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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

-------
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

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    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

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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

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                   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.

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                       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

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                                    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.)

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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

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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

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                      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

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                                            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

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                      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

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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

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                                         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

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                                    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

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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

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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

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                     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

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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

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                     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
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• -SURVEYED PRODUCTION
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-------
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-------
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             10      20     30      40

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                                    ($  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
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           o
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             50,000
              10,000
              5,000
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                                        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

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ime V
lakes
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Flocculation ,
ng 1
/Clarifier\ 1

1 VThlckener I '
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/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

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                      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

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                      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

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                   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

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                                           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

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                                          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

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                       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

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                      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

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                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
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                        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

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                       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

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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

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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

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                      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.
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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:
                         78

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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
                         80

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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
                         81

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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.
                         82

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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.
                          84

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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.
                       85

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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).
                       86

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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
                    87

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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
                          88

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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.
                    89

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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:
                         90

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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.
                         91

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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.
                    92

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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-
                          93

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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
                          94

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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
                          95

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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

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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

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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

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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

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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

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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

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                           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

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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

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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.
                             121

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                  APPENDIX A








INDUSTRIAL WASTE TREATMENT PRACTICES DATA FORM








                  Instructions



                  Dictionary



                  Form
                      122

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            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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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                          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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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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

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            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

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        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

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    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

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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

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      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

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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

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         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

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         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

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         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

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         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

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         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

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         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

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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

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               APPENDIX B
INORGANIC CHEMICAL INDUSTRY SURVEY DATA
                     176

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                                            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

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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

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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

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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

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       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

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                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

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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

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                   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

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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

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     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

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     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

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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

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           PHOSPHORIC  ACID PLANT  LOCATIONS

                        FIGURE  7
FURNACE PHOSPHORIC ACID
WET PROCESS  PHOSPHORIC ACID
NEW WET  PROCESS  PHOSPHORIC  ACID PLANT

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        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

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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

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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

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     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

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     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

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     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

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     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

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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

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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

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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

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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

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           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

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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

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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

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        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

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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

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                   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

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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

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     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

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    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

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                    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

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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

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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

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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

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    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

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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

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 APPENDIX F
BIBLIOGRAPHY
        459

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                      BIBLIOGRAPHY
 1.   Lawson,  Barry L.,  "Atlas of Industrial Water Use,"
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                            460

-------
                  BIBLIOGRAPHY (cont.)


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                             461

-------
                BIBLIOGRAPHY  (cont.)
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                             462

-------
                 BIBLIOGRAPHY (cont.)
37.  Rogers, W. R. and Muller, K., "Hydrofluoric Acid
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38.  "A Giant Goes into Action," Chemical Week, Vol. 103,
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39.  "Sodium Proves Cheap Key to Unlock Titanium,"
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41.  Sandors, Howard J., Gardiner, William C., and Wood,
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                             463

-------
                 BIBLIOGRAPHY (cont.)
48.  Dorsey, J. J., Jr. and Kaufman, J. T., "Stengel
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55.  Wilson, Frank W.,  "Handling the Industrial Waste Prob-
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                             464

-------
                 BIBLