuators
(pneumatic, hydraulic, electrical,
mechanical)
Replaces worn or defective valve and actuator
parts
Repairs and overhauls storage tanks, drums, and
vessels4:
Repairs leaks and defective portions of steel
storage facilities
Repairs leaks and defective portions of lined
steel storage facilities
Repairs leaks and defective portions of wood
storage facilities
Repairs leaks and defective portions of con-
crete storage facilities
Diagnoses cause of rust, corrosion, and leaks
See Chexn Add
-------
OIL REMOVAL
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
•sj
o
Operations
Monitors and verifies proper operation and condi-
tion of the following units of equipment:
Pressure floatation units/preaerators
Vacuum floatation units/preaerators
Gravity separation unit
Compressors or vacuum pumps
Centrifugal, reciprocating, and diaphragm pumps
Pressure and vacuum monitoring and control
equipment
Flow measuring devices
Manual and automatic control valves
Iron, steel, and plastic pipe and pipe fittings
Steel tanks, drums, and vessels
Belt, chain, and gear drive mechanisms
Reads and interprets status and control instru-
mentation of the following types:
Flow recorders and meters
Level indicators
Pressure indicators and recorders
Pilot lamps and voltage/current recorders and
indicators
Activates and controls units of equipment:
Adjusts manual valves to achieve specified flow,
pressure, and retention time
Switches to standby or parallel pumps
Overrides automatic controls to correct in
specific situations
OP
n
n
n
n
2
2
2
2
2
2
2
2
1
1
2
2
2
2
3
2
I/Shift
ii
n
n
ii
ii
n
n
n
it
ii
n
-------
OIL REMOVAL (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Activates collectors and skimmers on inter-
mittent basis or continuously
Removes and disposes of oil and floatable solids:
Withdraws skimmings from storage unit as
necessary
Removes skimmings from discharge weirs
Stores skimmings for disposal or disposes of
skimmings
Collects composite or grab samples of skimmings,
influent, and effluent for laboratory analysis
OP
11
11
1
1
I/Shift
As Req
I/Shift
to
Preventive Maintenance Activities
Services pressure and vacuum separation units:
Checks for pressure or vacuum leaks
Inspects for rust and corrosion
Drains and cleans interior, flushes sediment,
removes accumulated grit
Services air compressors and vacuum pumps:
Checks on-off thresholds
Cleans or changes air filters
Drains condensate from pressure storage tanks
Checks oil level in crank cases and sumps, adds
oil as required
Drains and refills oil reservoirs
Checks valves for leaks
Checks for overheating
2
2
2
2
2
2
2
2
2
As Req
wkly
dly
mthly
dly
I/Shift
-------
OIL REMOVAL (cont. )
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
10
Services status and control instrumentation:
Cleans and lubricates chart drive mechanisms
Cleans electrical sensors
Checks electrical contacts, connections, and
wiring
Checks pneumatic sensors for leaks
Checks zero or null setting on galvanometers
and pen recorders
Checks mechanical linkage for corrosion, rust,
and freedom of movement
Cleans indicator covers and glass viewing
windows
Cleans recorder pens and checks for ink flow
Checks indicated values against known standards
(checks calibration)
Services electric motors and auxiliary equipment:
Inspects motors for signs of overheating
Checks for excessive vibration or hum
Checks wiring insulation
Checks for dirt or moisture
Checks drive coupling and motor mounts for
play/loose fittings
Checks for sticking brushes or excessive
arcing
Checks pilot lights and alarms
Checks points and contacts for pitting
Cleans and tightens electrical connections
Checks and lubricates bearings
Checks switches and circuit breakers for proper
functioning
See Chem Add
"
"
"
"
"
"
"
-------
n
it
OCCUPATIONAL SKILL FREQUENCY
OIL REMOVAL (cont.) AREA LEVEL f
Services storage tanks, drums, and vessels:
Checks for leaks See Chem Add
Inspects for rust and corrosion "
Cleans and paints interior and exterior "
Removes accumulated deposits of sludge and
sediment "
Services mechanical drive systems:
Checks tension of flat and V-belt drives "
Checks and adjusts belt alignment
Checks belts for wear "
Checks and adjusts chain drive slack
Lubricates chain drive systems "
Checks lubricant levels in right-angle gear
NJ drives "
£j Checks lubricant levels in reduction gear
boxes "
Drains and changes oil in sump systems
Cleans and inspects variable speed belt drive
systems
Lubricates thrust and frame bearings for drive
shafts
Checks oil seals for leaks
Lubricates pressure grease fittings
Corrective Maintenance Activities
Repairs and overhauls air compressors and vacuum
pumps:
it
-------
OCCUPATIONAL SKILL FREQUENCY
OIL REMOVAL (cont.) AREA LEVEL f
Troubleshoots and diagnoses malfunctions in
compressors and vacuum pumps See Chem Add
Installs, removes, and replaces compressors
and vacuum pumps "
Disassembles and assembles compressors and
vacuum pumps "
Inspects and measures bearings and bearing
races for defects "
Repacks ball-thrust bearings, roller bearings,
and guide bearings "
Cleans and inspects pump and compressor inter-
ior "
Grinds and laps valves and valve seats "
Fits replacement parts, seals, and gaskets "
Inspects diaphragms for defects and service-
ability "
Lubricates mechanical fittings "
Cleans and paints exterior housing "
Tests and certifies pressure ratings "
Services centrifugal, reciprocating, and diaphragm
pumps:
Checks solenoid oiler flow; adjusts as necessary "
Checks oil level in ball bearing housing; fills
as necessary "
Checks grease cup; maintains proper pressure "
Checks enclosed shaft bearings; refills oil cup
as necessary "
Checks ball-thrust bearings; adds fresh grease
as necessary "
Checks guide bearings; adds grease as necessary
it
-------
OCCUPATIONAL SKILL FREQUENCY
OIL REMOVAL (cont.) AREA LEVEL f
Drains and adds fresh lubricant to shaft
bearings See Chem Add
Flushes bearing housing and adds fresh grease
Checks bearing temperatures; adjusts as neces-
sary
Checks stuffing boxes for leaks; tightens or
repacks as necessary
Checks water-seal systems for leaks; adjusts
pressure as necessary "
Clean and paint pump casing
Check, clean, lubricate, and adjust float
switch system "
Inspect check valves for leaks
Clean sediment and accumulated solids from
sumps
Check and clean strainers
Services flow measuring devices:
Cleans and flushes annular chambers
Cleans and flushes piezometer pressure taps "
Cleans and dresses orifice plates
Cleans and paints exterior
Inspects interior for corrosion
Purges connecting lines and fittings
Services pipes and pipe fittings:
Checks for leaks in pipes and pipe fittings
Inspects for rust and corrosion
Cleans and paints pipes and fittings JJ
Flushes dead-ends "
Checks and cleans sediment traps
-------
OCCUPATIONAL SKILL FREQUENCY
OIL REMOVAL (cont.) AREA . LEVEL f
Checks and cleans wells and sumps See Chem Add
Mechanically cleans pipes with augers and
snakes "
Services manual and automatic control valves:
Checks valves for leaks "
Inspects for rust and corrosion
Checks actuating bellows for leaks
Checks linkages for free movement
Checks for complete opening and closing
Checks calibration "
Lubricates control linkage "
Adjusts packing "
Cleans and paints exterior "
10 Cleans solenoid actuating mechanisms "
Repairs and overhauls status and control instru-
mentation:
Troubleshoots and diagnoses malfunctions in
status and control instrumentation "
Installs, removes, replaces status and control
instrumentation "
Disassembles and reassembles status and control
instrumentation "
Tests diaphragms, bourdon tubes, and bellows
for leaks or defects "
Tests bimetallic strips and thermocouples for
defects
Tests electrical circuitry for shorts, open
circuits, and resistance "
Cleans and adds mercury to manometers "
-------
OCCUPATIONAL SKILL FREQUENCY
OIL REMOVAL (cont.) AREA LEVEL f
"
Cleans and sets contact points See Chem Add
Cleans and checks knife edges "
Cleans and lubricates jeweled bearings "
Blows down pressure lines to remove restric-
tions or stoppages "
Cleans and checks orifices and nozzles "
Adjusts backlash in mechanical linkages
Calibrates indicators and recorder pens
against known standard
Replaces worn or defective parts , seals / and
bearings
Repairs and overhauls electric motors and auxiliary
equipment:
Diagnoses and troubleshoots electrical malfunc-
tions
Installs, removes, replaces electric motors,
wiring, and control devices
Inspects and tests rotor and stator windings
for shorts or open circuits
Inspects commutator for wear, shorts, and signs
of excessive heat
Checks brushes for wear and proper spring ten-
sion
Adjusts brushes to seat properly and prevent
sticking
Cleans, adjusts, and lubricates bearings
Checks thermal switches , circuit breakers , and
fuses
Cleans and polishes collector rings
Checks and tightens pigtails and mechanical
wire connections
"
"
-------
OCCUPATIONAL SKILL FREQUENCY
OIL REMOVAL (cont.) AREA LEVEL f
Replaces or repairs defective parts in motors
and control devices See Chem Add
Adjusts rotor and shaft alignment "
Reconditions or replaces contacts on relays
and switches "
Replaces defective wiring and conduit "
Inspects exposed equipment for defective gas-
kets and seals 1(
Measures voltage, current, and power consump-
tion
Checks motor speeds "
Repairs and overhauls centrifugal, reciprocating,
and diaphragm pumps:
Troubleshoots and diagnoses malfunctions in
pumps "
Installs, removes, and replaces pumps "
Disassembles and assembles pumps "
Inspects and measures bearings and bearing
races for defects "
Repacks ball-thrust bearings, roller bearings,
and guide bearings
Cleans and inspects pump interior
Checks stuffing box for free movement of gland
and excessive leakage
Repacks gland assembly and adjusts
Grinds and laps valves and valve seats
Inspects impellers for deposits, scaling, and
cavitation pits
Dynamically balances impellers
Checks and aligns drive system
-------
OIL REMOVAL (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
Fits replacement parts
Repairs bent float rods, binding mechanical
fittings
Lubricates mechanical fittings
Cleans and paints exterior housing
Repairs and replaces pipes and pipe fittings:
Troubleshoots and diagnoses nature and loca-
tion of stoppages
Removes and replaces sections of pipe, pipe
fittings, and couplings
Cuts and threads pipe
Cleans pipe using mechanical and hydraulically
propelled tools
Replaces gaskets and seals on flange type
joints
Bends pipe and tubing
Tests pipe systems for pressure capability
and leaks
May be required to repair and replace special
purpose pipe and fittings of the following
types:
Glass
Glass or plastic lined steel
Plastic and PVC
Aluminum
Wood
Vitrified tile
See Chem Add
-------
OIL REMOVAL (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f -
oo
o
Repairs and overhauls manual and automatic
control valves:
Troubleshoots and diagnoses malfunction in
manual and controlled valves
Installs, removes, and replaces valves
Assembles and disassembles valves and control
mechanisms
Inspects and measures valve clearances
Grinds, polishes, laps in valves and valve
seats
Cleans and inspects valve actuating mechanisms
Adjusts backlash in valve actuating mechanisms
Lubricates valve actuating mechanisms
Tests bellows and diaphragm actuators for leaks
Calibrates valve position and control actuator
Adjusts and replaces packing and seals
Tests valves for complete opening and shut-off
Tests functioning of control actuators (pneu-
matic, hydraulic, electrical, mechanical)
Replaces worn or defective valve and actuator
parts
Repairs and overhauls storage tanks, drums, and
vessels:
Repairs leaks and defective portions of steel
storage facilities
Repairs leaks and defective portions of lined
steel storage facilities
Repairs leaks and defective portions of wood
storage facilities
See Chem Add
it
-------
OCCUPATIONAL SKILL FREQUENCY
OIL REMOVAL (cont.) AREA LEVEL f
Repairs leaks and defective portions of con-
crete storage facilities See Chem Add
Diagnoses cause of rust, corrosion, and leaks "
Repairs and overhauls mixing and blending equip-
ment and mechanical appurtenances:
Troubleshoots and diagnoses malfunctions in
mechanical systems "
Installs, removes, and replaces arms, paddles,
and propellers "
Disassembles and assembles mechanical drive
systems »
Inspects and measures gear drives for wear and
defects «•
Inspects chain drives, replaces defective
links, adjusts tension 1!
Checks and measures sprocket alignment "
Inspects sprocket teeth for wear, hooks, and
other defects "
Inspects and measures screen and bar rakes for
wear and defects "
Inspects and measures bearings and races for
wear and defects «'
Cleans and finishes moving parts to prevent
freezing or binding "
Repacks bearings "
Fits and replaces parts showing excessive wear
or defects «
Inspects and replaces water and oil seals as
necessary »
-------
OCCUPATIONAL SKILL FREQUENCY
OIL REMOVAL (cont.) AREA LEVEL f
Dresses and reconditions scrapers, paddles,
and propellers See Chem Add
Cleans and paints exposed surfaces "
Replaces drive belts, pulleys, and tensioning
devices "
to
00
to
-------
SEDIMENTATION
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
CO
to
Operations
Monitors and verifies proper operation and condi-
tion of the following units of equipment:
Mechanically cleaned sedimentation tanks
Manually cleaned sedimentation tanks
Centrifugal, reciprocating, and diaphragm
pumps
Flow measuring devices
Pipe and pipe fittings
Manual and automatic control valves
Steel, wood, and concrete tanks
Electric motors, relays, and circuit breakers/
switches
Mixing and blending equipment
Belt, chain, and gear drive mechanisms
Reads and interprets status and control instru-
mentation:
Flow meters and recorders
Level indicators
Pilot lamps and voltage/current recorders and
meters
Collects and labels composite or grab samples for
laboratory analysis
Activates and controls units of equipment:
Adjusts manual valves to achieve specified
flow, pressure and retention times
Switches to standby or parallel pumps
OP
II
n
it
ii
it
n
n
n
n
n
n
ti
2
2
2
2
1
2
1
2
2
2
2
2
2
2
2
2
I/Shift
As Req
n
-------
SEDIMENTATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Overrides automatic controls to correct in
specific situations
Activates and adjusts mechanical sedimentation
and scum removal equipment
Adjusts distribution of flow in tank
Adjusts mechanical flocculation equipment
Removes and disposes of sludge and grit:
Scrapes and removes skimmings from weir
Cleans grit chambers
Dewaters and cleans tank and sludge withdrawl
equipment
Empties sludge collecting tanks and disposes
of sludge
OP
it
it
2
3
3
1
1
2
1
As Req
dly
dly
mthly
dly
00
Preventive Maintenance Activities
Services status and control instrumentation:
Cleans and lubricates chart drive mechanisms
Cleans electrical sensors
Checks electrical contacts, connections, and
wiring
Checks pneumatic sensors for leaks
Checks zero or null setting on galvanometers
and pen recorders
Checks mechanical linkage for corrosion, rust,
and freedom of movement
Cleans indicator covers and glass viewing
windows
Cleans recorder pens and checks for ink flow
2
2
2
2
2
2
2
2
2/yr
mthly
wkly
wkly
wkly
mthly
mthly
dly
-------
SEDIMENTATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
00
Checks, indicated values against known standards
(checks calibration)
Services electric motors .and auxiliary equipment:
Inspects motors for signs of overheating
Checks for excessive vibration or hum
Checks wiring insulation
Checks for dirt or moisture
Checks drive coupling and motor mounts for
play/loose fittings
Checks for sticking brushes or excessive arcing
Checks pilot lights and alarms
Checks points and contacts for pitting
Cleans and tightens electrical connections
Checks and lubricates bearings
Checks switches and circuit breakers for proper
functioning
Services centrifugal, reciprocating, and diaphragm
pumps:
Checks solenoid oiler flow; adjusts as necessary
Checks oil level in ball bearing housing; fills
as necessary
Checks grease cup; maintains proper pressure
Checks enclosed shaft bearings; refills oil cup
as necessary
Checks ball-thrust bearings; adds fresh grease
as necessary
Checks guide bearings; adds grease as necessary
Drains and adds fresh lubricant to shaft bear-
ings
OP
mthly
See Chem Add
M
11
II
II
It
II
II
tl
II
II
II
-------
SEDIMENTATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
CO
Flushes bearing housing and adds fresh grease
Checks bearing temperatures; adjusts as neces-
sary
Checks stuffing boxes for leaks; tightens or
repacks as necessary
Checks water-seal systems for leaks; adjusts
pressure as necessary
Clean and paint pump casing
Check, clean, lubricate, and adjust float
switch system
Inspect check valves for leaks
Clean sediment and accumulated solids from
sumps
Check and clean strainers
Services flow measuring devices:
Cleans and flushes annular chambers
Cleans and flushes piezometer pressure taps
Cleans and dresses orifice plates
Cleans and paints exterior
Inspects interior for corrosion
Purges connecting lines and fittings
Services pipes and pipe fittings:
Checks for leaks in pipes and pipe fittings
Inspects for rust and corrosion
Cleans and paints pipes and fittings
Flushes dead-ends
Checks and cleans sediment traps
Checks and cleans wells and sumps
Mechanically cleans pipes with augers and snakes
See Chem Add
-------
SEDIMENTATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
oo
•vj
Services manual and automatic control valves:
Checks valves for leaks
Inspects for rust and corrosion
Checks actuating bellows for leaks
Checks linkages for free movement
Checks for complete opening and closing
Checks calibration
Lubricates control linkage
Adjusts packing
Cleans and paints exterior
Cleans solenoid actuating mechanisms
Services storage tanks, drums, and vessels:
Checks for leaks
Inspects for rust and corrosion
Cleans and paints interior and exterior
Removes accumulated deposits of sludge and
sediment
Services mixing and blending equipment:
Cleans deposits from paddles, arms and pro-
pellers
Inspects for rust and corrosion
Inspects mechanical drive functioning
Lubricates mechanical drive system
Paints and protects exposed surfaces
Checks for homogeneity of mixed substances
Checks speed of mixing or blending
Services mechanical drive systems:
Checks tension of flat and V-belt drives
See Chem Add
n
n
ii
n
n
ii
it
ii
«
ii
n
ii
n
-------
SEDIMENTATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
00
00
Checks and adjusts belt alignment
Checks belts for wear
Checks and adjusts chain drive slack
Lubricates chain drive systems
Checks lubricant levels in right-angle gear
drives
Checks lubricant levels in reduction gear
boxes
Drains and changes oil in sump systems
Cleans and inspects variable speed belt drive
systems
Lubricates thrust and frame bearings for drive
shafts
Checks oil seals for leaks
Lubricates pressure grease fittings
Corrective Maintenance Activities
Repairs and overhauls status and control instru-
mentation:
Troubleshoots and diagnoses malfunctions in
status and control instrumentation
Installs, removes, replaces status and control
instrumentation
Disassembles and reassembles status and control
ins trumentation
Tests diaphragms, bourdon tubes, and bellows
for'leaks or defects
Tests bimetallic strips and thermocouples for
defects
See Chem Add
-------
SEDIMENTATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
00
Tests electrical circuitry for shorts/ open
circuits, and resistance
Cleans and adds mercury to manometers
Cleans and sets contact points
Cleans and checks knife edges
Cleans and lubricates jeweled bearings
Blows down pressure lines to remove restric-
tions or stoppages
Cleans and checks orifices and nozzles
Adjusts backlash in mechanical linkages
Calibrates indicators and recorder pens
against known standard
Replaces worn or defective parts, seals, and
bearings
Repairs and overhauls electric motors and auxiliary
equipment:
Diagnoses and troubleshoots electrical malfunc-
tions
Installs, removes, replaces electric motors,
wiring, and control devices
Inspects and tests rotor and stator windings
for shorts or open circuits
Inspects commutator for wear, shorts, and signs
of excessive heat
Checks brushes for wear and proper spring ten-
sion
Adjusts brushes to seat properly and prevent
sticking
Cleans, adjusts, and lubricates bearings
See Chem Add
n
-------
SEDIMENTATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
vo
o
Checks thermal switches, circuit breakers, and
fuses
Cleans and polishes collector rings
Checks and tightens pigtails and mechanical
wire connections
Replaces or repairs defective parts in motors
and control devices
Adjusts rotor and shaft alignment
Reconditions or replaces contacts or relays
and switches
Replaces defective wiring and conduit
Inspects exposed equipment for defective gas-
kets and seals
Measures voltage, current, and power consump-
tion
Checks motor speeds
Repairs and overhauls centrifugal, reciprocating,
and diaphragm pumps:
Troubleshoots and diagnoses malfunctions in
pumps
Installs, removes, and replaces pumps
Disassembles and assembles pumps
Inspects and measures bearings and bearing
races for defects
Repacks ball-thrust bearings, roller bearings,
and guide bearings
Cleans and inspects pump interior
Checks stuffing box for free movement of gland
and excessive leakage
Repacks gland assembly and adjusts
See Chem Add
it
-------
SEDIMENTATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
vo
Grinds and laps valves and valve seats
Inspects impellers for deposits, scaling, and
cavitation pits
Dynamically balances impellers
Checks and aligns drive system
Fits replacement parts
Repairs bent float rods, binding mechanical
fittings
Lubricates mechanical fittings
Cleans and paints exterior housing
Repairs and replaces pipes and pipe fittings:
Troubleshoots and diagnoses nature and loca-
tion of stoppages
Removes and replaces sections of pipe, pipe
fittings, and couplings
Cuts and threads pipe
Cleans pipe using mechanical and hydraulically
propelled tools
Replaces gaskets and seals on flange type
joints
Bends pipe and tubing
Tests pipe systems for pressure capability and
leaks
May be required to repair and replace special
purpose pipe and fittings of the following
types:
Glass
Glass or plastic lined steel
Plastic and PVC
See Chem Add
-------
SEDIMENTATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
VJD
10
Aluminum
Wood
Vitrified tile
Repairs and overhauls manual and automatic control
valves:
Troubleshoots and diagnoses malfunction in
manual and controlled valves
Installs, removes, and replaces valves
Assembles and disassembles valves and control
mechanisms
Inspects and measures valve clearances
Grinds, polishes, laps in valves and valve
seats
Cleans and inspects valve actuating mechanisms
Adjusts backlash in valve actuating mechanisms
Lubricates valve actuating mechanisms
Tests bellows and diaphragm actuators for leaks
Calibrates valve position and control actuator
Adjusts and replaces packing and seals
Tests valves for complete opening and shut-off
Tests functioning of control actuators {pneu-
matic, hydraulic, electrical, mechanical)
Replaces worn or defective valve and actuator
parts
Repairs and overhauls storage tanks, drums and
vessels:
Repairs leaks and defective portions of steel
storage facilities
See Chem Add
-------
SEDIMENTATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
Repairs leaks and defective portions of lined
steel storage facilities
Repairs leaks and defective portions of wood
storage facilities
Repairs leaks and defective portions of con-
crete storage facilities
Diagnoses cause of rust, corrosion, and leaks
Repairs and overhauls mixing and blending equipment
and mechanical appurtenances:
Troubleshoots and diagnoses malfunctions in
mechanical systems
Installs, removes, and replaces arms, paddles,
and propellers
Disassembles and assembles mechanical drive
systems
Inspects and measures gear drives for wear and
defects
Inspects chain drives, replaces defective links,
adjusts tension
Checks and measures sprocket alignment
Inspects sprocket teeth for wear, hooks, and
other defects
Inspects and measures screen and bar rakes for
wear and defects
Inspects and measures bearings and races for
wear and defects
Cleans and finishes moving parts to prevent
freezing or binding
Repacks bearings
Fits and replaces parts showing excessive wear
or defects
See Chem Add
-------
SEDIMENTATION (cent.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Inspects and replaces water and oil seals as
necessary
Dresses and reconditions scrapers, paddles,
and propellers
Cleans and paints exposed surfaces
Replaces drive belts, pulleys, and tensioning
devices
See Chem Add
to
to
-------
FILTRATION
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
N3
vo
Ul
Operations
Monitors and verifies proper operation and condi-
tion of the following units of equipment:
Diatomaceous earth filters
Rapid sand filters
Rotary vacuum filtration units
Plate and frame filters
Electric motors, relays/ and circuit breakers/
switches
Centrifugal, reciprocating, and diaphragm pumps
Flow measuring devices
Pipe and pipe fittings
Manual and automatic control valves
Steel tanks, drums, and vessels
Air compressors and vacuum pumps
Reads and interprets status and control instru-
mentation:
Sight windows
Level indicators
Flow meters and recorders
Pilot lamps
Activates and controls units of equipment:
Adjusts manual valves to achieve specified in-
fluent level
Opens and closes manual valves to perform back-
washing
Controls rate of backwash
Activates and controls influent and effluent
pumps
OP
n
ii
n
n
u
u
n
11
ii
n
ii
it
2
2
2
2
2
2
2
2
2
1
2
2
2
2
2
2
2
I/Shift
n
ti
n
n
it
it
it
it
n
n
»
it
-------
FILTRATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Overrides automatic controls to correct in
specific situations
Activates and controls vacuum pumps and air
compressors
Adjusts dosage frequency on intermittent sand
filters
Adjusts and sets rate controller according to
suspended solids in influent
Removes and disposes of backwash sludge and grit:
OP
3
2
2
3
I/Shift
to
\D
Preventive Maintenance Activities
Services diatomaceous earth filtration units:
Cleans and flushes grease and slime from dosing
tanks
Checks distributors for plugging
Checks and adjusts for even distribution of
influent
Checks for ponding, insects, odors, and icing
Checks for rust and corrosion
Cleans and paints exposed surfaces
Checks water distribution system for clogging
Services rapid sand filters:
Cleans and flushes backwash weirs
Checks condition of filter bed for cracks,
clogging, mounds, and craters
Cleans and inspects underdrain system
Rakes and screens filter bed
11
n
2
2
3
2
2
1
2
2
2
2
wkly
I/Shift
As Req
2/Shift
wkly
wkly
-------
FILTRATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
vo
-J
Surface scours filter bed
Cleans filter bed through chemical addition
Checks for rust and corrosion
Checks water distribution system for clogging
Services plate and frame filters:
Checks and adjusts tension on frame mountings
Checks for rust and corrosion
Cleans and paints exterior
Services status and control instrumentation:
Cleans and lubricates chart drive mechanisms
Cleans electrical sensors
Checks electrical contacts, connections, and
wiring
Checks pneumatic sensors for leaks
Checks zero or null setting on galvanometers
and pen recorders
Checks mechanical linkage for corrosion, rust,
and freedom of movement
Cleans indicator covers and glass viewing
windows
Cleans recorder pens and checks for ink flow
Checks indicated values against known standards
(checks calibration)
Services electric motors and auxiliary equipment:
Inspects motors for signs of overheating
Checks for excessive vibration or hum
Checks wiring insulation
Checks for dirt or moisture
OP
n
it
it
tt
n
n
it
n
it
2
2
2
2
2
2
2
2
2
2
2
2
2
2
2
wkly
it
it
I/Shift
wkly
yrly
2/yr
mthly
wkly
mthly
dly
mthly
See Chem Add
-------
FILTRATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
K)
V£)
00
Checks drive coupling and motor mounts for
play/loose fittings
Checks for sticking brushes or excessive arcing
Checks pilot lights and alarms
Checks points and contacts for pitting
Cleans and tightens electrical connections
Checks and lubricates bearings
Checks switches and circuit breakers for proper
functioning
Services centrifugal, reciprocating/ and diaphragm
pumps:
Checks solenoid oiler flow; adjusts as necessary
Checks oil level in ball bearing housing; fills
as necessary
Checks grease cup; maintains proper pressure
Checks enclosed shaft bearings; refills oil cup
as necessary
Checks ball-thrust bearings; adds fresh grease
as necessary
Checks guide bearings; adds grease as necessary
Drains and adds fresh lubricant to shaft bear-
ings
Flushes bearing housing and adds fresh grease
Checks bearing temperatures; adjusts as neces-
sary
Checks stuffing boxes for leaks; tightens or
repacks as necessary
Checks water-seal systems for leaks, adjusts
pressure as necessary
Clean and paint pump casing
See Chem Add
-------
OCCUPATIONAL SKILL FREQUENCY
FILTRATION (cont.) AREA LEVEL f
Check, clean, lubricate, and adjust float
switch system See Chem Add
Inspect check valves for leaks "
Clean sediment and accumulated solids from
sumps "
Check and clean strainers "
Services flow measuring devices:
Cleans and flushes annular chambers "
Cleans and flushes piezometer pressure taps "
Cleans and dresses orifice plates "
Cleans and paints exterior "
Inspects interior for corrosion "
Purges connecting lines and fittings "
Services pipes and pipe fittings:
Checks for leaks in pipes and pipe fittings "
Inspects for rust and corrosion "
Cleans and paints pipes and fittings "
Flushes dead-ends "
Checks and cleans sediment traps "
Checks and cleans wells and sumps' "
Mechanically cleans pipes with augers and snakes "
Services manual and automatic control valves:
Checks valves for leaks "
Inspects for rust and corrosion "
Checks actuating bellows for leaks "
Checks linkages for free movement "
Checks for complete opening and closing "
Checks calibration "
-------
FILTRATION (cont.J
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Lubricates control linkage
Adjusts packing
Cleans and paints exterior
Cleans solenoid actuating mechanisms
Services storage tanks, drums, and vessels:
Checks for leaks
Inspects for rust and corrosion
Cleans and paints interior and exterior
Removes accumulated deposits of sludge and
sediment
See Chem Add
11
00
o
o
Corrective Maintenance Activities
Repairs and overhauls diatomaceous earth filtration
units:
Drains and inspects filter bed and underdrain
system
Removes sediment cake and sludge
Replaces filter bed
Cleans and replaces underdrain system
Repairs leaks
Troubleshoots and diagnoses malfunctions in slow
sand filters
Cleans and unclogs water distribtuion system
Repairs and overhauls rapid sand filters:
Troubleshoots and diagnoses malfunctions in
rapid sand filters
ir
11
11
if
11
n
n
-------
FILTRATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Drains filter and inspects composition of filter
bed
Removes filter bed materials and replaces
Cleans and replaces backwash system
Repairs and overhauls plate and frame filters:
Troubleshoots and diagnoses malfunctions in
plate and frame filters
Disassembles and assembles plate and frame
filters
Inspects filter frames for clogging or other
defects
Inspects gaskets and seals for defects and
serviceability
Cleans or replaces filters, gaskets, and seals
Repairs and overhauls status and control instru-
mentation :
Troubleshoots and diagnoses malfunctions in
status and control instrumentation
Installs, removes, replaces status and control
instrumentation
Disassembles and reassembles status and control
instrumentation
Tests diaphragms, bourdon tubes, and bellows for
leaks or defects
Tests bimetallic strips and thermocouples for
defects
Tests electrical circuitry for shorts, open cir-
cuits, and resistance
Cleans and adds mercury to manometers
See Chem Add
IT
ir
ii
ii
-------
OCCUPATIONAL SKILL FREQUENCY
FILTRATION (cont.) AREA LEVEL f
Cleans and sets contact points See Chem Add
Cleans and checks knife edges "
Cleans and lubricates jeweled bearings "
Blows down pressure lines to remove restrictions
or stoppages "
Cleans and checks orifices and nozzles "
Adjusts backlash in mechanical linkages "
Calibrates indicators and recorder pens against
known standard n
Replaces worn or defective parts, seals, and
bearings "
Repairs and overhauls electric motors and auxiliary
equipment:
Diagnoses and troubleshoots electrical malfunc-
tions
Installs, removes, replaces electric motors,
wiring, and control devices
Inspects and tests rotor and stator windings for
shorts or open circuits
Inspects commutator for wear, shorts, and signs
of excessive heat
Checks brushes for wear and proper spring ten-
sion
Adjusts brushes, to seat properly and prevent
sticking
Cleans, adjusts, and lubricates bearings
Checks thermal switches, circuit breakers, and
fuses
Cleans and polishes collector rings
n
n
-------
OCCUPATIONAL SKILL FREQUENCY
FILTRATION (cont.) AREA LEVEL f
Checks and tightens pigtails and mechanical
wire connections See Chem Add
Replaces or repairs defective parts in motors
and control devices "
Adjusts rotor and shaft alignment "
Reconditions or replaces contacts on relays and
switches "
Replaces defective wiring and conduit "
Inspects exposed equipment for defective gas-
kets and seals "
Measures voltage, current, and power consump-
tion
Checks motor speeds "
2 Repairs and overhauls centrifugal, reciprocating,
and diaphragm pumps:
Troubleshoots and diagnoses malfunctions in
pumps "
Installs, removes, and replaces pumps "
Disassembles and assembles pumps "
Inspects and measures bearings and bearing races
for defects "
Repacks ball-thrust bearings, roller bearings,
and guide bearings "
Cleans and inspects pump interior "
Checks stuffing box for free movement of gland
and excessive leakage "
Repacks gland assembly and adjusts "
Grinds and laps valves and valve seats "
Inspects impellers for deposits, scaling, and
cavitation pits
-------
OCCUPATIONAL SKILL FREQUENCY
FILTRATION (cont.) AREA LEVEL f
Dynamically balances impellers See Chein Add
Checks and aligns drive system "
Fits replacement parts
Repairs bent float rods, binding mechanical
fittings
Lubricates mechanical fittings
Cleans and paints exterior housing
ii
it
ii
11
Repairs and replaces pipes and pipe fittings:
Troubleshoots and diagnoses nature and location
of stoppages "
Removes and .replaces sections of pipe, pipe fit-
tings, and couplings "
Cuts and threads pipe
Cleans pipe using mechanical and hydraulically
propelled tools
Replaces gaskets and seals on flange type
joints
Bends pipe and tubing "
Tests pipe systems for pressure capability and
leaks
May be required to repair and replace special
purpose pipe and fittings of the following
types:
Glass "
Glass or plastic lined steel "
Plastic and PVC "
Aluminum
Wood
Vitrified tile
-------
OCCUPATIONAL SKILL FREQUENCY
FILTRATION (cont.) AREA LEVEL f
Repairs and overhauls manual and automatic control
valves:
Troubleshoots and diagnoses malfunction in
manual and controlled valves See Chem Add
Installs, removes, and replaces valves "
Assembles and disassembles valves and control
mechanisms "
Inspects and measures valve clearances "
Grinds, polishes, laps-in valves and valve
seats "
Cleans and inspects valve actuating mechanisms "
Adjusts backlash in valve actuating mechanisms "
Lubricates valve actuating mechanisms
w Tests bellows and diaphragm actuators for leaks
° Calibrates valve position and control actuator
Adjusts and replaces packing and seals "
Tests valves for complete opening and shut-off "
Tests functioning of control actuators (pneu-
matic, hydraulic, electrical, mechanical) "
Replaces worn or defective valve and actuator
parts "
Repairs and overhauls storage tanks, drums, and
vessels:
Repairs leaks and defective portions of steel
storage facilities "
Repairs leaks and defective portions of lined
steel storage facilities "
Repairs leaks and defective portions of wood
storage facilities "
it
n
-------
OCCUPATIONAL SKILL FREQUENCY
FILTRATION (cont.) &RSA LEVEL f
Repairs leaks and defective portions of concrete
storage facilities See Chem Add
Diagnoses cause of rust, corrosion, and leaks "
u>
o
a\
-------
REVERSE OSMOSIS
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Operations
Monitors and verifies proper operation and condi-
tion of the following units of equipment:
Reverse osmosis unit (plate-and-frame, large
tube, spiral-wound module)
Centrifugal and reciprocating pumps
Pressure measuring devices and control instru-
mentation
Flow measuring devices and control instrumenta-
tion
Steel pipe and pipe fittings
Belt, chain, and gear drive mechanisms
Electric motors, relays, and circuit breakers/
switches
pH status instrumentation
Conductivity status instrumentation
Reads and interprets status and control instru-
mentation:
pH recorders and meters
Conductivity recorders and meters
Flow and pressure recorders and meters
Pilot lamps and alarms
Activates and controls units of equipment:
Activates and controls high-pressure pumps
Adjusts manual valves to control pressure and
flow rate
Overrides automatic controls to shutdown or
correct in specific situations
OP
n
ii
n
n
ii
n
n
n
n
ii
2
2
2
1
2
2
2
2
2
2
2
2
2
2
3
I/Shift
n
ii
ii
n
n
ii
n
As Req
-------
REVERSE OSMOSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Activates and controls valves to bleed off
concentrates
Collects composite or grab samples for laboratory
analysis
OP
2
2
I/Shift
CO
o
00
Preventive Maintenance Activities
Services reverse osmosis units:
Inspects RO units for leaks
Checks for rust and corrosion
Cleans and paints exterior
Checks and adjusts tension on plate and frame
components
Services status and control instrumentation:
Cleans and lubricates chart drive mechanisms
Cleans electrical senors
Checks electrical contacts, connections, and
wiring
Checks pneumatic sensors for leaks
Checks zero or null setting on galvanometers
and pen recorders
Checks mechanical linkage for corrosion, rust,
and freedom of movement
Cleans indicator covers and glass viewing
windows
Cleans recorder pens and checks for ink flow
Checks indicated values against known standards
(checks calibration)
it
it
n
11
II
n
it
n
2
2
1
2
2
2
2
2
2
2
2
wkly
2/yr
dly
2/yr
mthly
wkly
mthly
dly
mthly
-------
REVERSE OSMOSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
o
vo
Services electric motors and auxiliary equipment:
Inspects motors for signs of overheating
Checks for excessive vibration or hum
Checks wiring insulation
Checks for dirt or moisture
Checks drive coupling and motor mounts for play/
loose fittings
Checks for sticking brushes or excessive arcing
Checks pilot lights and alarms
Checks points and contacts for pitting
Cleans and tightens electrical connections
Checks and lubricates bearings
Checks switches and circuit breakers for proper
functioning
Services centrifugal, reciprocating, and diaphragm
pumps:
Checks solenoid oiler flow; adjusts as necessary
Checks oil level in ball bearing housing; fills
as necessary
Checks grease cup; maintains proper pressure
Checks enclosed shaft bearings; refills oil cup
as necessary
Checks ball-thrust bearings; adds fresh grease
as necessary
Checks guide bearings; adds grease as necessary
Drains and adds fresh lubricant to shaft bear-
ings
Flushes bearing housing and adds fresh grease
Checks bearing temperatures; adjusts as neces-
sary
OP
it
it
2
2
2
2
2
2
2
2
2
1
1
2
2
2
2
2
dly
dly
wkly
dly
dly
dly
I/Shift
mthly
mthly
wkly
dly
wkly
dly
dly
dly
mthly
4/yr
wkly
-------
REVERSE OSMOSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Checks stuffing boxes for leaks; tightens or
repacks as necessary
Checks water-seal systems for leaks; adjusts
pressure as necessary
Clean and paint pump casing
Check, clean, lubricate, and adjust float switch
system
Inspect check valves for leaks
Clean sediment and accumulated solids from sumps
Check and clean strainers
Services flow measuring devices:
Cleans and flushes annular chambers
Cleans and flushes piezometer pressure taps
Cleans and dresses orifice plates
Cleans and paints exterior
Inspects interior for corrosion
Purges connecting lines and fittings
Services pipes and pipe fittings:
Checks for leaks in pipes and pipe fittings
Inspects for rust and corrosion
Cleans and paints pipes and fittings
Flushes dead-ends
Checks and cleans sediment traps
Checks and cleans wells and sumps
Mechanically cleans pipes with augers and snakes
Services manual and automatic control valves:
Checks valves for leaks
Inspects for rust and corrosion
OP
ir
ir
ii
2
1
2
2
1
1
See Chem Add
n
n
n
n
n
n
n
n
n
n
ii
dly
dly
dly
wkly
dly
mthly
dly
-------
REVERSE OSMOSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
10
H
Checks actuating bellows for leaks
Checks linkages for free movement
Checks for complete opening and closing
Checks calibration
Lubricates control linkage
Adjusts packing
Cleans and paints exterior
Cleans solenoid actuating mechanisms
Services storage tanks, drums, and vessels:
Checks for leaks
Inspects for rust and corrosion
Cleans and paints interior and exterior
Removes accumulated deposits of sludge and
sediment
Services mechanical drive systems:
Checks tension of flat and V-belt drives
Checks and adjusts belt alignment
Checks belts for wear
Checks and adjusts chain drive slack
Lubricates chain drive systems
Checks lubricant levels in right-angle gear
drives
Checks lubricant levels in reduction gear
boxes
Drains and changes oil in sump systems
See Chem Add
it
11
ir
n
n
it
ii
it
it
n
ii
-------
REVERSE OSMOSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
CorrectiveMaintenance Activities
Repairs and overhauls reverse osmosis units:
Troubleshoots and diagnoses malfunctions in
reverse osmosis units
Disassembles and assembles reverse osmosis
units
Inspects membranes for plugging and other de-
fects
Inspects gaskets and seals for defects and
serviceability
Cleans membranes and backing plates or supports
Replaces membranes and seals
Tests rebuilt units for high-pressure leaks and
efficiency of operation
Repairs and overhauls status and control instru-
mentation:
Troubleshoots and diagnoses malfunctions in
status and control instrumentation
Installs, removes, replaces status and control
ins trumentation
Disassembles and reassembles status and control
ins trumentati on
Tests diaphragms, bourdon tubes, and bellows for
leaks or defects
Tests bimetallic strips and thermocouples for
defects
Tests electrical circuitry for shorts, open cir-
cuits , and resistance
Factory Rep
See Chem Add
-------
REVERSE OSMOSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Cleans and adds mercury to manometers
Cleans and sets contact points
Cleans and checks knife edges
Cleans and lubricates jeweled bearings
Blows down pressure lines to remove restric-
tions or stoppages
Cleans and checks orifices and nozzles
Adjusts backlash in mechanical linkages
Calibrates indicators and recorder pens
against known standard
Replaces worn or defective parts, seals, and
bearings
Repairs and overhauls electric motors and auxi-
liary equipment:
Diagnoses and troubleshoots electrical mal-
functions
Installs, removes, replaces electric motors,
wiring, and control devices
Inspects and tests rotor and stator windings
for shorts or open circuits
Inspects commutator for wear, shorts, and
signs of excessive heat
Checks brushes for wear and proper spring
tension
Adjusts brushes to seat properly and prevent
sticking
Cleans, adjusts, and lubricates bearings
Checks thermal switches, circuit breakers,
and fuses
Cleans and polishes collector rings
See Chem Add
n
11
ii
it
n
-------
REVERSE OSMOSIS (cent.}
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
OJ
Checks and tightens pigtails and mechanical
wire connections
Replaces or repairs defective parts in motors
and control devices
Adjusts rotor and shaft alignment
Reconditions or replaces contacts on relays
and switches
Replaces defective wiring and conduit
Inspects exposed equipment for defective gas-
kets and seals
Measures voltage, current, and power consump-
tion
Checks motor speeds
Repairs and overhauls centrifugal, reciprocating,
and diaphragm pumps:
Troubleshoots and diagnoses malfunctions in
pumps
Installs removes and replaces pumps
Disassembles and assembles pumps
Inspects and measures bearings and bearing
races for defects
Repacks ball-thrust bearings, roller bearings,
and guide bearings
Cleans and inspects pump interior
Checks stuffing box for free movement of gland
and excessive leakage
Repacks gland assembly and adjusts
Grinds and laps valves and valve seats
Inspects impellers for deposits, scaling/ and
cavitation pits
See Chem Add
n
it
n
n
II
n
11
n
II
li
n
n
-------
REVERSE OSMOSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
CO
M
in
Dynamically balances impellers
Checks and aligns drive system
Fits replacement parts
Repairs bent float rods, binding mechanical
fittings
Lubricates mechanical fittings
Cleans and paints exterior housing
Repairs and replaces pipes and pipe fittings:
Troubleshoots and diagnoses nature and location
of stoppages
Removes and replaces sections of pipe, pipe
fittings, and couplings
Cuts and threads pipe
Cleans pipe using mechanical and hydraulically
propelled tools
Replaces gaskets and seals on flange type
joints
Bends pipe and tubing
Tests pipe systems for pressure capability and
leaks
May be required to repair and replace special
purpose pipe and fittings of the following
types:
Glass
Glass or plastic lined steel
Plastic and PVC
Aluminum
Wood
Vitrified tile
See Chem Add
u
ti
ir
ii
ir
it
-------
REVERSE OSMOSIS (cent.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Repairs and overhauls manual and automatic
control valves:
Troubleshoots and diagnoses malfunction in
manual and controlled valves
Installs, removes, and replaces valves
Assembles and disassembles valves and con-
trol mechanisms
Inspects and measures valve clearances
Grinds, polishes, laps-in valves and valve
seats
Cleans and inspects valve actuating mechanisms
Adjusts backlash in valve actuating mechanisms
Lubricates valve actuating mechanisms
Tests bellows and diaphragm actuators for
leaks
Calibrates valve position and control actuator
Adjusts and replaces packing and seals
Tests valves for complete opening and shut-off
Tests functioning of control actuators (pneu-
matic, hydraulic, electrical, mechanical)
Replaces worn or defective valve and actuator
parts
Repairs and overhauls storage tanks, drums, and
vessels:
Repairs leaks and defective portions of steel
storage facilities
Repairs leaks and defective portions of lined
steel storage facilities
Repairs leaks and defective portions of wood
storage facilities
See Chem Add
-------
REVERSE OSMOSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Repairs leaks and defective portions of
concrete storage facilities
Diagnoses cause of rust, corrosion, and
leaks
See Chem Add
-------
ELECTRODIALYSIS
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
CO
H
00
Operations
Monitors and verifies proper operation and
condition of the following units of equipment:
Permeable membrane electrodialysis unit
Centrifugal, reciprocating, and diaphragm
pumps
Flow measuring devices and control instru-
mentation
Manual and automatic control valves
Steel, lined steel, and wood tanks and drums
Electric motors, relays, and circuit breakers/
switches
pH status instrumentation
Conductivity status instrumentation
Pressure status and control instrumentation
DC generator or rectifier
Reads and interprets status and control instru-
mentation:
pH meters and recorders
ORP meters and recorders
Rate of flow meters and recorders
Pilot lamps and alarms
AC and DC voltmeters, ammeters, and watt-
meters
Pressure indicators and recorders
Activates and controls units of equipment:
Activates pumps and switches pumps in standby
or parallel operations
OP
n
ii
ii
II
H
ii
it
it
ii
n
n
n
n
n
2
2
2
2
1
2
2
2
2
2
2
2
2
2
2
2
I/Shift
As Req
-------
ELECTRODIALYSIS (cent.)
OCCUPATIONAL SKILL FREQUENCY
AREA LEVEL f
Adjusts manual valves to control pressure and
flow rates
Overrides automatic controls to shutdown or
correct in specific situations
Adjusts and controls AC input to rectifiers
or DC generators
Collects composite or grab samples for laboratory
analysis
OP
2
3
2
As Reg
I/Shift
co
H1
\O
Preventive Maintenance Activities
Services permeable membrane electrodialysis units:
Checks pressure drop across input filter
Cleans or replaces input filter
Probes membrane stack with voltmeter to
identify scale deposits
Checks membrane stack for leaks in anode,
cathode, and dilute compartments
Inspects for rust and corrosion
Cleans and paints exterior
Services status and control instrumentation:
Cleans and lubricates chart drive mechanisms
Cleans electrical sensors
Checks electrical contacts, connections, and
wiring
Checks pneumatic sensors for leaks
Checks zero or null setting on galvanometers
and pen recorders
2
2
2
2
1
See Chem Add
it
if
n
it
wkly
2/yr
-------
ELECTRODIALYSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
Checks mechanical linkage for corrosion,
rust, and freedom of movement
Cleans indicator covers and glass viewing
windows
Cleans recorder pens and checks for ink flow
Checks indicated values against known stan-
dards (checks calibration)
Services electric motors and auxiliary equipment:
Inspects motors for signs of overheating
Checks for excessive vibration or hum
Checks wiring insulation
Checks for dirt or moisture
Checks drive coupling and motor mounts for
play/loose fittings
Checks for sticking brushes or excessive arcing
Checks pilot lights and alarms
Checks points and contacts for pitting
Cleans and tightens electrical connections
Checks and lubricates bearings
Checks switches and circuit breakers for
proper functioning
Services centrifugal, reciprocating, and diaphragm
pumps:
Checks solenoid oiler flow; adjusts as necessary
Checks oil level in ball bearing housing; fills
as necessary
Checks grease cup; maintains proper pressure
Checks enclosed shaft bearings; refills oil cup
as necessary
See Chem Add
-------
ELECTRODIALYSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
Checks ball-thrust bearings; adds fresh
grease as necessary
Checks guide bearings; adds grease as
necessary
Drains and adds fresh lubricant to shaft
bearings
Flushes bearing housing and adds fresh grease
Checks bearing temperatures; adjusts as
necessary
Checks stuffing boxes for leaks; tightens or
repacks as necessary
Checks water-seal systems for leaks; adjusts
pressure as necessary
Clean and paint pump casing
Check, clean, lubricate, and adjust float
switch system
Inspect check valves for leaks
Clean sediment and accumulated solids from
sumps
Check and clean strainers
Services flow measuring devices:
Cleans and flushes annular chambers
Cleans and flushes piezometer pressure taps
Cleans and dresses orifice plates
Cleans and paints exterior
Inspects interior for corrosion
Purges connecting lines and fittings
Services pipes and pipe fittings:
Checks for leaks in pipes and pipe fittings
See Chem Add
n
n
n
it
n
it
n
u
n
n
ii
ii
-------
ELECTRODIALYSIS (cont.)
OCCUPATIONAL SKILL FREQUENCY
AREA LEVEL f
NJ
ro
Inspects for rust and corrosion
Cleans and paints pipes and fittings
Flushes dead-ends
Checks and cleans sediment traps
Checks and cleans wells and sumps
Mechanically cleans pipes with augers and
snakes
Services manual and automatic control valves:
Checks valves for leaks
Inspects for rust and corrosion
Checks actuating bellows for leaks
Checks linkages for free movement
Checks for complete opening and closing
Checks calibration
Lubricates control linkage
Adjusts packing
Cleans and paints exterior
Cleans solenoid actuating mechanisms
Services storage tanks, drums, and vessels:
Checks for leaks
Inspects for rust and corrosion
Cleans and paints interior and exterior
Removes accumulated deposits of sludge and
sediment
Services mechanical drive systems:
Checks tension of flat and V-belt drives
Checks and adjusts belt alignment
Checks belts for wear
See Chem Add
n
n
11
11
11
n
n
ii
11
n
n
n
n
n
H
n
it
-------
ELECTRODIALYSIS (cont.)
OCCUPATIONAL SKILL FREQUENCY
AREA LEVEL f
Checks and adjusts chain drive slack
Lubricates chain drive systems
Checks lubricant levels in right-angle gear
drives
Checks lubricant levels in reduction gear
boxes
Drains and changes oil in sump systems
See Chem Add
ir
U)
10
U)
Corrective Maintenance Activities
Repairs and overhauls permeable membrane
electrodialysis units:
Troubleshoots and diagnoses malfunctions in
electrodialysis units
Assembles and disassembles electrodialysis
units
Cleans and inspects metal cathodes and anodes
Cleans and inspects plastic cation membranes
Cleans and inspects plastic anion membranes
Cleans and inspects plastic spacers, seals,
and gaskets
Replaces unserviceable parts and membranes
Tests efficiency of repaired or overhauled
unit
Repairs and overhauls status and control instru-
mentation:
Troubleshoots and diagnoses malfunctions in
status and control instrumentation
Factory Rep
n
ii
n
n
n
ir
See Chem Add
-------
ELECTRODIALYSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
U)
Installs, removes, replaces status and control
ins trumentation
Disassembles and reassembles status and con-
trol instrumentation
Tests diaphragms, bourdon tubes, and bellows
for leaks or defects
Tests bimetallic strips and thermocouples for
defects
Tests electrical circuitry for shorts, open
circuits, and resistance
Cleans and adds mercury to manometers
Cleans and sets contact points
Cleans and checks knife edges
Cleans and lubricates jeweled bearings
Blows down pressure lines to remove restric-
tions or stoppages
Cleans and checks orifices and nozzles
Adjusts backlash in mechanical linkages
Calibrates indicators and recorder pens
against known standard
Replaces worn or defective parts, seals, and
bearings
Repairs and overhauls electric motors and auxiliary
equipment:
Diagnoses and troubleshoots electrical malfunc-
tions
Installs, removes, replaces electric motors,
wiring, and control devices
Inspects and tests rotor and stator windings
for shorts or open circuits
See Chem Add
-------
BLECTHODIALYSIS (cent,)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
Ul
Inspects commutator for wear, shorts, and
signs of excessive heat
Checks brushes for wear and proper spring
tension
Adjusts brushes to seat properly and prevent
sticking
Cleans, adjusts, and lubricates bearings
Checks thermal switches, circuit breakers,
and fuses
Cleans and polishes collector rings
Checks and tightens pigtails and mechanical
wire connections
Replaces or repairs defective parts in motors
and control devices
Adjusts rotor and shaft alignment
Reconditions or replaces contacts on relays
and switches
Replaces defective wiring and conduit
Inspects exposed equipment for defective
gaskets and seals
Measures voltage, current, and power consump-
tion
Checks motor speeds
Repairs and overhauls centrifugal, reciprocating,
and diaphragm pumps:
Troubleshoots and diagnoses malfunctions in
pumps
Installs, removes, and replaces pumps
Disassembles and assembles pumps
See Chem Add
u
If
II
II
II
II
II
n
n
it
n
-------
ELECTRODIALYSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u>
Inspects and measures bearings and bearing
races for defects
Repacks ball-thrust bearings, roller bear-
ings , and guide bearings
Cleans and inspects pump interior
Checks stuffing box for free movement of
gland and excessive leakage
Repacks gland assembly and adjusts
Grinds and laps valves and valve seats
Inspects impellers for deposits, scaling,
and cavitation pits
Dynamically balances impellers
Checks and aligns drive system
Fits replacement parts
Repairs bent float rods, binding mechanical
fittings
Lubricates mechanical fittings
Cleans and paints exterior housing
Repairs and replaces pipes and pipe fittings:
Troubleshoots and diagnoses nature and loca-
tion of stoppages
Removes and replaces sections of pipe, pipe
fittings, and couplings
Cuts and threads pipe
Cleans pipe using mechanical and hydraulically
propelled tools
Replaces gaskets and seals on flange type
joints
Bends pipe and tubing
See Chem Add
n
ti
ii
ii
ii
n
n
-------
ELECTRODIALYSIS fcont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u>
to
Tests pipe systems for pressure capability
and leaks
May be required to repair and replace special
purpose pipe and fittings of the following
types:
Glass
Glass or plastic lined steel
Plastic and PVC
Aluminum
Wood
Vitrified tile
Repairs and overhauls manual and automatic con-
trol valves:
Troubleshoots and diagnoses malfunction in
manual and controlled valves
Installs, removes, and replaces valves
Assembles and disassembles valves and control
mechanisms
Inspects and measures valve clearances
Grinds, polishes, laps-in valves and valve
seats
Cleans and inspects valve actuating mechanisms
Adjusts backlash in valve actuating mechanisms
Lubricates valve actuating mechanisms
Tests bellows and diaphragm actuators for
leaks
Calibrates valve position and control actuator
Adjusts and replaces packing and seals
See Chem Add
it
ri
ti
ir
ii
ii
n
n
ii
n
n
-------
ELECTRODIALYSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
00
Tests valves for complete opening and shut-off
Tests functioning of control actuators (pneu-
matic, hydraulic, electrical, mechanical)
Replaces worn or defective valve and actuator
parts
Repairs and overhauls storage tanks, drums, and
vessels:
Repairs leaks and defective portions of steel
storage facilities
Repairs leaks and defective portions of lined
steel storage facilities
Repairs leaks and defective portions of wood
storage facilities
Repairs leaks and defective portions of con-
crete storage facilities
Diagnoses cause of rust, corrosion, and leaks
Repairs and overhauls mechanical appurtenances:
Troubleshoots and diagnoses malfunctions in
mechanical systems
Disassembles and assembles mechanical drive
systems
Inspects and measures gear drives for wear
and defects
Inspects chain drives, replaces defective
links, adjusts tension
Checks and measures sprocket alignment
Inspects sprocket teeth for wear, hooks, and
other defects
See Chem Add
it
n
ii
ti
-------
ELECTRODIALYSIS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Inspects and measures bearings and races for
wear and defects
Cleans and finishes moving parts to prevent
freezing or binding
Repacks bearings
Fits and replaces parts showing excessive wear
or defects
Inspects and replaces water and oil seals as
necessary
Cleans and paints exposed surfaces
Replaces drive belts, pulleys, and tensioning
devices
See Chem Add
it
n
it
n
to
Note: The electrodialysis unit and DC power
supplies used in this treatment pose
electrical hazards.
-------
ION EXCHANGE
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
LO
o
Operations
Monitors and verifies the proper operation and
condition of the following units of equipment:
Sodium cation exchange units
Hydrogen cation exchange units
Anion exchanger units
Centrifugal, reciprocating, and diaphragm
pumps
Pressure measuring and control devices
Flow measuring devices and control instru-
mentation
Steel pipe and pipe fittings
Belt, chain, and gear drive mechanisms
Electric motors, relays, and circuit breakers/
switches
pH status instrumentation
Conductivity status instrumentation
Dry and liquid chemical feeders and injectors
Reads and interprets status and control instru-
mentation:
pH recorders and meters
Rate of flow meters and recorders
Pressure recorders and meters
Pilot lamps and alarms
Conductivity meters and recorders
Activates and controls units of equipment:
Adjusts and controls manual valves to accom-
plish regeneration
OP
n
n
if
ii
it
it
n
n
ii
ii
n
ii
n
ii
ii
ii
2
2
2
2
2
2
1
2
2
2
2
2
2
2
2
2
2
I/Shift
-------
ION EXCHANGE (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
Overrides automatic controls to correct in
specific situations
Adjusts regeneration cycle time and wash flow
rate
Activates and controls influent and chemical
feed pumps
Collects composite or grab samples for laboratory
analysis
Collects and disposes of backwash from regenera-
tion
Maintains supply of regeneration chemicals in
tanks and hoppers
OP
3
3
2
2
1
I/Shift
As Req
I/Shift
Preventive Maintenance Activities
Services ion exchange units:
Inspects gravity and pressure flow ion exchange
units for leaks
Checks for rust and corrosion
Cleans and paints exterior
Services dry chemical feeders:
Removes chemical dust accumulations from
hoppers and feed mechanism
Checks for loose bolts and defective parts
Cleans solution tanks of accumulated sediment
Lubricates drive mechanism and moving parts
2
2
1
See Chem Add
2/yr
-------
ION EXCHANGE (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
OJ
to
Checks for rust/corrosion
Checks rate of feed against known standard
Paints exposed parts
Services liquid displacement feeders:
Cleans sediment from trap and chemical
storage tanks
Checks for loose or defective parts
Lubricates moving parts and drive mechanisms
Checks pilot tubes and needle valves for proper
operation
Checks rate of feed against known standard
Paints exposed parts
Services status and control instrumentation:
Cleans and lubricates chart drive mechanisms
Cleans electrical sensors
Checks electrical contacts, connectionsr and
wiring
Checks pneumatic sensors for leaks
Checks zero or null setting on galvanometers
and pen recorders
Checks mechanical linkage for corrosion, rust,
and freedom of movement
Cleans indicator covers and glass viewing
windows
Cleans recorder pens and checks for ink flow
Checks indicated values against known stan-
dards (checks calibration)
See Chem Add
it
n
ii
n
ii
11
ii
it
-------
ION EXCHANGE (cent.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
u>
U)
Services electric motors and auxiliary equipment:
Inspects motors for signs of overheating
Checks for excessive vibration or hum
Checks wiring insulation
Checks for dirt or moisture
Checks drive coupling and motor mounts for
play/loose fittings
Checks for sticking brushes or excessive
arcing
Checks pilot lights and alarms
Checks points and contacts for pittings
Cleans and tightens electrical connections
Checks and lubricates bearings
Checks switches and circuit breakers for
proper functioning
Services centrifugal, reciprocating, and diaphragm
pumps:
Checks solenoid oiler flow; adjusts as necessary
Checks oil level in ball bearing housing; fills
as necessary
Checks grease cup; maintains proper pressure
Checks enclosed shaft bearings; refills oil cup
as necessary
Checks ball-thrust bearings; adds fresh grease
as necessary
Checks guide bearings; adds grease as necessary
Drains and adds fresh lubricant to shaft bear-
ings
Flushes bearing housing and adds fresh grease
See Chem Add
it
it
11
n
n
ii
n
ii
n
H
ii
ii
-------
ION EXCHANGE (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u»
Checks bearing temperatures; adjusts as
necessary
Checks stuffing boxes for leaks; tightens
or repacks as necessary
Checks water-seal systems for leaks; adjusts
pressure as necessary
Clean and paint pump casing
Check, clean, lubricate, and adjust float
switch system
Inspect check valves for leaks
Clean sediment and accumulated solids from
sumps
Check and clean strainers
Services flow measuring devices:
Cleans and flushes annular chambers
Cleans and flushes piezometer pressure taps
Cleans and dresses orifice plates
Cleans and paints exterior
Inspects interior for corrosion
Purges connecting lines and fittings
Services pipes and pipe fittings:
Checks for leaks in pipes and pipe fittings
Inspects for rust and corrosion
Cleans and paints pipes and fittings
Flushes dead-ends
Checks and cleans sediment traps
Checks and cleans wells and sumps
Mechanically cleans pipes with augers and
snakes
See Chem Add
n
n
n
n
n
n
n
n
n
-------
ION EXCHANGE (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
OJ
OJ
in
Services manual and automatic control valves:
Checks valves for leaks
Inspects for rust and corrosion
Checks actuating bellows for leaks
Checks linkages for free movement
Checks for complete opening and closing
Checks calibration
Lubricates control linkage
Adjusts packing
Cleans and paints exterior
Cleans solenoid actuating mechanisms
Services storage tanks, drums, and vessels:
Checks for leaks
Inspects for rust and corrosion
Cleans and paints interior and exterior
Removes accumulated deposits of sludge and
sediment
Services mechanical drive systems:
Checks tension of flat and V-belt drives
Checks and adjusts belt alignment
Checks belts for wear
Checks and adjusts chain drive slack
Lubricates chain drive systems
Checks lubricant levels in right-angle gear
drives
Checks lubricant levels in reduction gear
boxes
Drains and changes oil in sump systems
See Chem Add
•r
IF
ti
n
n
it
n
-------
ION EXCHANGE (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Cleans and inspects variable speed belt drive
systems
Lubricates thrust and frame bearings for
drive shafts
Checks oil seals for leaks
Lubricates pressure grease fittings
See Chem Add
it
M
u>
Corrective Maintenance Activities
Repairs and overhauls ion exchange units:
Troubleshoots and diagnoses malfunctions in
ion exchange units
Disassembles and assembles ion exchange units
Cleans and inspects water distributor for
clogging or defects
Repairs or replaces resin bed supports
Inspects gaskets and seals for defects and
serviceability
Replaces defective parts and seals
Repairs and overhauls dry chemical feeders:
Troubleshoots and diagnoses malfunctions
Installs, removes, and replaces chemical
feeder units
Inspects and measures parts for wear and
defects
Checks and adjusts stroke rods
Cleans pockets of star feeder and scraper
Checks and cleans feeding gates
Checks feeder scale sensitivity and null balance
Factory Rep
See Chem Add
n
ii
n
n
n
-------
ION EXCHANGE (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u>
-J
Replaces worn or defective parts and bearings
Fits parts, seals, and gaskets
Reassembles feeding unit
Tests and calibrates feed rate against known
standard
Cleans and paints all exposed surfaces
Repairs and overhauls liquid and solution chemical
feeders:
Troubleshoots and diagnoses malfunctions
Installs, removes, and replaces chemical feeder
units
Disassembles feeder units and reassembles
Inspects and measures parts for wear and de-
fects
Repairs linings and diaphragms
Measures and adjusts float valve settings
Fits parts, seals, and gaskets
.Replaces worn or defective parts, seals, and
gaskets
Tests and calibrates feed rate against known
standard
Cleans and paints all exposed surfaces
Repairs and overhauls status and control instru-
mentation:
Troubleshoots and diagnoses malfunctions in
status and control instrumentation
Installs, removes, replaces status and control
instrumentation
See Chem Add
n
n
it
n
n
n
-------
ION EXCHANGE (oont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u>
00
Disassembles and reassembles status and
control instrumentation
Tests diaphragms, bourdon tubes, and bellows
for leaks or defects
Tests bimetallic strips and thermocouples for
defects
Tests electrical circuitry for shorts, open
circuits, and resistance
Cleans and adds mercury to manometers
Cleans and sets contact points
Cleans and checks knife edges
Cleans and lubricates jeweled bearings
Blows down pressure lines to remove restric-
tions or stoppages
Cleans and checks orifices and nozzles
Adjusts backlash in mechanical linkages
Calibrates indicators and recorder pens
against known standard
Replaces worn or defective parts, seals, and
bearings
Repairs and overhauls electric motors and auxiliary
equipment:
Diagnoses and troubleshoots electrical malfunc-
tions
Installs, removes, replaces electric motors,
wiring, and control devices
Inspects and tests rotor and stator windings
for shorts or open circuits
Inspects commutator for wear, shorts, and
signs of excessive heat
See Chem Add
it
it
-------
ION EXCHANGE (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u>
Checks brushes for wear and proper spring
tension
Adjusts brushes to seat properly and prevent
sticking
Cleans, adjusts, and lubricates bearings
Checks thermal switches, circuit breakers,
and fuses
Cleans and polishes collector rings
Checks and tightens pigtails and mechanical
wire connections
Replaces or repairs defective parts in motors
and control devices
Adjusts rotor and shaft alignment
Reconditions or replaces contacts on relays and
switches
Replaces defective wiring and conduit
Inspects exposed equipment for defective gas-
kets c*nd seals
Measures voltage, current/ and power consump-
tion
Checks motor speeds
Repairs and overhauls centrifugal, reciprocating,
and diaphragm pumps:
Troublesshoots and diagnoses malfunctions in
pumps
Installs, removes, and replaces pumps
Disassembles and assembles pumps
Inspects and measures bearings and bearing
races for defects
See Chem Add
n
ii
n
-------
ION EXCHANGE (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
CJ
j*
o
Repacks ball-thrust bearings, roller bear-
ings, and guide bearings
Cleans and inspects pump interior
Checks stuffing box for free movement of
gland and excessive leakage
Repacks gland assembly and adjusts
Grinds and laps valves and valve seats
Inspects impellers for deposits, scaling,
and cavitation pits
Dynamically balances impellers
Checks and aligns drive system
Fits replacement parts
Repairs bent float rods, binding mechanical
fittings
Lubricates mechanical fittings
Cleans and paints exterior housing
Repairs and replaces pipes and pipe fittings:
Troubleshoots and diagnoses nature and loca-
tion of stoppages
Removes and replaces sections of pipe, pipe
fittings, and couplings
Cuts and threads pipe
Cleans pipe using mechanical and hydraulically
propelled tools
Replaces gaskets and seals on flange type
joints
Bends pipe and tubing
Tests pipe systems for pressure capability
and leaks
See Chem Add
n
it
n
n
ii
ii
n
n
n
n
ii
n
-------
ION EXCHANGE (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
be required to repair and replace special
purpose pipe and fittings of the following
types:
Glass
Glass or plastic lined steel
Plastic and PVC
Aluminum
Wood
Vertrified tile
Repairs and overhauls manual and automatic control
valves:
Troubleshoots and diagnoses malfunction in
manual and controlled valves
Installs, removes, and replaces valves
Assembles and disassembles valves and
control mechanisms
Inspects and measures valve clearances
Grinds, polishes, laps-in valves and valve
seats
Cleans and inspects valve actuating mechanisms
Adjusts backlash in valve actuating mechanisms
Lubricates valve actuating mechanisms
Tests bellows and diaphragm actuators for leaks
Calibrates valve position and control actuator
Adjusts and replaces packing and seals
Tests valves for complete opening and shut-off
Tests functioning of control actuators (pneu-
matic, hydraulic, electrical, mechanical)
Replaces worn or defective valve and actuator
parts
See Chem Add
it
it
-------
ION EXCHANGE (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Repairs and overhauls storage tanks, drums, and
vessels:
Repairs leaks and defective portions of steel
storage facilities
Repairs leaks and defective portions of lined
steel storage facilities
Repairs leaks and defective portions of wood
storage facilities
Repairs leaks and defective portions of con-
crete storage facilities
Diagnoses cause of rust/ corrosion, and leaks
See Chem Add
11
it
u>
*».
to
Note: Acids and alkalies used in this treatment
are extremely hazardous.
-------
MULTIPLE EFFECT EVAPORATORS
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Operations
Monitors and verifies proper operation and condi-
tion of the following units of equipment:
Single and multiple stage evaporators and
condensers
Steam, coal, gas, or oil heat exchange
medium
Temperature status and control instrumentation
Electric motors, relays, and circuit breakers/
switches
Pressure status and control instrumentation
Centrifugal and reciprocating pumps
Iron, steel, and copper pipe and pipe fittings
Manual and automatic control valves
Steel and lined steel tanks, drums, and
vessels
Belt, chain, and gear drive mechanisms
Flow recorders and meters/level indicators
Reads and interprets status and control instru-
mentation :
Temperature gages and recorders
Pressure gages and recorders
Flow meters and recorders
Pilot lamps and voltage/current recorders
and meters
Manometers and sight glasses
OP
11
it
n
it
ii
n
it
It
11
n
ii
n
ii
n
n
2
2
2
2
2
1
2
1
2
2
2
2
2
2
2
I/Shift
ii
n
n
n
n
n
ii
ii
it
It
n
it
ti
n
ii
-------
MULTIPLE EFFECT EVAPORATORS (cent.)
OCCUPATIONAL SKILL FREQUENCY
AREA LEVEL f
U)
£t
•N
Activates and controls units of equipment:
Controls manual valves for feedwater inlet,
blowdown, and distillate
Overrides automatic control valves to correct
in emergency situations
Adjusts steam or fuel feeds/forced draft
blowers
Switches to standby or parallel pumps
Removes and disposes of blowdown
Collects composite or grab samples of blowdown
and feedwater for laboratory analysis
Preventive Maintenance Activities
Services multiple effect evaporators:
Drains and cleans evaporator shell and tube
nest with soda or acid solution to remove
scale
Cleans evaporator chamber using steam hose,
brushes, and scrapers
Checks for rust and corrosion
Inspects for leaks
Services status and control instrumentation:
Cleans and lubricates chart drive mechanisms
Cleans electrical sensors
Checks electrical contacts, connections, and
wiring
OP
a
a
n
it
ii
2
3
2
2
2
2
2
2
2
As Req
I/Shift
4/yr
wkly
I/Shift
2/yr
mthly
wkly
-------
MULTIPLE EFFECT EVAPORATORS (cent.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
ui
Checks pneumatic sensors for leaks
Checks zero or null setting on galvanometers
and on pen recorders
Checks mechanical linkage for corrosion, rust,
and freedom of movement
Cleans indicator covers and glass viewing
windows
Cleans recorder pens and checks for ink flow
Checks indicated values against known stan-
dards (checks calibration)
Services electric motors and auxiliary equipment:
Inspects motors for signs of overheating
Checks for excessive vibration or hum
Checks wiring insulation
Checks for dirt or moisture
Checks drive coupling and motor mounts for
play/loose fittings
Checks for sticking brushes or excessive arcing
Checks pilot lights and alarms
Checks points and contacts for pitting
Cleans and tightens electrical connections
Checks and lubricates bearings
Checks switches and circuit breakers for
proper functioning
Services centrifugal, reciprocating, and diaphragm
pumps:
Checks solenoid oiler flow; adjusts as necessary
Checks oil level in ball bearing housing; fills
as necessary
OP
n
rt
n
ii
n
n
ii
n
n
ii
ii
ii
2
2
2
2
2
wkly
2
1
mthly
dly
mthly
2
2
2
2
2
2
2
2
2
1
dly
dly
wkly
dly
dly
dly
I/Shift
mthly
mthly
wkly
dly
wkly
dly
-------
MULTIPLE EFFECT EVAPORATORS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u>
Checks grease cup; maintains proper pressure
Checks enclosed shaft bearings; refills oil
cup as necessary
Checks ball-thrust bearings; adds fresh grease
as necessary
Checks guide bearings; adds grease as neces-
sary
Drains and adds fresh lubricant to shaft
bearings
Flushes bearing housing and adds fresh grease
Checks bearing temperatures; adjusts as neces-
sary
Checks stuffing boxes for leaks; tightens or
repacks as necessary
Checks water-seal systems for leaks; adjusts
pressure as necessary
Clean and paint pump casing
Check, clean, lubricate, and adjust float
switch system
Inspect check valves for leaks
Clean sediment and accumulated solids from
sumps
Check and clean strainers
Services flow measuring devices:
Cleans and flushes annular chambers
Cleans and flushes piezometer pressure taps
Cleans and dresses orifice plates
Cleans and paints exterior
Inspects interior for corrosion
Purges connecting lines and fittings
OP
II
II
II
II
II
It
II
II
II
II
2
2
2
2
2
2
2
2
2
1
2
2
1
1
dly
dly
mthly
wkly
mthly
4/yr
wkly
dly
dly
dly
wkly
dly
mthly
dly
2
2
2
1
2
2
mthly
mthly
2/yr
yrly
mthly
wkly
-------
MULTIPLE EFFECT EVAPORATORS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u>
Services pipes and pipe fittings:
Checks for leaks in pipes and pipe fittings
Inspects for rust and corrosion
Cleans and paints pipes and fittings
Flushes dead-ends
Checks and cleans sediment traps
Checks and cleans wells and sumps
Mechanically cleans pipes with augers and
snakes
Services manual and automatic control valves:
Checks valves for leaks
Inspects for rust and corrosion
Checks actuating bellows for leaks
Checks linkages for free movement
Checks for complete opening and closing
Checks calibration
Lubricates control linkage
Adjusts packing
Cleans and paints exterior
Cleans solenoid actuating mechanisms
Services storage tanks, drums, and vessels:
Checks for leaks
Inspects for rust and corrosion
Cleans and paints interior and exterior
Removes accumulated deposits of sludge and
sediment
OP
it
n
n
n
it
it
n
»
11
n
ii
ii
n
n
n
n
1
1
1
2
1
1
2
2
2
2
2
3
2
2
1
2
1
1
1
wkly
wkly
yrly
mthly
wkly
wkly
As Req
dly
wkly
dly
dly
dly
mthly
wkly
wkly
yrly
dly
dly
wkly
yrly
wkly
-------
MULTIPLE EFFECT EVAPORATORS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
U)
**.
00
Services mixing and blending equipment:
Cleans deposits from paddles, arms, and
propellers
Inspects for rust and corrosion
Inspects mechanical drive functioning
Lubricates mechanical drive system
Paints and protects exposed surfaces
Checks for homogeneity of mixed substances
Checks speed of mixing or blending
Servicesmechanical drive systems:
Checks tension of flat and V-belt drives
Checks and adjusts belt alignment
Checks belts for wear
Checks and adjusts chain drive slack
Lubricates chain drive systems
Checks lubricant levels in right-angle gear
drives
Checks lubricant levels in reduction gear
boxes
Drains and changes oil in sump systems
Cleans and inspects variable speed belt drive
systems
Lubricates thrust and frame bearings for drive
shafts
Checks oil seals for leaks
Lubricates pressure grease fittings
OP
n
n
n
n
it
ii
ii
1
1
2
2
1
2
2
2
2
2
2
2
2
2
2
2
2
wkly
yrly
dly
dly
dly
dly
wkly
mthly
wkly
dly
wkly
-------
"
"
OCCUPATIONAL SKILL FREQUENCY
MULTIPLE EFFECT EVAPORATORS (cont.) AREA LEVEL f
Corrective Maintenance Activities
Repairs and overhauls multiple effect evaporators:
Troubleshoots and diagnoses malfunctions Evap Repmn 3 As Req
Installs, removes, and replaces double pipe
or shell and tube exchangers " 3
Repairs leaks in evaporators and condensers " 3
Uses compressed air rotary scraper to remove
heavy scale deposits from tubes " 3 "
Fits parts, seals and gaskets " 3 "
Repairs and overhauls status and control instru-
mentation :
Troubleshoots and diagnoses malfunctions in
status and control instrumentation Ins Repmn 3 "
Installs, removes, replaces status and con-
trol instrumentation " 3 "
Disassembles and reassembles status and con-
trol instrumentation " 3 "
Tests disphragms, bourdon tubes, and bellows
for leaks or defects " 3
Tests bimetallic strips and thermocouples for
defects 3
Tests electrical circuitry for shorts, open
circuits, and resistance " 3 "
Cleans and adds mercury to manometers " 3
Cleans and sets contact points " 3
Cleans and checks knife edges " 3
Cleans and lubricates jeweled bearings " 3
Blows down pressure lines to remove restric-
tions or stoppages " 3
it -3 11
II O II
II -3 II
II
-------
MULTIPLE EFFECT EVAPORATORS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
01
o
Cleans and checks orifices and nozzles
Adjusts backlash in mechanical linkages
Calibrates indicators and recorder pens
against known standard
Replaces worn or defective parts, seals,
and bearings
Repairs and overhauls electric motors and auxiliary
equipment:
Diagnoses and troubleshoots electrical mal-
functions
Installs, removes, replaces electric motors,
wiring, and control devices
Inspects and tests rotor and stator windings
for shorts or open circuits
Inspects commutator for wear, shorts, and signs
of excessive heat
Checks brushes for wear and proper spring ten-
sion
Adjusts brushes to seat properly and prevent
sticking
Cleans, adjusts, and lubricates bearings
Checks thermal switches, circuit breakers,
and fuses
Cleans and polishes collector rings
Checks and tightens pigtails and mechanical
wire connections
Replaces or repairs defective parts in motors
and control devices
Adjusts rotor and shaft alignment
Ins Repmn
it
Elec
3
3
3
3
As Req
3
3
3
3
3
3
3
3
3
3
3
n
ii
-------
OCCUPATIONAL SKILL FREQUENCY
MULTIPLE EFFECT -EVAPORATORS (cont.) AREA LEVEL f
Replaces defective wiring and conduit Elec 3 As Req
Inspects exposed equipment for defective
gaskets and seals " 3 "
Measures voltage, current, and power consump-
tion " 3
Checks motor speeds " 3 "
Repairs and overhauls centrifugal, reciprocating,
and diaphragm pumps:
Troubleshoots and diagnoses malfunctions in
pumps Pump Serv 3 "
Installs, removes, and replaces pumps " 3 "
Disassembles and assembles pumps " 3 "
Inspects and measures bearings and bearing
races for defects " 3 "
Repacks ball-thrust bearings, roller bearings,
and guide bearings " 3 "
Cleans and inspects pump interior " 3 "
Checks stuffing box for free movement of gland
and excessive leakage " 3
Repacks gland assembly and adjusts " 3
Grinds and laps valves and valve seats " 3
Inspects impellers for deposits, scaling, and
cavitation pits " 3
Dynamically balances impellers " 3
Checks and aligns drive system " 3
Fits replacement parts " 3
Repairs bent float rods, binding mechanical
fittings " 3
Lubricates mechanical fittings " 3
Cleans and paints exterior housing " 3
-------
MULTIPLE EFFECT EVAPORATORS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
ui
to
Repairs and replaces pipes and pipe fittings:
Troubleshoots and diagnoses nature and
location of stoppages
Removes and replaces sections of pipe, pipe
fittings, and couplings
Cuts and threads pipe
Cleans pipe using mechanical and hydraulically
propelled tools
Replaces gaskets and seals on flange type
joints
Bends pipe and tubing
Tests pipe systems for pressure capability
and leaks
May be required to repair and replace special
purpose pipe and fittings of the following
types:
Glass
Glass or plastic lined steel
Plastic and PVC
Aluminum
Wood
Vitrified tile
Repairs and overhauls manual and automatic control
valves:
Troubleshoots and diagnoses malfunction in man-
ual and controlled valves
Installs, removes, and replaces valves
Assembles and disassembles valves and control
mechanisms
Pipe Ftr
it
it
Ins Repmn
3
3
3
3
3
3
3
3
3
3
3
3
As Req
II
n
ii
ii
ii
it
n
n
ii
ii
-------
MULTIPLE EFFECT EVAPORATORS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u>
tn
U>
Inspects and measures valve clearances
Grinds, polishes, laps-in valves and valve
seats
Cleans and inspects valve actuating mechanisms
Adjusts backlash in valve actuating mechanisms
Lubricates valve actuating mechanisms
Tests bellows and diaphragm actuators for leaks
Calibrates valve position and control actuator
Adjusts and replaces packing and seals
Tests valves for complete opening and shut-off
Tests functioning of control actuators (pneu-
matic, hydraulic, electrical, mechanical)
Replaces worn or defective valve and actuator
parts
Repairs and overhauls storage tanks drums, and
vessels:
Repairs leaks and defective portions of steel
storage facilities
Repairs leaks and defective portions of lined
steel storage facilities
Repairs leaks and defective portions of wood
storage facilities
Repairs leaks and defective portions of con-
crete storage facilities
Diagnoses cause of rust, corrosion, and leaks
Ins Repmn
As Req
M
n
ii
ii
n
Mech Main
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
n
n
-------
DEEP WELL INJECTION
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u>
m
Operations
Monitors and verifies proper operation and condi-
tion of the following units of equipment:
Centrifugal and reciprocating pumps
Electric motors, relays, and circuit breakers/
switches
Pressure meters and recorders
Belt, chain, and gear drive mechanisms
Iron and steel pipe and pipe fittings
Flow measuring devices and recorders
Manual and automatic control valves
Temperature measuring devices and recorders
Reads and interprets status and control instru-
mentation:
Temperature gauges and recorders
Flow rate instruments and controllers
Pressure instruments and controllers
Pilot lamps and alarms
Activates and controls units of equipment:
Adjusts and controls injection rate
Switches to standby or parallel pumps
Overrides automatic controls to adjust in
specific situations
Adjusts manual valves to achieve specified
flow, pressure, or volume
Collects composite or grab samples for laboratory
analysis
OP
2
2
2
1
2
2
2
2
2
2
2
3
2
3
2
I/Shift
H
II
H
II
II
11
II
II
II
It
II
As Req
-------
DEEP WELL INJECTION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
LO
U1
en
Preventive Maintenance Activities
Services status and control instrumentation:
Cleans and lubricates chart drive mechanisms
Cleans electrical sensors
Checks electrical contacts, connections, and
wiring
Checks pneumatic sensors for leaks
Checks zero or null setting on galvanometers
and pen recorders
Checks mechanical linkage for corrosion, rust,
and freedom of movement
Cleans indicator covers and glass viewing
windows
Cleans recorder pens and checks for ink flow
Checks indicated values against known stan-
dards (checks calibration)
Services electric motors and auxiliary equipment:
Inspects motors for signs of overheating
Checks for excessive vibration or hum
Checks wiring insulation
Checks for dirt or moisture
Checks drive coupling and motor mounts for
play/loose fittings
Checks for sticking brushes or excessive arcing
Checks pilot lights and alarms
Checks points and contacts for pitting
Cleans and tightens electrical connections
Checks and lubricates bearings
Checks switches and circuit breakers for proper
functioning
See Chem Add
11
11
-------
DEEP WELL INJECTION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
en
m
Services centrifugal and reciprocating pumps:
Checks solenoid oiler flow; adjusts as necessary
Checks oil level in ball bearing housing; fills
as necessary
Checks grease cup; maintains proper pressure
Checks enclosed shaft bearings; refills oil cup
as necessary
Checks ball-thrust bearings; adds fresh grease
as necessary
Checks guide bearings; adds grease as necessary
Drains and adds fresh lubricant to shaft bear-
ings
Flushes bearing housing and adds fresh grease
Checks bearing temperatures; adjusts as neces-
sary
Checks stuffing boxes for leaks; tightens or
repacks as necessary
Checks water-seal systems for leaks; adjusts
pressure as necessary
Clean and paint pump casing
Check, clean, lubricate, and adjust float switch
system
Inspect check valves for leaks
Clean sediment and accumulated solids from sumps
Check and clean strainers
Services flow measuring devices:
Cleans and flushes annular chambers
Cleans and flushes piezometer pressure taps
Cleans and dresses orifice plates
Cleans and paints exterior
See Chem Add
n
it
ii
ii
ii
n
n
n
ii
n
ii
ti
ii
ii
-------
DEEP WELL INJECTION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
LJ
en
-vl
Inspects interior for corrosion
Purges connecting lines and fittings
Services pipes and pipe fittings:
Checks for leaks in pipes and pipe fittings
Inspects for rust and corrosion
Cleans and paints pipes and fittings
Flushes dead-ends
Checks and cleans sediment traps
Checks and cleans wells and sumps
Mechanically cleans pipes with augers and
snakes
Services manual and automatic control valves:
Checks valves for leaks
Inspects for rust and corrosion
Checks actuating bellows for leaks
Checks linkages for free movement
Checks for complete opening and closing
Checks calibration
Lubricates control linkage
Adjusts packing
Cleans and paints exterior
Cleans solenoid actuating mechanisms
Services storage tanks, drums, and vessels:
Checks for leaks
Inspects for rust and corrosion
Cleans and paints interior and exterior
Removes accumulated deposits of sludge and
sediment
See Chem Add
n
it
ii
n
11
n
n
n
n
n
n
it
it
ii
n
n
n
n
n
-------
DEEP WELL INJECTION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
LJ
en
00
Services mechanical drive systems:
Checks tension of flat and V-belt drives
Checks and adjusts belt alignment
Checks belts for wear
Checks and adjusts chain drive slack
Lubricates chain drive systems
Checks lubricant levels in right-angle gear
drives
Checks lubricant levels in reduction gear
boxes
Drains and changes oil in sump systems
Cleans and inspects variable speed belt
drive systems
Lubricates thrust and frame bearings for
drive shafts
Checks oil seals for leaks
Lubricates pressure grease fittings
See Chem Add
Corrective Maintenance Activities
Repairs and overhauls status and control instru-
mentation :
Troubleshoots and diagnoses malfunctions in
status and control instrumentation
Installs, removes, replaces status and control
instrumentation
Disassembles and reassembles status and con-
trol instrumentation
Tests diaphragms, bourdon tubes, and bellows
for leaks or defects
-------
DEEP WELL INJECTION (cent.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
U)
tn
Tests bimetallic strips and thermocouples for
defects
Tests electrical circuitry for shorts, open
circuits, and resistance
Cleans and adds mercury to manometers
Cleans and sets contact points
Cleans and checks knife edges
Cleans and lubricates jeweled bearings
Blows down pressure lines to remove restric-
tions or stoppages
Cleans and checks orifices and nozzles
Adjusts backlash in mechanical linkages
Calibrates indicators and recorder pens
against known standard
Replaces worn or defective parts, seals, and
bearings
Repairs and overhauls electric motors and auxiliary
equipment:
Diagnoses and troubleshoots electrical mal-
functions
Installs, removes, replaces electric motors,
wiring, and control devices
Inspects and tests rotor and stator windings
for shorts or open circuits
Inspects commutator for wear, shorts, and signs
of excessive heat
Checks brushes for wear and proper spring
tension
Adjusts brushes to seat properly and prevent
sticking
See Chem Add
-------
DEEP WELL INJECTION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
CO
a\
o
Cleans, adjusts, and lubricates bearings
Checks thermal switches, circuit breakers, and
fuses
Cleans and polishes collector rings
Checks and tightens pigtails and mechanical
wire connections
Replaces or repairs defective parts in motors
and control devices
Adjusts rotor and shaft alignment
Reconditions or replaces contacts on relays
and switches
Replaces defective wiring and conduit
Inspects exposed equipment for defective
gaskets and seals
Measures voltage, current, and power consump-
tion
Checks motor speeds
Repairs and overhauls centrifugal, reciprocating,
and diaphragm pumps:
Troubleshoots and diagnoses malfunctions in
pumps
Installs, removes, and replaces pumps
Disassembles and assembles pumps
Inspects and measures bearings and bearing
races for defects
Repacks ball-thrust bearings, roller bearings,
and guide bearings
Cleans and inspects pump interior
Checks stuffing box for free movement of gland
and excessive leakage
See Chem Add
it
it
-------
DEEP WELL INJECTION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
w
Repacks gland assembly and adjusts
Grinds and laps valves and valve seats
Inspects impellers for deposits, scaling, and
cavitation pits
Dynamically balances impellers
Checks and aligns drive system
Fits replacement parts
Repairs bent float rods, binding mechanical
fittings
Lubricates mechanical fittings
Cleans and paints exterior housing
Repairs and replaces pipes and pipe fittings:
Troubleshoots and diagnoses nature and location
of stoppages
Removes and replaces sections of pipe, pipe
fittings, and couplings
Cuts and threads pipe
Cleans pipe using mechanical and hydraulically
propelled tools
Replaces gaskets and seals on flange type
joints
Bends pipe and tubing
Tests pipe systems for pressure capability and
leaks
May be required to repair and replace special
purpose pipe and fittings of the following
types:
Glass
Glass or plastic lined steel
See Chem Add
it
-------
DEEP WELL INJECTION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u>
cr>
to
Plastic and PVC
Aluminum
Wood
Vitrified tile
Repairs and overhauls manual and automatic control
valves:
Troubleshoots and diagnoses malfunction in
manual and controlled valves
Installs, removes, and replaces valves
Assembles and disassembles valves and control
mechanisms
Inspects and measures valve clearances
Grinds, polishes, laps-in valves and valve seats
Cleans and inspects valve actuating mechanisms
Adjusts backlash in valve actuating mechanisms
Lubricates valve actuating mechanisms
Tests bellows and diaphragm actuators for leaks
Calibrates valve position and control actuator
Adjusts and replaces packing and seals
Tests valves for complete opening and shut-off
Tests functioning of control actuators (pneu-
matic, hydraulic, electrical, mechanical)
Replaces worn or defective valve and actuator
parts
Repairs and overhauls mechanical drive systems:
Troubleshoots and diagnoses malfunctions in
mechanical systems
Disassembles and assembles mechanical drive
systems
See Chem Add
-------
DEEP WELL INJECTION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
ot
to
Inspects and measures gear drives for wear and
defects
Inspects chain drives, replaces defective links,
adjusts tension
Checks and measures sprocket alignment
Inspects sprocket teeth for wear, hooks, and
other defects
Inspects and measures bearings and races for
wear and defects
Cleans and finishes moving parts to prevent
freezing or binding
Repacks bearings
Fits and replaces parts showing excessive wear
or defects
Inspects and replaces water and oil seals as
necessary
Cleans and paints exposed surfaces
Replaces drive belts, pulleys, and tensioning
devices
See Chem Add
-------
LAGOONING/COOLING PONDS/SOLAR
EVAPORATION PONDS
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
10
CTl
Operations
Monitors and verifies the proper operation and
condition of the following units of equipment:
Concrete or masonry dams
Earthen dams or pits
Masonry spillways or overflow pipes
Centrifugal and reciprocating pumps
Electric motors, relays, and circuit breakers/
switches
Iron, steel, plastic, ceramic, and copper pipe
and pipe fittings
Flow and level indicating devices
Manual and automatic control valves
Belt, chain, and gear drive mechanisms
Reads and interprets status and control instru-
mentation:
Total suspended solids measuring units and
recorders
Temperature measuring and recording devices
Flow meters and recorders
Conductivity recorders and meters
Activates and controls units of equipment:
Switches to standby or parallel pumps
Adjusts manual valves to control flow and
retention time
Overrides automatic controls to correct in
specific situations
OP
2
2
2
2
1
2
2
2
2
2
2
2
2
3
3
dly
dly
I/Shift
var
-------
LAGOONING/COOLING PONDS/SOLAR
EVAPORATION PONDS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Checks flow time for individual lagoons or ponds
using dye solutions
Collects composite or grab samples for laboratory
analysis
OP
I/Shift
CO
ON
Ul
Preventive Maintenance Activities
Services lagoons, cooling ponds, and evaporation
ponds:
Checks dams for leaks and deterioration
Checks for debris which might block spillways
or overflow pipes
Checks for signs of overtopping or overflow
Checks dam area for signs of seepage
Cleans growths and sediment from spillways
Checks for algae blooms and plant growths
Checks depth of sediment
Repairs earthen dams with clay and earth (with
hand tools)
Repairs minor leaks in concrete or masonry dams
with cement and mortar
Services electric motors and auxiliary equipment:
Inspects motors for signs of overheating
Checks for excessive vibration or hum
Checks wiring insulation
Checks for dirt or moisture
Checks drive coupling and motor mounts for
play/loose fittings
ir
it
it
N
ii
2
2
2
1
2
2
dly
wkly
ii
nvthly
As Req
See Chem Add
-------
LAGOONING/COOLING PONDS/SOLAR
EVAPORATION PONDS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Checks for sticking brushes or excessive
arcing
Checks pilot lights and alarms
Checks points and contacts for pitting
Cleans and tightens electrical connections
Checks and lubricates bearings
Checks switches and circuit breakers for
proper functioning
Services centrifugal, reciprocating, and diaphragm
pumps:
Checks solenoid oiler flow; adjusts as necessary
Checks oil level in ball bearing housing; fills
as necessary
Checks grease cup; maintains proper pressure
Checks enclosed shaft bearings; refills oil cup
as necessary
Checks ball-thrust bearings; adds fresh grease
as necessary
Checks guide bearings; adds grease as necessary
Drains and adds fresh lubricant to shaft bear-
ings
Flushes bearing housing and adds fresh grease
Checks bearing temperatures; adjusts as neces-
sary
Checks stuffing boxes for leaks;' tightens or
repacks as necessary
Checks water-seal systems for leaks; adjusts
pressure as necessary
Clean and paint pump casing
See Chem Add
-------
LAGOONING/COOLING PONDS/SOLAR
EVAPORATION PONDS (cent.)
OCCUPATIONAL SKILL FREQUENCY
AREA LEVEL f
u>
Check, clean, lubricate, and adjust float
switch system
Inspect check valves for leaks
Clean sediment and accumulated solids from
sumps
Check and clean strainers
Services flow measuring devices:
Cleans and flushes annular chambers
Cleans and flushes piezometer pressure taps
Cleans and dresses orifice plates
Cleans and paints exterior
Inspects interior for corrosion
Purges connecting lines and fittings
Services pipes and pipe fittings:
Checks for leaks in pipes and pipe fittings
Inspects for rust and corrosion
Cleans and paints pipes and fittings
Flushes dead-ends
Checks and cleans sediment traps
Checks and cleans wells and sumps
Mechanically cleans pipes with augers and
snakes
Services manual and automatic control valves:
Checks valves for leaks
Inspects for rust and corrosion
Checks actuating bellows for leaks
Checks linkages for free movement
Checks for complete opening and closing
See Chem Add
n
ii
n
-------
LAGOONING/COOLING PONDS/SOLAR OCCUPATIONAL SKILL FREQUENCY
EVAPORATION PONDS (cont.) AREA LEVEL f
Checks calibration See Chem Add
Lubricates control linkage "
Adjusts packing "
Cleans and paints exterior "
Cleans solenoid actuating mechanisms "
Services storage tanks/ drums, and vessels:
Checks for leaks "
Inspects for rust and corrosion "
Cleans and paints interior and exterior "
Removes accumulated deposits of sludge and
sediment "
Services mechanical drive systems:
Checks tension of flat and V-belt drives "
Checks and adjusts belt alignment "
Checks belts for wear "
Checks and adjusts chain drive slack "
Lubricates chain drive systems "
Checks lubricant levels in right-angle gear
drives
Checks lubricant levels in reduction gear
boxes "
Drains and changes oil in sump systems
Cleans and inspects variable speed belt drive
systems "
Lubricates thrust and frame bearings for drive
shafts
Checks oil seals for leaks "
Lubricates pressure grease fittings
"
"
-------
LAGOONING/COOLING PONDS/SOLAR
EVAPORATION PONDS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Corrective Maintenance Activities
Repairs and cleans lagoons, cooling ponds, and
evaporation ponds:
Dredges sludge and sediment from lagoons and
cooling ponds
Removes sludge cake with shovel and wheel-
barrow
Repairs and reinforces earthen dams (using
heavy equipment)
Performs major repairs on faulty concrete
or masonry dams
Repairs and overhauls status and control
instrumentation:
Troubleshoots and diagnoses malfunctions in
status and control instrumentation
Installs, removes, replaces status and control
ins trumentation
Disassembles and reassembles status and con-
trol instrumentation
Tests diaphragms, bourdon tubes, and bellows
for leaks or defects
Tests bimetallic strips and thermocouples for
defects
Tests electrical circuitry for shorts, open
circuits, and resistance
Cleans and adds mercury to manometers
Cleans and sets contact points
Cleans and checks knife edges
Cleans and lubricates jeweled bearings
Heavy Eq OP
OP
Heavy Eq OP
Cem Mason
3
1
3
3
As Req
See Chem Add
-------
LAGOONING/COOLING PONDS/SOLAR OCCUPATIONAL SKILL FREQUENCY
EVAPORATION PONDS (cont.) AREA LEVEL f
Blows down pressure lines to remove restric-
tions or stoppages See Chem Add
Cleans and checks orifices and nozzles "
Adjusts backlash in mechanical linkages "
Calibrates indicators and recorder pens
against known standard "
Replaces worn or defective parts, seals, and
bearings "
Repairs and overhauls electric motors and auxi-
liary equipment:
Diagnoses and troubleshoots electrical mal-
functions "
Installs, removes, replaces electric motors,
w wiring, and control devices "
o Inspects and tests rotor and stator windings
for shorts or open circuits "
Inspects commutator for wear, shorts, and
signs of excessive heat "
Checks brushes for wear and proper spring
tension "
Adjusts brushes to seat properly and prevent
sticking "
Cleans , adjusts , and lubricates bearings
Checks thermal switches, circuit breakers, and
fuses
Cleans and polishes collector rings
Checks and tightens pigtails and mechanical
wire connections
Replaces or repairs defective parts in motors
and control devices
"
-------
LAGOONING/COOLING PONDS/SOLAR OCCUPATIONAL SKILL FREQUENCY
EVAPORATION PONDS (cont.) AREA LEVEL f
Adjusts rotor and shaft alignment See Chem Add
Reconditions or replaces contacts on relays
and switches "
Replaces defective wiring and conduit "
Inspects exposed equipment for defective
gaskets and seals "
Measures voltage, current, and power consump-
tion
Checks motor speeds "
Repairs and overhauls centrifugal, reciprocating,
and diaphragm pumps:
Troubleshoots and diagnoses malfunctions in
pumps "
Installs, removes, and replaces pumps "
Disassembles and assembles pumps "
Inspects and measures bearings and bearing
races for defects "
Repacks ball-thrust bearings, roller bearings,
and guide bearings "
Cleans and inspects pump interior "
Checks stuffing box for free movement of gland
and excessive leakage "
Repacks gland assembly and adjusts "
Grinds and laps valves and valve seats "
Inspects impellers for deposits, scaling, and
cavitation pits "
Dynamically balances impellers "
Checks and aligns drive system "
Fits replacement parts "
Repairs bent float rods, binding mechanical
fittings
-------
LAGOONING/COOLING PONDS/SOLAR OCCUPATIONAL SKILL FREQUENCY
EVAPORATION PONDS (cont.) AREA LEVEL f
Lubricates mechanical fittings See Chem Add
Cleans and paints exterior housing "
Repairs and replaces pipes and pipe fittings:
Troubleshoots and diagnoses nature and loca-
tion of stoppages "
Removes and replaces sections of pipe, pipe
fittings, and couplings "
Cuts and threads pipe "
Cleans pipe using mechanical and hydraulically
propelled tools "
Replaces gaskets and seals on flange type
joints "
Bends pipe and tubing "
Tests pipe systems for pressure capability and
leaks
May be required to repair and replace special
purpose pipe and fittings of the following
types:
Glass "
Glass or plastic lined steel "
Plastic and PVC "
Aluminum "
Wood
Vitrified tile
Repairs and overhauls manual and automatic control
valves:
Troubleshoots and diagnoses malfunction in
manual and controlled valves "
-------
LAGOONING/COOLING PONDS/SOLAR OCCUPATIONAL SKILL FREQUENCY
EVAPORATION PONDS (cont.) AREA LEVEL f
Installs, removes, and replaces valves See Chem Add
Assembles and disassembles valves and control
mechanisms "
Inspects and measures valve clearances "
Grinds, polishes, laps-in valves and valve
seats
Cleans and inspects valve actuating mechanisms "
Adjusts backlash in valve actuating mechanisms "
Lubricates valve actuating mechanisms "
Tests bellows and diaphragm actuators for
leaks
Calibrates valve position and control actuator "
Adjusts and replaces packing and seals "
Tests valves for complete opening and shut-off "
Tests functioning of control actuators (pneu-
matic, hydraulic, electrical, mechanical) "
Replaces worn or defective valve and actuator
parts "
Repairs and overhauls mechanical drive systems:
Troubleshoots and diagnoses malfunctions in
mechanical systems "
Installs, removes/ and replaces arms, paddles,
and propellers
Disassembles and assembles mechanical drive
systems "
Inspects and measures gear drive for wear and
defects "
Inspects chain drives, replaces defective
links, adjusts tension
Checks and measures sprocket alignment "
-------
LAGOONING/COOLING PONDS/SOLAR
EVAPORATION PONDS (cont.)
OCCUPATIONAL SKILL FREQUENCY
AREA LEVEL f
CO
Inspects sprocket teeth for wear, hooks,
and other defects
Inspects and measures bearings and races
for wear and defects
Cleans and finishes moving parts to prevent
freezing or binding
Repacks bearings
Fits and replaces parts showing excessive
wear or defects
Inspects and replaces water and oil seals
as necessary
Cleans and paints exposed surfaces
Replaces drive belts, pulleys, and tension-
ing devices
See Chem Add
it
it
-------
CENTRIFUGATION
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
GJ
Operations
Monitors and verifies proper operation and condi-
tion of the following units of equipment:
Continuous horizontal centrifugals
Suspended basket centrifugals
Undriven centrifugals
Electric motors, relays, and circuit
breakers/switches
Pressure status and control instrumentation
Centrifugal and reciprocating pumps
Iron, steel, copper, and plastic pipe and
pipe fittings
Manual and automatic control valves
Flow and liquid level instrumentation
Belt, chain, and gear drive mechanisms
Reads and interprets status and control instru-
mentation :
Pressure gages and recorders
Flow meters and recorders
Conductivity recorders and meters
Pilot lamps and voltage/current meters and
recorders
Activates and controls units of equipment:
Adjusts and controls manual valves to achieve
desired flow and retention time
Overrides automatic control valves to correct
in emergency situations
OP
N
tl
II
II
II
II
II
II
II
II
II
(I
2
2
2
2
2
2
1
2
2
2
2
2
2
2
3
I/Shift
As Req
-------
CENTRIFUGATION (cont.)
OCCUPATIONAL
AREA
SKILL FREQUENCY
LEVEL f
Switches to standby or parallel pumps
Regulates speed of centrifugal units
Removes and disposes of solids and slurries
Collects composite or grab samples for laboratory
analysis
OP
it
2
2
1
2
As Req
I/Shift
to
Preventive Maintenance Activities
Services centrifugals:
Replaces filter cloth and screen basket of
centrifugals
Checks for worn plow tips and slingers
Cleans and lubricates moving parts
Cleans and paints exterior
Inspects drive belts for wear and proper
tension
Checks for rust and corrosion
Checks for leaks
Services status and control instrumentation:
Cleans and lubricates chart drive mechanisms
Cleans electrical sensors
Checks electrical contacts, connectionsr and
wiring
Checks pneumatic sensors for leaks
Checks zero or null setting on galvanometers
and on pen recorders
2
2
2
1
2
2
2
2
2
2
2
ir
wkly
n
yrly
dly
wkly
dly
2/yr
mthly
wkly
n
-------
CENTRIPUGATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Checks mechanical linkage for corrosion, rust,
and freedom of movement
Cleans indicator covers and glass viewing
windows
Cleans recorder pens and checks for ink flow
Checks indicated values against known stan-
dards (checks calibration)
Services electric motors and auxiliary equipment:
Inspects motors for signs of overheating
Checks for excessive vibration or hum
Checks wiring insulation
Checks for dirt or moisture
Checks drive coupling and motor mounts for
play/loose fittings
Checks for sticking brushes or excessive arcing
Checks pilot lights and alarms
Checks points and contacts for pitting
Cleans and tightens electrical connections
Checks and lubricates bearings
Checks switches and circuit breakers for proper
functioning
Services centrifugal, reciprocating, and diaphragm
pumps:
Checks solenoid oiler flow; adjusts as necessary
Checks oil level in ball bearing housing; fills
as necessary
Checks grease cup; maintains proper pressure
Checks enclosed shaft bearings; refills oil cup
as necessary
OP
n
n
n
ti
n
ir
it
n
2
2
2
2
2
2
2
2
2
2
2
1
1
2
wkly
mthly
dly
mthly
dly
it
wkly
dly
I/Shift
mthly
ii
wkly
dly
wkly
dly
-------
CENTRIFUGATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u»
«4
00
Checks ball-thrust bearings; adds fresh
grease as necessary
Checks guide bearings; adds grease as necessary
Drains and adds fresh lubricant to shaft bear-
ings
Flushes bearing housing and adds fresh grease
Checks bearing temperatures; adjusts as neces-
sary
Checks stuffing boxes for leaks; tightens or
repacks as necessary
Checks water-seal systems for leaks; adjusts
pressure as necessary
Clean and paint pump casing
Check, clean lubricate, and adjust float switch
system
Inspect check valves for leaks
Clean sediment and accumulated solids from sumps
Check and clean strainers
Services flow measuring devices:
Cleans and flushes annular chambers
Cleans and flushes piezometer pressure taps
Cleans and dresses orifice plates
Cleans and paints exterior
Inspects interior for corrosion
Purges connecting lines and fittings
Services pipes and pipe fittings:
Checks for leaks in pipes and pipe fittings
Inspects for rust and corrosion
Cleans and paints pipes and fittings
OP
it
ri
n
n
ii
ii
ii
n
ii
ii
n
2
2
2
2
2
2
2
1
2
2
1
1
2
2
2
1
2
2
1
1
1
mthly
wkly
mthly
4/yr
wkly
dly
H
II
wkly
dly
mthly
dly
mthly
ii
2/yr
yrly
mthly
wkly
yrly
-------
CENTRIFUGATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
co
•*j
vo
Flushes dead-ends
Checks and cleans sediment traps
Checks and cleans wells and sumps
Mechanically cleans pipes with augers and
snakes
Services manual and automatic control valves:
Checks valves for leaks
Inspects for rust and corrosion
Checks actuating bellows for leaks
Checks linkages for free movement
Checks for complete opening and closing
Checks calibration
Lubricates control linkage
Adjusts packing
Cleans and paints exterior
Cleans solenoid actuating mechanisms
Services storage tanks, drums, and vessels:
Checks for leaks
Inspects for rust and corrosion
Cleans and paints interior and exterior
Removes accumulated deposits of sludge and
sediment
Services mixing and blending equipment:
Cleans deposits from paddles, arms, and
propellers
Inspects for rust and corrosion
Inspects mechanical drive functioning
Lubricates mechanical drive system
OP
n
n
n
it
ii
n
ii
M
II
II
II
H
It
II
II
II
n
ti
n
2
1
1
2
2
2
2
2
3
2
2
1
2
1
1
1
1
1
2
2
mthly
wkly
As Req
dly
wkly
dly
mthly
wkly
M
yrly
dly
wkly
yrly
wkly
-------
CENTRIFUGATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
CJ
00
o
Paints and protects exposed surfaces
Checks for homogeneity of mixed substances
Checks speed of mixing or blending
Services mechanical drive systems:
Checks tension of flat and V-belt drives
Checks and adjusts belt alignment
Checks belts for wear
Checks and adjusts chain drive slack
Lubricates chain drive systems
Checks lubricant levels in right-angle gear
drives
Checks lubricant levels in reduction gear
boxes
Drains and changes oil in sump systems
Cleans and inspects variable speed belt
drive systems
Lubricates thrust and frame bearings for
drive shafts
Checks oil seals for leaks
Lubricates pressure grease fittings
OP
1
2
2
2
2
2
2
2
2
2
2
2
2
yrly
dly
wkly
mthly
wkly
dly
wkly
Corrective Maintenance Activities
Repairs and overhauls centrifugals:
Troubleshoots and diagnoses malfunctions in
centrifugals
Installs, removes, and replaces screen and
solid bowls
Removes and replaces worn or defective plow
tips and slingers
Mech Main
3
3
As Req
-------
CENTRIFUCATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
00
Repairs and replaces basket liners, brakes,
and baskets
Replaces worn or defective bearings, seals,
and gaskets
Repairs and overhauls status and control instru-
mentation :
Troubleshoots and diagnoses malfunctions in
status and control instrumentation
Installs, removes, replaces status and
control instrumentation
Disassembles and reassembles status and
control instrumentation
Tests diaphragms, bourdon tubes, and bellows
for leaks or defects
Tests bimetallic strips and thermocouples for
defects
Tests electrical circuitry for shorts, open
circuits, and resistance
Cleans and adds mercury to manometers
Cleans and sets contact points
Cleans and checks knife edges
Cleans and lubricates jeweled bearings
Blows down pressure lines to remove restric-
tions or stoppages
Cleans and checks orifices and nozzles
Adjusts backlash in mechanical linkages
Calibrates indicators and recorder pens
against known standard
Replaces worn or defective parts, seals,
and bearings
Mech Main
Ins Repmn
3
3
As Req
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
it
it
-------
CENTRIFUGATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u>
CO
to
Repairs and overhauls electric motors and
auxiliary equipment:
Diagnoses and troubleshoots electrical mal-
functions
Installsf removes, replaces electric motors,
wiring, and control devices
Inspects and tests rotor and stator windings
for shorts or open circuits
Inspects commutator for wear, shorts, and
signs of excessive heat
Checks brushes for wear and proper spring
tension
Adjusts brushes to seat properly and prevent
sticking
Cleans, adjusts, and lubricates bearings
Checks thermal switches, circuit breakers,
and fuses
Cleans and polishes collector rings
Checks and tightens pigtails and mechanical
wire connections
Replaces or repairs defective parts in motors
and control devices
Adjusts rotor and shaft alignment
Reconditions or replaces contacts on relays
and switches
Replaces defective wiring and conduit
Inspects exposed equipment for defective
gaskets and seals
Measures voltage, current, and power consump-
tion
Checks motor speeds
Elec
ii
ii
it
ii
ii
ii
n
it
ii
ii
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
As Req
it
it
ii
n
ii
it
-------
CENTRIFUGATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
U)
CO
OJ
Repairs and overhauls centrifugal, reciprocatingr
and diaphragm pumps:
Troubleshoots and diagnoses malfunctions in
pumps
Installs, removes, and replaces pumps
Disassembles and assembles pumps
Inspects and measures bearings and bearing
races for defects
Repacks ball-thrust bearings, roller bearings,
and guide bearings
Cleans and inspects pump interior
Checks stuffing box for free movement of gland
and excessive leakage
Repacks gland assembly and adjusts
Grinds and laps valves and valve seats
Inspects impellers for deposits, scaling, and
cavitation pits
Dynamically balances impellers
Checks and aligns drive system
Fits replacement parts
Repairs bent float rods, binding mechanical
.fittings
Lubricates mechanical fittings
Cleans and paints exterior housing
Repairs and replaces pipes and pipe fittings:
Troubleshoots and diagnoses nature and location
of stoppages
Removes and replaces sections of pipe, pipe
fittings, and couplings
Cuts and threads pipe
Pump Serv
n
Pipe Ftr
3
3
3
3
3
3
3
3
3
3
3
3
3
3
1
3
3
As Reg
11
n
n
n
n
it
n
n
ii
-------
CENTRIFUGATION (cont.}
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u»
oo
Cleans pipe using mechanical and hydraulically
propelled tools
Replaces gaskets and seals on flange type
joints
Bends pipe and tubing
Tests pipe systems for pressure capability
and leaks
May be required to repair and replace special
purpose pipe and fittings of the following
types:
Glass
Glass or plastic lined steel
Plastic and PVC
Aluminum
Wood
Vitrified tile
Repairs and overhauls manual and automatic control
valves:
Troubleshoots and diagnoses malfunctions in
manual and controlled valves
Installs, removes, and replaces valves
Assembles and disassembles valves and control
mechanisms
Inspects and measures valve clearances
Grinds, polishes, laps in valves and valve
seats
Cleans and inspects valve actuating mechanisms
Adjusts backlash in valve actuating mechanisms
Lubricates valve actuating mechanisms
Pipe Ftr
n
n
n
n
Ins Repmn
II
II
It
II
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
As Req
n
ii
ir
ii
ir
11
n
n
ti
it
ti
IP
-------
CENTRIFUGATION (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
00
Ul
Tests bellows and diaphragm actuators for
leaks
Calibrates valve position and control
actuator
Adjusts and replaces packing and seals
Tests valves for complete opening and shut-off
Tests functioning of control actuators (pneu-
matic, hydraulic, electrical, mechanical)
Replaces worn or defective valve and actuator
parts
Repairs and overhauls storage tanks, drums, and
vessels:
Repairs leaks and defective portions of steel
storage facilities
Repairs leaks and defective portions of lined
steel storage facilities
Repairs leaks and defective portions of wood
storage facilities
Repairs leaks and defective portions of con-
crete storage facilities
Diagnoses cause of rust, corrosion, and leaks
Ins Repmn
ir
it
it
Mech Main
3
3
3
3
3
3
3
3
3
3
As Req
-------
COOLING TOWERS
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
00
0\
Operations
Monitors and verifies proper operation and condi-
tion of the following units of equipment:
Forced draft cooling towers
Convection cooling towers
Centrifugal and reciprocating pumps
Electric motors, relays, and circuit breakers/
switches
Iron, steel, copper, plastic, and ceramic pipe
and pipe fittings
Temperature measuring and recording devices
Belt, chain, and gear drive mechanisms
Manual and automatic control valves
Flow rate indicators and recorders
pH meters and recorders
Conductivity meters and recorders
Reads and interprets status and control instru-
mentation:
Temperature indicators and recorders
pH meters and recorders
Flow meters and control instrumentation
Conductivity recorders and meters
Pilot lamps and alarm devices
Activates and controls units of equipment:
Switches to standby or parallel pumps
Adjusts manual valves to control flow and re-
circulation rate
Activates forced draft fans and blowers
OP
2
2
2
1
2
2
2
2
2
2
2
2
2
2
2
I/Shift
n
ii
ti
n
n
n
ti
it
2
2
As Req
-------
COOLING TOWERS (cent.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Collects composite or grab samples of blowdown for
laboratory analysis
OP
I/Shift
00
-J
Preventive Maintenance Activities
Services cooling towers:
Checks wood baffles for rotting and general
deterioration
Cleans growths and heavy deposits front baffles
Cleans and inspects water distribution system
Inspects condition of tower structural members
Services status and control instrumentation:
Cleans and lubricates chart drive mechanisms
Cleans electrical sensors
Checks electrical contacts, connections, and
wiring
Checks pneumatic sensors for leaks
Checks zero or null setting on galvanometers and
pen recorders
Checks mechanical linkage for corrosion, rust,
and freedom of movement
Cleans indicator covers and glass viewing
windows
Cleans recorder pens and checks for ink flow
Checks indicated values against known standards
(checks calibration)
2
1
2
2
See Chem Add
n
it
As Req
n
mthly
-------
COOLING TOWERS (cent.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
oo
00
Services electric motors and auxiliary equipment:
Inspects motors for signs of overheating
Checks for excessive vibration or hum
Checks wiring insulation
Checks for dirt or moisture
Checks drive coupling and motor mounts for
play/loose fittings
Checks for sticking brushes or excessive arcing
Checks pilot lights and alarms
Checks points and contacts for pitting
Cleans and tightens electrical connections
Checks and lubricates bearings
Checks switches and circuit breakers for proper
functioning
Services centrifugal, reciprocating, and diaphragm
pumps:
Checks solenoid oiler flow; adjusts as necessary
Checks oil level in ball bearing housing; fills
as necessary
Checks grease cup; maintains proper pressure
Checks enclosed shaft bearings, refills oil cup
as necessary
Checks ball-thrust bearings, adds fresh grease
as necessary
Checks guide bearings; adds grease as necessary
Drains and adds fresh lubricant to shaft bear-
ings
Flushes bearing housing and adds fresh grease
Checks bearing temperatures; adjusts as neces-
sary
See Chem Add
II
II
(I
II
n
n
n
H
n
n
ti
it
n
-------
COOLING TOWERS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
u>
00
vo
Checks stuffing boxes for leaks; tightens or
repacks as necessary
Checks water-seal systems for leaks, adjusts
pressure as necessary
Clean and paint pump casing
Check, clean, lubricate, and adjust float
switch system
Inspect check valves for leaks
Clean sediment and accumulated solids from
sumps
Check and clean strainers
Services flow measuring devices:
Cleans and flushes annular chambers
Cleans and flushes piezometer pressure taps
Cleans and dresses orifice plates
Cleans and paints exterior
Inspects interior for corrosion
Purges connecting lines and fittings
Services pipes and pipe fittings:
Checks for leaks in pipes and pipe fittings
Inspects for rust and corrosion
Cleans and paints pipes and fittings
Flushes dead-ends
Checks and cleans sediment traps
Mechanically cleans pipes with augers and
snakes
See Chem Add
ir
ir
ii
n
ii
11
it
ii
it
ti
11
-------
COOLING TOWERS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
vo
P
Services manual and automatic control valves:
Checks valves for leaks
Inspects for rust and corrosion
Checks actuating bellows for leaks
Checks linkages for free movement
Checks for complete opening and closing
Checks calibration
Lubricates control linkage
Adjusts packing
Cleans and paints exterior
Cleans solenoid actuating mechanisms
Services storage tanks, drums, and vessels:
Checks for leaks
Inspects for rust and corrosion
Cleans and paints interior and exterior
Removes accumulated deposits of sludge and
sediment
Services mechanical drive systems:
Checks tension of flat and V-belt drives
Checks and adjusts belt alignment
Checks belts for wear
Checks and adjusts chain drive slack
Lubricates chain drive systems
Checks lubricant levels in right-angle gear
drives
Checks lubricant levels in reduction gear
boxes
Drains and changes oil in sump systems
See Chem Add
-------
COOLING TOWERS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
Cleans and inspects variable speed belt drive
systems
Lubricates thrust and frame bearings for drive
shafts
Checks oil seals for leaks
Lubricates pressure grease fittings
See Chem Add
CO
VO
I-1
Corrective Maintenance Activities
Repairs and rebuilds wooden cooling towers:
Erects scaffolding
Dissassembles and assembles cooling tower
structure
Cuts and fits replacement baffles and struc-
tural members
Repairs and overhauls status and control instru-
mentation:
Troubleshoots and diagnoses malfunctions in
status and control instrumentation
Installs, removes, replaces status and control
instrumentation
Disassembles and reassembles status and control
instrumentation
Tests diaphragms, bourdon tubes/ and bellows
for leaks or defects
Tests bimetallic strips and thermocouples for
defects
Tests electrical circuitry for shorts, open
circuits, and resistance
Main Carp
As Req
3
3
See Chera Add
-------
COOLING TOWERS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
Cleans and adds mercury to manometers
Cleans and sets contact points
Cleans and checks knife edges
Cleans and lubricates jeweled bearings
Blows down pressure lines to remove restric-
tions or stoppages
Cleans and checks orifices and nozzles
Adjusts backlash in mechanical linkages
Calibrates indicators and recorder pens
against known standard
Replaces worn or defective parts, seals, and
bearings
Repairs and overhauls electric motors and auxiliary
equipment:
Diagnoses and troubleshoots electrical malfunc-
tions
Installs, removes, replaces electric motors,
wiring, and control devices
Inspects and tests rotor and stator windings
for shorts or open circuits
Inspects commutator for wear, shorts, and signs
of excessive heat
Checks brushes for wear and proper spring ten-
sion
Adjusts brushes to seat properly and prevent
sticking
Cleans, adjusts, and lubricates bearings
Checks thermal switches, circuit breakers, and
fuses
Cleans and polishes collector rings
See Chem Add
n
it
tt
ii
11
n
n
H
ir
-------
COOLING TOWERS (cont.)
OCCUPATONAL SKILL
AREA LEVEL
FREQUENCY
f
co
u>
GO
Checks and tightens pigtails and mechanical
wire connections
Replaces or repairs defective parts in motors
and control devices
Adjusts rotor and shaft alignment
Reconditions or replaces contacts on relays
and switches
Replaces defective wiring and conduit
Inspects exposed equipment for defective
gaskets and seals
Measures voltage, current, and power consump-
tion
Checks motor speeds
Repairs and overhauls centrifugal, reciprocating,
and diaphragm pumps:
Troubleshoots and diagnoses malfunctions in
pumps
Installs, removes, and replaces pumps
Disassembles and assembles pumps
Inspects and measures bearings and bearing
races for defects
Repacks ball-thrust bearings, roller bearings,
and guide bearings
Cleans and inspects pump interior
Checks stuffing box for free movement of gland
and excessive leakage
Repacks gland assembly and adjusts
Grinds and laps valves and valve seats
Inspects impellers for deposits, scaling and
cavitation pits
See Chem Add
it
11
n
n
-------
COOLING TOWERS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
CO
vo
Dynamically balances impellers
Checks and aligns drive system
Fits replacement parts
Repairs bent float rods, binding mechanical
fittings
Lubricates mechanical fittings
Cleans and paints exterior housing
Repairs and replaces pipes and pipe fittings:
Troubleshoots and diagnoses nature and loca-
tion of stoppages
Removes and replaces sections of pipe, pipe
fittings, and couplings
Cuts and threads pipe
Cleans pipe using mechanical and hydraulically
propelled tools
Replaces gaskets and seals on flange type
joints
Bends pipe and tubing
Tests pipe systems for pressure capability
and leaks
May be required to repair and replace special
purpose pipe and fittings of the following
types:
Glass
Glass or plastic lined steel
Plastic and PVC
Aluminum
Wood
Vitrified tile
See Chem Add
it
it
-------
COOLING TOWERS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
to
vo
01
Repairs and overhauls manual and automatic control
valves:
Troubleshoots and diagnoses malfunction in
manual and controlled valves
Installs, removes, and replaces valves
Assembles and disassembles valves and control
mechanisms
Inspects and measures valve clearances
Grinds, polishes, laps-in valves and valve
seats
Cleans and inspects valve actuating mechanisms
Adjusts backlash in valve actuating mechanisms
Lubricates valve actuating mechanisms
Tests bellows and diaphragm actuators for leaks
Calibrates valve position and control actuator
Adjusts and replaces packing and seals
Tests valves for complete opening and shut-off
Tests functioning of control actuators (pneu-
matic, hydraulic, electrical, mechanical)
Replaces worn or defective valve and actuator
parts
Repairs and overhauls storage tanks, drums, and
vessels:
Repairs leaks and defective portions of steel
storage facilities
Repairs leaks and defective portions of lined
steel storage facilities
Repairs leaks and defective portions of wood
storage facilities
Repairs leaks and defective portions of con-
crete storage facilities
See Chem Add
-------
COOLING TOWERS (cont.)
OCCUPATIONAL SKILL
AREA LEVEL
FREQUENCY
f
CO
VD
Diagnoses cause of rust, corrosion, and
leaks
Repairs and overhauls mechanical drive systems:
Troubleshoots and diagnoses malfunctions in
mechanical systems
Disassembles and assembles mechanical drive
systems
Inspects and measures gear drives for wear
and defects
Inspects chain drives, replaces defective
links, adjusts tension
Checks and measures sprocket alignment
Inspects sprocket teeth for wear, hooks, and
other defects
Inspects and measures bearings and races for
wear and defects
Cleans and finishes moving parts to prevent
freezing or binding
Repacks bearings
Fits and replaces parts showing excessive wear
or defects
Inspects and replaces water and oil seals as
necessary
Cleans and paints exposed surfaces
Replaces drive belts, pulleys, and tensioning
devices
See Chem Add
-------
APPENDIX E
COSTS OF UNIT WASTEWATER TREATMENT PRACTICES
Neutralization
Deep Well Disposal
Reverse Osmosis
Electrodialysis
Ion Exchange
Multiple Effect Evaporation
Solar Evaporation
Cooling Towers
397
-------
COSTS OF UNIT WASTEWATER TREATMENT PRACTICES
An envelope of extreme values of TDS and flow rate that
have been considered for the subsequent cost calculations
are shown in Figure 1. The following are the combina-
tions within the triangle of flow, acidity, suspended and
dissolved solids chosen for the study:
Flow rate 0.5, 1.0, 10.0, 50.0 mgd
Acidity 500, 1000, 20,000 mg/1 (as CaCO3)
Suspended solids 100, 500 mg/1
TDS 3000, 30,000, 150,000 mg/1
The flow sheet used for the cost calculations is shown in
Figure 2. When neutralization is not required, the
neutralization portion will be bypassed.
398
-------
UJ
200,000
100,000
50,000
:DEEP WELL
FIGURE I
APPLICABLE RANGES OF
DEMINERALIZATION UNITS
(O
o
en
o
UJ
O
CO
(O
t-
o
10,000
5,000
DISPOSAL
.
EVAPORATION
•NVELOPE OF TDS - MGD
COMBINATION
REVERSE OSMOSIS
DISTILLATION
ELECT RODIALYSISS
1.0 5.0 10.0
PLANT CAPACITY ( MGD)
50.0 100.0
-------
NO NEUTRALIZATION FOR DEEP WELL EVAPORATION
DEEPWELL
OQO
OR DEMINERALIZATION
FILTRATE
OR
CENTRATE
ALTERNATIVE:
SETTLING POND
O
O
Vacuum Filter
or
Centrifuge
L
Sludge
DIRECT TO EVAPORATION OR CONTROLLED DISCHARGE
EVAPORATION
(alternative
to deep well)
Reverse
Osmosis
Distillation
Ion Exchange
REUSE OR
DISCHARGE
FIGURE 2
SCHEMATIC LAYOUT OF TREATMENT PLANT FOR WASTES FROM THE INORGANIC
CHEMICAL INDUSTRY SHOWING VARIOUS POSSIBLE COMBINATIONS OF UNITS
-------
NEUTRALIZATION
Neutralization of inorganic industrial wastes usually
implies the use of some form of lime for the neutralization
of acidic wastes or sulfuric acid for the neutralization of
alkaline wastes. Acidic wastes are more prevalent and
neutralization presents more of a problem with such wastes.
All forms of inexpensive neutralizing material produces
sludge which is difficult to dewater. For large scale
plants, economy requires the use of some form of lime or
limestone for treatment. Hydrated lime has been used
extensively for neutralization of acidic wastes but recent
studies (1) seem to indicate that greater economy could
be achieved by the use of limestone, both from the view-
point of lower cost of the alkali combined with a lower
cost of sludge dewatering (2). Few cost figures are
available for limestone treatment facilities, and for the
purpose of this study, only hydrated lime treatment will
be considered.
Neutralization with lime combined with aeration will remove
iron as a necessary consequence since the solubility of
ferric ions decreases rapidly above a pH of 3.0. Mangan-
ese, alumina, and silica, as well as many of the heavy
metal ions, also are removed by lime neutralization result-
ing in a decrease in total hardness.
The capital costs were calculated for a flow sheet shown
in Figure 3. Equalization capacity is required to supply
a constant flow of waste to the flash mixer. Lime from
the lime storage tank is fed into the slaker together with
some clarified effluent. Lime slurry from the slaker is
added to the waste stream in a flash mixer. After flash
mixing, the mixture is flocculated and aerated. Next the
waste is thickened in a clarifier-thickener or in a
sludge settling pond. The underflow from the thickeners
with 2% to 3% solids may be passed on to a vacuum filter
(1) Mihok, E. A., et al "Mine Water Research-The Lime-
stone Neutralization Process, U.S. Bureau of Mines
R.I. 7191, September, 1968.
(2) Rice & Company, "Engineering Economic Studies of
Mine Drainage Control Techniques," Appendix B to
Acid Mine Drainage in Appalachia, A Report by the
Appalachian Regional Commission.
401
-------
lime
Equalization Basin
O
to
filtrate
To stream or
deminerallzation
plant
Sludge to
disposal
occasional
removal of
sludge after
drying
FIGURE 3
FLOW SHEET FOR NEUTRALIZATION PLANT
Alternative
flow pattern
'Sludge
jsettlinQj
pond
To stream
-------
iooo r
O
O
O
100
O
UJ
CO
O
O
Q.
<
O
10
FfG. 4
CAP COST OF NEUTRALIZATION
FACILITIES EXCLUDING
SLUDGE TREATMENT
I I I I I 1
I I I I I I
FROM RICE REPORT (2)
FROM BARNARD THESIS(4)
L 1 I I I 1
1.0 10.0
PLANT CAPACITY MGD
-------
HYDRATED LIME TREATMENT PLANT
FIGURE 5
CAR COST. VS ACIDtTY FOR 1 MGD PLANT (INCLUDING SLUDGE DISPOSAL)
(FROM OPERATION YELLOWBOY) (2)
10,000
O
O
O
CO
O
O
o:
<
o
1000
000
i i 11
100
1000 10,000
ACIDITY, ppm (AS CaC03)
100,000
-------
•ta.
o
Ul
o
o
o
CO
O
O
g
Q.
O
1000
100
40
i I I I I I I
1.0
10.0
50.0
VOLUME OF BASIN (IN MILLION GAL.)
FIG. 6 CAPITAL COST OF EQUALIZATION BASINS REF. (3)
-------
or a centrifuge for dewatering or may be discharged to a
dewatering pond. Sludge will be dewatered mechanically
to approximately 20% solids at which consistency it can be
trucked to disposal. If abundant land is available, the
waste will be discharged from the flocculator directly into
a settling pond. If land.is scarce but available within
pumping distance, only the thickened sludge will be settled
in a pond.
Costs for hydrated lime treatment of acid drainage includ-
ing sludge disposal by thickening and disposal of the
slurry in ponds are presented in a report on the economics
of acid mine drainage (2). These cost curves show a
decrease in the unit capital cost of neutralization
facilities with increase of acidity, but no such decrease
in unit cost with increase in the volume of waste treated
daily. This is contrary to previous findings (4) that
the overall cost increase is proportional to flow rate to
the power of 0.83 (see Figure 4). Combining these two
values, the general overall cost for neutralization,
thickening and sludge holding ponds can then be expressed
as:
Capital Cost (in $1000)=172 Cj0.83A0.79 (see Figure 5)
where
Q = flow rate in mgd
A = acidity in mg/1
From available cost curves for (1) the equalization basin,
(2) lime plant, mixes and flocculator (3) the clarifier
thickener and (4) the vacuum filter or centrifuge, it was
also possible to synthesize the cost for full sludge de-
watering.
The cost curve for equalization basins (shown in Figure 6)
is based on findings by Chow (3) and additional costs
determined by Barnard (4).
(2) Rice, ibid
(3) Chow, C. S., Malina, J. F. and Eckenfelder, W. W.,
"Effluent Quality and Treatment Economics," Report
published by the Center for Research in Water Re-
sources Technical Report EHE 07-6801, CRWR 28,
The University of Texas at Austin.
(4) Barnard, J. L., "Treatment Cost Relationships for
Wastes from the Organic Chemical Industry," M.S.
Thesis, The University of Texas at Austin, June, 1969
406
-------
The cost curve for the lime plant mixer and flocculator is
based on costs extracted by Barnard (4) and additional
costs obtained from Operation Yellow Boy (2). These
curves shown little variation with acidity which influences
mainly the sludge handling units, but they are dependent
on the plant size.
Costs for the clarifier thickener were based mainly on
flow since clarification and thickening is combined into
one unit. Clarification requires a minimum overflow rate
for effluent control and this will determine the size of
the unit. The amount of thickening obtained is then
calculated from zone settling considerations to determine
the consistency of the thickener underflow. Costs were
obtained from the Mine Drainage Report (2) and calculated
from parameters obtained from a laboratory study of
neutralized acid wastes.
The size of the clarifier itself is based on an overflow
rate of 700 gpd/ft2. in order to produce an effluent
suitable for further use or treatment, it will be
necessary to use polymers to reduce the suspended solids
in the effluent and to filter the effluent. The thickener
design was based on values from laboratory studies (5) as
shown in Figures 7 and 8.
The design is based on the following mathematical model
by Edde and Eckenfelder (6):
Cu _ -i _ kB
Ci (ML)n
where
Cu = solids concentration of the underflow in mg/1
Ci = influent solids concentration in mg/1
ku = constant depending on Ci as shown in Figure 8
ML = mass loading in Ibs. solids per day/sq. ft. of
tank surface
(2) Rice, ibid
(4) Barnard, ibid
(5) Atlas Chemicals, Marshall, Texas, Private Report.
(6) Edde, H., and Eckenfelder, W. W., "Theoretical Concept
of Gravity Sludge Thickening," Presented at 40th
Annual Conference of the Water Pollution Control
Federation, New York, New York, October 8, 1967.
407
-------
o
CO
30
20
' 10
o|6
FIG.
^
n
i "
7 THICKI
...,.„.,._..£• n rt fc i
r ROM
•O.SS^ba^
i t i i
ENER PAR)
NEUTRALS
&METE
NATION
\
RS F
OF
7OR
AC
SL
IDK
.U[
•* \
)GE
WASTES
10
20
3O 40 SO 6070
MASS LOADING (Ibs/ft2-day)
REF C5)
-------
m
70
6O
50
40
30
20
10
0
\
\
FIG. 8
VARIATION
SOLIDS CO
REF.(5)
s
\
H \,
\
^ — _
OF KB wn
NCENTRAl
* 1
'H INITIAL
ION
1
8
10
12
INITIAL SOLIDS CONCENTRATION C\ (lOOOmg/l)
-------
This model will be applied to determine the underflow solids
discharged to the vacuum filter or centrifuge.
Sludge Dewatering
The cost functions used for the calculation of costs for
vacuum filters and centrifuges are based on those applied
by Quirck (7) for industrial wastes. The unit capacity
or loading factor for vacuum filters, expressed as Ib.
solids per hour through one square foot Ibs/hr will be
-------
neutralization is CaSC-4, the concentration of the salt in
the effluent will be determined by the solubility
product. (Ca++) (804) = 10 x 10"^, thus the molar concen-
ration of CaS04 in solution would be 0.00315 molar or
428 mg/1. Metal precipitates will add to the sludge as
will initial suspended solids. These values are normally
not high. Where suspended solids are high, they will be
dealt with separately under the cost function. As some
metals will precipitate during neutralization, these will
be added to the total acidity for the purpose of this
study.
Thus, total sludge produced given by sludge (mg/1) =
1.36 x acidity
+0.31 x acidity for unreactive lime constituents
+15% of acidity for metal ppts
-428 mg/1
=1.36 x 2000 + 0.31 x 2000 + 0.15 x 2000 - 428 =
3400 mg/1
Assume sludge production 1.7 x acidity.
Equalization for 6 hours, i.e., basin size 0.25 MG
From cost curve, Capital Cost = $20,000
Neutralization installation
From Figure 4 Capital Cost - $54,000
Thickener - clarifier
From Figure 9 Capital Cost = $110,000
Assume
Underflow solids concentration 2% solids
Volume of sludge produced = 3400 x 8.33 = 170,000 gal/day
0.02 x 8.13
Vacuum filter Lf = 2.5 Ibs/day based °* ^f (7)
sq. ft.
Filter area = 3400 x 8.33
2.5 x 16
= 710 sq. ft. for 16 hrs/day operation
Capital Cost = $4820 x (710)0'58
= $216,000
Capital Cost of Centrifuge
Sludge volume = 170,000 gpd
- 142 gpm for a 20 hour day
411
-------
to
600
500
400
300
200
O
o
O
V)
o
o
100
50
40
30
O.I
FIG.9 CAPITAL COST OF THICKENERS
REF (2)
*
^
0.5 1.0 2.0
PLANT SIZE (MGD)
3.0 4.0 5.0
too
-------
which requires 142 HP
Capital Cost = $15,700 x (142)°*40
= $114,000
The cost of the vacuum filter is much higher than for the
centrifuge but there will be a substantial saving in the
operating cost as little chemicals will be required to
achieve the desired results. The capital cost for vacuum
filtration will be used here.
Total cost (excluding trucking)
Equalization 20,000
Neutralization 54,000
Thickener clarifier 110,000
Vacuum filter 216,000
400,000
Add 35% for site preparation
pipework, etc. 140,000
$540,000
Calculating a range of values for flow Q from 0.5 to 50
mgd and for acidity A from 500 mg/1 to 10,000 mg/1, the
following cost model was found:
Capital Cost (in $1000) = 300 x Q0-71A0.34
The acidity seems to be less of a factor in this model
but only because trucking or other disposal of the filter
cake has been included in the total calculated costs.
Also, the operating cost will be much higher than for
lagooning of the sludge. Although the capital costs
will be lower, the total annual cost for mechanically
dewatered sludge will be high.
Operating costs were determined from the acid mine drain-
age report without sludge disposal and the operating costs
of vacuum filters were added to that. The resultant
curves are shown in Figure 10.
Suspended Solids
The sludge produced from the lime neutralization process
has more definite properties than the sludge produced by
the settling of other suspended matter. It was assumed
that at worst the suspended solids will- have the same
properties and for this reason, it was lumped together
with acidity in the calculation of total costs.
413
-------
200
J
<
O
0 I0°
§ 90
0 80
v. 70
^ 60
— 50
g 40
(O
8 30
0
Z on
H- 20
<
o:
UJ
Q.
o
10
((
OPERATING COS
(COST
i < \S
TS FROB
> FOR C
>
i i i
K RICE REPORT (2)
EWATERING ADDE
-x
^
X* ^
/ ' s*
s/
\ \ 1
).)
*»5r^
o^ c
^tf§v
\5^
iiit
c\^H
*gA?
a9^°
• i
)0 500 1,000 5000 10,000
NET ACIDITY mg/l.
FIGURE 10
OPERATING COSTS FOR LIME NEUTRALIZATION INCLUDING
SLUDGE DEWATERING BY VACUUM FILTRATION
-------
Filtration
The cost values used for filtration were obtained from
Smith's (8) curves and they are reproduced in Figure 11.
The capital costs and operating costs were calculated
at ENR index 1285.
(8) Smith, R., "Cost of Conventional and Advanced Treat-
ment of Wastewater, Journal Water Pollution Control
Federation, Vol. 40, 69, September, 1968.
415
-------
I-J
2OOO
1000
O
O
O
CO 100
V)
O
O
Q.
<
O
1.0 10.0 50.0
DESIGN CAPACITY (MGD)
FIGURE II. COST OF FILTRATION THROUGH SAND OR GRADED MEDIA
AFTER SMITH (8)
-------
DEEP WELL DISPOSAL
The capital cost and operating cost for deep well injection
systems are presented in the attached Figures 12 and 13.
These costs are presented for different flow rates as well
as casing head pressures. The capital costs are expressed
in terms of total capital investment and the operating
cost is expressed on an annual basis. In order to develop
usable curves, it is necessary to select typical geologi-
cal and hydraulic systems (9). Therefore, the following
items were constant:
Depth
Effective Thickness
Porosity
Permeability
Reservoir Pressure of the Disposal Horizon
The diameter of the injection stream was also held constant
and for this particular example was seven inches. The
geological characteristics assumed were based on evaluation
of existing data and are valued to represent the conditions
at more than 50 percent of the existing installations. The
operating costs are based on a power cost of 0.005 dollars
per kilowatt hour, an interest rate of five percent and a
payout period of 20 years.
The ENR building cost index of 700 was used for estimating
the capital cost. These cost flows include minimal ser-
vice treatment. If service treatment greater than filtra-
tion is required, the cost of the additional unit process
must be added to the capital and operating cost shown in
Figures 12 and 13.
In order to convert costs to 1969 values with ENR index
1285, the values from the curve were multiplied by 1.84.
(9) Moseley, J. C., and J. F. Malina, Jr., "Relationships
Between Selected Physical Parameters and Cost
Responses for the Deep-Well Disposal of Aqueous Indus-
trial Wastes," Report published by the Center for
Research in Water Resources, Technical Report, EHE-
07-6801, CRWR-28, The University of Texas at Austin,
(August, 1968).
417
-------
FOO
90
tr
<
LJ
o
o
o
80
— 70
H
co
o
o
60
a:
UJ
CL
o
so
40
30
0.2
INJECTION
PRESSURE
/
0.4 0.6 0.8
FLOW RATE (M60)
1400 psi
1000 psi
• GOOpsi
0 psi
1.0
FIG. 12
ANNUAL OPERATING COST OF DEEP WELL
INJECTION SYSTEMS FOR WASTE DISPOSAL
418
-------
280
~ 260
O
O
O
240
o
o
220
200
180
0,2
0.4
0.6
0.8
FLOW RATE (MGD)
INJECTION
PRESSURE
1400 psi
1000 psi
600 psi
0 psi
1.0
FIGURE 13
CAPITAL COST OF DEEP WELL
INJECTION SYSTEMS FOR
WASTE DISPOSAL
419
-------
REVERSE OSMOSIS
The curves actually used for cost calculation were obtained
from the Acid Mine Drainage Report (2) and they are repro-
duced in Figures 14-17. The pretreatment and brine disposal
required was considered separately. These curves gave
generalized cost figures. If more accurate assessments
are required, one can calculate the yield and the actual
membrane size required. This is demonstrated below. For
a high total dissolved solids content, it is necessary to
make an assumption as to the number of units required to
produce the desired effluent. Also, the feasibility of
rejection of brine at certain levels should be considered.
From the viewpoint of producing palatable water only, one
may reject a large quantity of brine for every unit of
water produced if brine disposal presents no problem. How-
ever, when brine disposal does present a problem, the
amount produced must be minimized. For disposal for treat-
ment purposes, both the value of the water produced and the
cost of brine disposal will determine the degree to which
the concentration of the brine must be increased or, con-
versely, the total volume of the brine decreased.
The curves (Figures 14-16) were plotted from actual data
of pilot and demonstration plants. The membrane area
required depends on many factors including: membrane
characteristics (salt rejection, porosity/ etc.), applied
pressure, water characteristics, and the feed flow.
The capital costs quoted here are for the entire plant
including installation. However, the operating costs
are for power consumption only. Membrane replacement
costs have been estimated at $0.35/1000 gal. of product
flow. The estimated overall projected figure would be
.35 + .98 = $1.33/1000 gal of treated water (10). This
is a very conservative estimate and does not consider
future improvements in membrane technology.
The operating costs do not include pretreatment to remove
undesirable pollutants such as iron, manganese, organics,
etc., and do not consider ultimate disposal of the brine.
(2) Rice, ibid
(10) Spiegler, K. S., Principles of Desalination, Academic
Press, (1966).
420
-------
100,000-
•t.
to
Q
CD
M
I-'
U_
o
u.
o
UJ
Ul
UJ
10,000
0.30
0.40
FIG. 14
AREA OF MEMBRANES AS
A FUNCTION OF
PRODUCTION RATE
REF: "SALINE WATER
CONVERSION REPORT;'
U.S. DEPT. OF SALINE
WATER (19671
0.50
0,60
PRODUCTION FLOW/ FEED FLOW
-------
to
K)
M
UJ
a:
100
00,000
10,000-
1000-
0
001
PRODUCT FLOW CURVE
MEMBRANE AREA REQUIRED
VS
FEED AND PRODUCT FLOWS
I
PRODUCT FLOW©
FEED FLOW *
Reference:
"Saline Water Conversion
Report," U.S. Dept. of
Interior, Office of
Saline Water (1967).
0.01
FLOW MOD
O.I
0.3
m
01
-------
to
o
o
o
JC
t
O
a.
2
CO
z
o
o
a:
LJ
o
a.
uu-
9O
8O
7O
6O
50
4O
30
20
_
•^
-^
e
X
<
s
1
i
»
> \®
FIG. 16
POWER
kS A Fl
PRODUC
REF (1C
\
CONSUMPTION
JNCTION OF
TION RATE.
0 SPIEGLER, ibid
5 6 7 8 9 10
20
30 40
PRODUCTION RATE (gpd/ft.2)
-------
FIG. 17
CAPITAL COST AS A FUNCTION
OF PRODUCTION RATE
REF (10) SPIEGLER.ibid
3.0
2,0
•o
a.
o>
4A.
""l.O
-------
The latter was considered separately for calculating the
cost of treatment.
Most work with reverse osmosis has been concerned with
TDS levels of 1000-5000 mg/1. Thus, the plots presented
are based on these ranges. Higher levels of TDS would
probably require much more specific surface for equivalent
removals, thus increasing capital expenditures. Also,
maintenance costs would be increased due to increased
scaling, etc.
I. REQUIRED DATA: Plant Flow, Removal Desired Produc-
tion Flow (amount of plant flow to be recovered
through membrane)
If plant flow = 1 mgd and a recovery factor of 60%
is desired, then the production flow = 600,000
gpd = 0.60 mgd waste flow = 0.40 mgd
At influent concentration of 5000 mg/1 TDS and a
desired effluent of 500 mg/1, the desired removal
or fractional "cut" would be 0.90.
II. SIZE OF PLANT AND POWER CONSUMPTION
Product flow =0.60 mgd
Prod/Feed =0.60 •
From Figure 14: Area/Feed flow = 102,000 ft^/mgd
.-. Total Area = 102,000 ft2
check: From Figure 15: @ Prod. Flow = 600,000 gpd,
Area = 102,000 ft2
Production rate = 600,000/100,000 =6.0 gpd/ft2
From Figure 16: Power = 44 KW-hr/k gal - 44,000
KW - hr/day
III. COSTS
Capital Cost
Production rate =5.0 gpd/ft2
.•.From Figure 17:
Capital Cost =1.20 $/gpd + 10b gpd
Operating Cost
Power Consumption = 44,000 kw-hr/day (Figure 16)
,*.@ $0.015/kw-hr
Power Cost = $660/day
425
-------
N>
10.0
-------
10.0
<
<9
O
O
O
to
I-
co
O
O
O
<
o:
UJ
o.
o
o
UJ
<
UJ
o:
i-
UJ
i-
co
I
1.0
O.I
TIG-19~| 1 f
OPERATING COST FOR REVERSE OSMOSIS PLANT
REF(2) RICE, ibid
I I i i i i i
O.I
1.0 JO
TREATMENT PLANT CAPACITY
(MGD)
30
-------
ELECTRODIALYSIS
Cost figures for electrodialysis were difficult to obtain
because this method is mostly used where brine disposal
does not represent a problem or very high concentrations
of effluent brine or not necessarily required. As a
treatment method to concentrate and thus reduce the volume
of brine produced, a slightly increased number of cells
will have to be used and a proper balance between brine
produced and usable water production will depend on the
need or cost of the clean water as well as the cost of
brine removal. To get some idea of the number of units
required to concentrate waste streams and produce a
product effluent of less than 500 mg/1 total dissolved
solids, a study was made of existing data (11) to produce
the set of curves in Figure 20. This will give some
idea of the number of units required and the relative
amounts of effluent and brine produced. With recircula-
tion of the waste through the cells the concentration
in each cell will reach an equilibrium value which is
not easy to calculate. Certain values were assumed and
the units calculated according to this. Using basic
design parameters, the size of the plant was calculated
for waste with varying values of total dissolved solids.
These values were then used for calculating the final
capital costs. From Figure 22, the volume of brine was
calculated and the cost of disposal of the brine was
added to the cost of treatment.
Design Equations
= 100° Fd
CE (i/Cd)0(2K2Cdi (1-f) +
nAp = effective transfer area, cm2 (n=number of
individual cell pairs)
f = fraction of total cut through filter (the TDS
removal factor) (measure of approach to
polarization and film diffusion limitations)
should stay less than 0.5
(11) Electrodialysis in Advanced Waste Treatment, FWPCA
Publ. No. WP-20-AWTR-8, Water Pollution Control
Research Service (1967).
420
-------
10
VD
Z3
U_
a:
LJ
CD
10
9000 60OO 4900 3300
2200
1500
1000
500
APPROXIMATE UNIT OPERATIONAL LEVELS
IN mg/l TDS.
FIGURE 20
DETERMINATION OF TOTAL NUMBER OF UNITS REQUIRED FOR
TREATMENT
-------
10,000
Ul
c
500
0.0
O.I
50,000 TDS
10,000 IDS
1,000 TDS
RELATIONSHIP OF PLATE
AREA REQUIRED FOR A
DESIRED TDS REMOVAL
(ELECTRQDIALYSIS)
REF. (II)
0.2 0.3 0.4
TOTAL CUT f
0.5
0-6
-------
100,000
10,000
0
>
UJ
N
o:
UJ
o
UJ
cc
1,000
100
I00,0 0.1
100,000 TDS
50,000 TDS
FIG.22
RELATIONSHIP OF
RECTIFIER SIZE TO
SPECIFIC TDS REMOVAL
DESIRED
(ELECTRODIALYSIS)
REF(ll)
10,000
1,000 T
TDS
DS
0.2 0.3 0-4
TOTAL CUT, f
0.5 0.6
431
-------
i = Cde)/Cdi
F = Faraday's constant, 96,500 coulombs/equivalent
i = current density, ma/cm^
influent dilute stream flow rate, liters/sec
influeirt dilute stream concentration, equiva-
lent/liter
Cci = concentrated stream concentration equivalent/
liter
kl,k2 = constants depending on various membranes,
solutions, and temperature parameters
ki/ca = a solution resistance term
k2 = a membrane resistance term
Y = 1 + (l~f )g (i/Cd) = a measure of approach
(gf+1) ° polarization. Thus,
there is an upper
limit to this ratio.
z = ln
(l-gf)
g = Cdi/cci
CE = current efficiency
Vp = potential drop across membranes, volts
I = Fd F f Cdi
nCE
DC power requirement = p = (Vpl) in kva
432
-------
TABLE I
SUMMARY
Influent
TDS
1,000
10,000
50,000
100,000
f
0.50
.35
.25
.10
0.50
.35
.25
.10
0.50
.20
.10
0.50
.35
.25
.10
Plate Area
(ft2)
5,180
3,110
2,038
731
6,120
3,440
2,177
742
6,560
1,678
745
6,640
3,585
2,270
747
DC Energy
(kw-hr)
988
742
553
235
26,200
21,600
17,800
8,220
494,000
307,000
171,000
1,890,000
1,710,000
1,450,000
649,000
ED Unit
Cost $
45,380
27,160
17,830
6,400
53,600
30,140
19,040
6,480
57,450
14,690
6,503
58,150
31,410
19,860
6,531
Rectifier
Cost
2,500
1,875
1,400
595
66,100
54,600
45,000
20,800
1,250,000
776,000
431,000
4,770,000
4,330,000
3,550,000
1,641,000
Operating
Cost
DC Energy
Cost $/MGD
9.88
7.42
5.53
2.35
262
216
178
82
4,940
3,070
1,710
18,900
17,100
14,050
6,490
-------
Example: 10 mgd plant
TDS = 1000 mg/1
Normality = 0.01 equiv./liter
Allowable effluent concentration =600 mg/1
.'. f = 1000 - 600/1000 = 0.40
Capital Considerations
From Figure 21: Area of plates
= 3,700 ft2/mgd + 10 mgd
= 37,000 ft2 total
From Figure 22: Rectifier size
= 30.25 ku-a/mgd + 10 = 302.5 ku-a
From Figure 23: Capital cost of plates, spacers, membranes
and electrodes
= 31.500/mgd
= $315.000 total
From Figure 24: Capital cost of rectifier
= $2100/mgd + 10 mgd
= $21,000 total
Capital Cost = $315,000 + $21,000 = $336,000
Stack hardware = $500/mgd = 5,000
10% installation = 0.10 (341,000) = 3,410
Auxiliary equip, (installed @ 40%)
pumps, valves and fittings,
control panels, acid tanks,
conduct = 20.000/mgd = 200,000
(10% miscellaneous included)
Total ±/ $544,400
I/ exclusive of building, spare parts, etc.
Operating Conditions
From Figure 25: DC Energy Requirements
= 840 kw-hrs/mgd
= 8400 kw-hrs
434
-------
FIGURE 23
to
Ln
o
e>
O
o
CL
<
O
50,000
40,000
30,000
20,000
10,000
*nnr>
. CAPITAL COST OF MEMBRANES,
SPACERS, END PLATES, AND
ELECTRODES ( ELECTRODIALYSIS )
- REF. (11)
>
<
/
/
X
r
^/
Ss/
rf
-------
10,000,000
1,000,000
o
(9
S
O
o
100,000
g
a
u
o
UJ
DC
10,000
1,000
0.0
O.I
FIG.24
CAPITAL COST CURVES
-FOR DC RECTIFIER FOR—
ELECTRODIALYSIS REF(il)
100,000 TOS
0.2 0.3 0.4
TOTAL CUT, f
50,000 TDS
10,000 TDS
1,000 TDS
0.5
0.6
436
-------
ICOOOpOOr
1,000,000
100,000
o
tr
UJ
z
UJ
o
o
10,000
1,000
•100,000 IDS
5QOOOTDS
FIGURE 25
RELATIONSHIP OF DC ENERGY
REQUIRED FOR A DESIRED -
IDS REMOVAL
(ELECTRODIALYSIS) REF (II)
TOTAL CUT, f
437
-------
From Figure 26: DC Energy Operating Costs @ $0.01/kw-hrs
= 8.40/mgd
Total I/ = $8.40/day
Costs for 0.5 mgd wastewater at 3000 mg/1 total dissolved
solids.
From Figure 20, the following units would be required to
deliver equal volumes of product water at 500 mg/1 total
dissolved solids and brine at 10,000 mg/1.
Approximate
Feed
Concentration
3,000
2,200
1,500
1,000
4,900
6,000
# Units/ Cost/
mgd Unit
2.8 58,000
2.0 52,000
1.4 50,000
0.7 47,000
1.8 70,000
1.0 78,000
Plus 25% for pumps
Total
Cost
81,000
52,000
35,000
16,000
63,000
78,000
325,000
81,000
406,000
These costs were obtained from costs calculated from the
fundamental design equations. Similar costs evaluated
for other points and those were plotted on Figure 27.
Values for operating costs were calculated as shown in the
Appendix and the values also are shown in Figure 27. One
value obtained from Ref. (12) is shown to be within the
calculated range of operating costs.
I/ Must include maintenance costs:
Membrane replacement = 4 sets/25 years
Spacer replacement = 4 sets/25 years
Anode maintenance - $200/stack year
Other maintenance - 1-1/2% of capital investment/year
Labor = 2 man-hrs./day plus 100 man-hrs. per stack year
Other operating costs would be acid or alkali additions
to maintain a suitable pH.
(12) Lacey, R. E., Lang, E. W., and Huffman, E. L.,
"Economics of Demineralization by Electrodialysis,"
Saline Water Concession II. Advances in Chemistry
Series 38. American Chemical Society, 1155 16th St.,
N.W., Washington, D.C., 1963.
438
-------
100,000
10,000
Q
0
1000
O)
O
O
cc
UJ
z
ID
O
O
100
10
FIGURE 26
OPERATING COST OF DC ENERGY
REQUIRED FOR SPECIFIC
TDS REMOVAL
(ELECTRODIALYSIS) REF. (II)
0.0
O.I
0.2 0,3 0.4
TOTAL CUT, f
0.6
439
-------
FIGURE 27
CAPITAL AND OPERATING COSTS FOR
ELECTRODIALYSIS BASED ON FEED FLOW
TO PLANT AT 3000 ppm T. D. S.
10.0
<£>
0)
o
o
1.0
CL
<
O
O.I
0
B COSTS AS CALCULATED
V FROM REFEREN
LACEY, ibid
I III!
1.0 10.0 20.0
PLANT SIZE (MGD)
440
-------
ION EXCHANGE
The cost of ion exchange plants is dependent on the total
volume of waste treated but also to a large extent on the
total amount of dissolved solids removed or exchanged since
the flow rate through the media remains fairly constant.
The regenerant chemical cost will also be in direct propor-
tion to the rate of electrolyte removal. The water used
for the wash cycle may for the purpose of treatment, be
returned to the filter and recycled and will thus be added
to the waste stream. The waste stream will be very concen-
trated and provide a possibility of recovery of chemicals
if such chemicals have any commercial values.
The cost curves in Figure 28 were obtained from the Acid
Mine Drainage Report (2) for the Nalco process for an
influent TDS of 1500 mg/1. The curve for the Desal Process
was obtained from Kunin, et al (13).
The No. 3 curve in Figure 28 was calculated on the basis
of the increased capacity required for the increased ion
concentration in the waste.
Operating costs for ion exchange were obtained from various
sources and pieced together to give a reasonable estimate
of the total operating costs. Costs for chemicals used
per Ib. of TDS removed varies with the initial concentra-
tion of the solids in the influent. The curve in Figure
29 was drawn from the following information:
Influent TDS Chemical Cost per Pound
(mq/1) TDS Removed
200 10.2 Ref (14)
354 4.05 Ref (14)
1000 2.0 Ref (15)
(2) Rice/ ibid
(13) Kunin, R., et al "Desal Process-Economic Exchange
System for Treating Brackish and Acid Mine Drainage
Waters and Waste Effluents," Chemical Engineering
Progress Symposium Series No. 90, Vol. 64, AICHE,
1968.
(14) Levendusky, et al "An Innovation in Ion Exchange,"
Industrial Water Engineering, Vol. 2, 11, Nov., 1965.
(15) Lyons, D., M.S. Thesis, University of Texas at Aus-
tin, 1969.
441
-------
io.o
to
1.0
O
O
<
(L
O
OJ
0.1
SAL PROCESS REF. (13)
.CO PROCESS RER (14)
J MATED
t i i i i i i i
I i 1 I I i l
1.0 100
PLANT CAPACITY (MGD)
FIGURE 28 CAPITAL COST OF ION EXCHANGE PLANT
-------
10
£ 9
8
7
6
5
4
3
O
LJ
O
UJ
C
(0
O
I-
CD
o:
UJ
Q.
(O
O
O
UJ
z
o
1000
2000
3000
INFLUENT DISSOLVED SOLIDS
(mg/l)
FIG. 29 CHEMICAL COST PER POUND TDS REMOVED
BY ION EXCHANGE
443
-------
The total operating cost for an influent TDS of 3000 mg/1
was calculated as follows:
For 0.5 mgd - 2500 mg/1 removed for effluent concentra-
tion of 500 mg/1
Chemical Costs:
0.001 x 1.5 x 2500 x 8.33 = 31.2C/1000 gal.
Other Costs
Labor
Material
Chemicals
Utilities
For 1.0 mgd
Labor
Material
Chemicals
Utilities
For 10.0 mgd
Labor
Material
Chemicals
Utilities
1.1
1.4
31.2
1.3
3370 <=/1000 gal.
0.9
1.2
30.0
1.2
3TT3 C/1000 gal
0.7
0.9
27.0
1.0
29.6 C/1000 gal
444
-------
MULTIPLE EFFECT EVAPORATION
The capital and operating costs for multiple effect
evaporation was obtained from the report "Cost of Purify-
ing Municipal Wastewater by Distillation." Environmental
Health Series, Report No. AWTR-6, U.S. Department of HEW
(1963). The costs were based on product water and from the
above report, it appears that approximately 10% brine is
produced. Few operating costs were available. Additional
points were obtained from a report in the 1965 report
"Saline Water Conversion Report," U.S. Department of the
Interior, Office of Saline Water.
The capital and operating costs are shown in Figure 30.
445
-------
10.0
CAPITAL COST
o
o»
O
O
o
0.05
CO
o
o
o
tr
LJ
o.
o
0.02
10.0 100.0
PLANT SIZE MGD (PRODUCT WATER)
FIGURE 30
CAPITAL AND OPERATING COST FOR MULTIPLE
EFFECT EVAPORATION (DISTILLATION)
-------
SOLAR EVAPORATION
Pond evaporation would only be considered in areas where
the land is cheap and the net evaporation exceeds the net
rainfall by a sufficient margin so as to keep the
evaporation ponds within reasonable limits. An example
of such a calculation is given below. No areas of pond
required are calculated and land value is assumed to be
a minimal $100/acre. The costs for construction of the
ponds shown in the curve in Figure 34 does not include the
cost of land.
Example:
Industry located in Austin, Texas
Discharge -0.1 mgd high solids. T° @ 140°F
METHOD 1 - Average conditions (long term) (Empirical
approach)
Determine annual precip. from U.S. Weather Bureau data -
32"
Determine annual lake evaporation from U.S. Weather
Bureau = 60"
Net evaporation - 60-32 = 28"/yr or .0735"/day
From Figure 33 enter @ evaporation/day = .074
Read chart @ acres/mgd = 520
Average required - .1 x 520 = 52 acre
(values are 50% occurrence values).
METHOD II - short term conditions - (Rational Approach)
(1) from local weather bureau, or compiled data (17)
Determine (95% occurrence value)
(16) The Nation's Water Resources, USGPO, Washington, D.C.,
1968, Part 1.
(17) Evaluated Weather Data for Cooling Equipment, Flow
Products Company, Santa Rosa, Calif. (1958)
447
-------
.fc.
00
COX CHART
REF(I8) HIMELBLAU, ibid
VAPOR PRESSURE OF WATER VS TEMPERATURE
0.10
1.0 10.0
VAPOR PRESSURE, INCHES Hg
50.0
FIGURE 31
-------
vo
o.ot
O.I
I EVAPORATION
i VS
VAPOR PRESSURE
DIFFERENTIAL REFU7)
E=CAe
where C= 0.55W
and W=wmd velocity,
mph
>r
a:
o
a.
100
UJ
CO
UJ
o
z
1.0 10
VAPOR PRESSURE DIFF, Ac (inches Hg)
10
100
FIGURE 32
-------
10,000
1.0
10.0
100.0
INCHES WATER
EVAPORATION
1000
O
-------
10 20
SURFACE AREA (IN ACRES)
FIGURE 34
CAPITAL COST RELATIONSHIP FOR
LAGOONS REF (4)
30
451
-------
(a) temperature range
wet bulb temp 77° (Figure 19 , Ref. 17)
dry bulb temp 95° (Figure 75, Ref. 17)
(b) wind speed - 15 mph (Figure 73, Ref. 17)
(c) relative humidity - 45% (psychrometric chart
Figure 69, Ref. 18)
(2) From Figure 31
Determine vapor pressures
water @ 140° = 5.8"
Atmosphere @ 95°F = 1.67 x .45 = .75
= 5.8 - .75 = 5.05
From Figure 32 Evap. = 5.8"/day
(3) From Figure 33 @ 5. 8 "/day evap.
read acres/mgd = 6.8 acre/mgd
@ .1 mgd - require .68 acre
Controlled Discharge (19)
Example :
Industry flow @ 200 mgd 308 cfm
Cone @ 1000 TDS - Ci
Stream flow @ 1200 cfs (775 mgd) mean annual flow = SF
Cone (§100 ppm TDS = Cs
Coefficient variation @
Allowable stream concentration 500 ppm TDS = Ca
Based upon concentration factor -
allowable ratio = IF = Ca-Cs
SF Ci-Ca
or, IF = 500-100 = 400 = .8
SF 1000-500 3W
(17) Flow Products Co., ibid
(18) Himelblau, D. M., "Basic Principles and Calculations
in Chemical Engineering," Prentice Hall, Inc.,
England, New Jersey, 1967.
(19) Industrial Waste Guide on Thermal Pollution, U.S.
Department of the Interior, FWPCA, Pacific Northwest
Laboratory, Corvallis, Oregon, September, 1968.
452
-------
.'. @ any time, industrial flow can be 80% of stream
flow or, stream flow must be 125% waste flow
From flow duration curve (USGS)
(1) determine 84% occurrence value and 16% occurrence
value
(2) calculate average ratio between these values and
50% occurrence value (Mode); this is Sigma (G) or
standard geometric deviation.
(3) Determine coefficient of variation = sigma
mode
(refer to fraction of flow duration curve)
Example - 50% value - 1200 cfm
85% value - 7100 cfm
16% value - 280 cfm
= 7100 =5.9 1200 = 4.3, G Avg =5.1
1200" 280
plotting geometric normal distribution
low (16%) 6 1200 •*• 5.1 = 234 high (84%) @ 1200 x 5.1 =
6120
Coef of variation = 280 = .233
1200
or
1200 = .17
7100".
average = .23 + .17 =.20
2
Entering draft/storage @ ratio industry flow to stream
flow
IF/SF = 200/775 = .257
and cost of variability @ .25
Storage factor = .063 MAG
.063 x 775 mgd = 488 MG
Storage required
488 mgd x 365 days = 17,800 MG or 89 days
(4) from flow duration curve, flow of 318 cfm would be
exceeded approximately 80% of the time
(5) allowing for dilution factor storage must be
minimal by 25% or 17,800 mg x 125% = 22,300 MG
453
-------
Note: No consideration of rainfall and evaporation has
been made; each individual application should consider
these factors separately.
Cooling Ponds
Temperature drop through a pond
(1) To = (Ti-E)e~a' +E
where
To = outlet temperature °F
Ti = inlet temperature °F
(2) a1 = KA
pCpQi
where
a1 - decay e ? -1
K = energy exchange coef. (BTU ft day" )
A = pond area (ft2)
P = water density (62.4# ft"3)
Cp = specific heat function (1BTU Ib"1 F"1)
Qi = influent flow (ft3 day~M
E = equilibrium
Solving for K = 157 + (0.26 + B) (bW)
where
W = wind speed in mph
b = experimental evaporation coef.
B = proportionality coefficient
from E(°F) B(mmHg-l)
50-60 0.405
60-70 0.555
70-80 0.744
80-90 0.990
Example
Assume b = 12
K = 118
To = 80°F
E = 769 °F
from eq. (1)
80 = (93-769}e-a* + 76.9
e-a1 = 0.193
a1 = 1.65
Eq. (2)
a1 = 118A
(62.4)(1)(1500)(24)(3600)
a1 = (1.46 x 10-8) A=1.65
A = 11.3 x 10? ft2
A = 2590 acres
454
-------
COOLING TOWERS
Parameter affecting cooling tower costs are (Ref. 20)
(1) Wet bulb temperature - WBT
(2) Approach (CWT-WBT) = A
(3) Range (HWT-CWT) = R
where :
CWT is cooled water temperature
HWT is hot water temperature °F
WBT is web bulb temperature
Example:
An industry is located on a stream having an average dry
weather flow of 1 cfm and a dry weather temperature averag-
ing 70°F. Industrial discharge totals 400 gpm at 110°F.
Local regulations limit temperature rise to 10 °F.
By dilution alone, allowable discharge temperature can be
computed by the relationship :
TM = Ti Qi + Ts Qs where
Qi + Qs
or,
Ti = Tm (Qi + Qs) - TsQs
so, allowable discharge temp.
Ti = 80(400 + 450) - 70 (450) = 91°
__ 400
and the cooling tower must lower the water temperature
from 110°F to 91°F, or a range of approximately 20°. From
local data (U.S. Weather Bureau) the average wet bulb
temperature is 70° giving an approach of approximately
20°
Entering Figure 35 @ range of 20° , approach of 20°, and
WBT of 70° - the relative rating factor of .8.
Using a cost factor of $10.00 per gpm (Ref. 20 + cost
index increase)
The capital cost in 1000 x 400 gpm x .8 = $3,200
(20) Cootner, P. H., Lof, Go. O., "Water Demand for Stream
Electric Generation," John Hopkins Press, Baltimore,
Maryland, 1965, p. 69.
455
-------
3.0
2.0
0.9,
0.7-
APPROACH
VALUES
FIG-35
RELATIVE RATING FACTORS
vs
WET BULB TEMPERATURES
RANGE-
0.6
0.5
10*
15'
QL
O
O
3.0
2.0
0.9
1.0
5°F
0.8
-------
Operating Cost
Cooling tower operating costs
Losses = 0.00112 R
Chemical = .033 Y + 17
C
Acquisition = Wa
Power = (0.14K + 0.005A)p
where:
R = range, °F
Y = alkalinity, ppm CaCO3
C = concentration factor
Wa = cost of water/1000 gal.
K = Relative factor
P = Power costs in C/KWH
A = pumping head in
Total operating costs - (C/1000 gal)
when C=l, assuming Wa=10<:/1000 gal, power @ 1C/KWH and
allowing 0.5 KWH consumption for lifting 1000 gallon
100 feet (approximatey 85% efficiency).
Operating Cost = 0.00112 R (.033 Y + 17) + 10 + (.14K +
.005A)
Example using graph in Figure 36:
Cooling tower operating under @ 20° range with a rela-
tive rating factor of 1.0, alkalinity of 1000, and
assuming 100 foot operating head, cost/1000 gal= 2
-------
00
CD
O
O
O
cfl
H
cn
o
o
(£
UJ
Q.
O
COOLING TOWERS
0.0
0.5
1.0 1.5 2.0 2.5
RELATIVE RATING FACTOR, K
-------
APPENDIX F
BIBLIOGRAPHY
459
-------
BIBLIOGRAPHY
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460
-------
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-------
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463
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48. Dorsey, J. J., Jr. and Kaufman, J. T., "Stengel
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464
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Volume 6 - Cost File 85- 96 Jan., '64 - Dec., '64
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467
* U. S. GOVERNMENT PRINTING OFFICE , 1970 O - 384-098
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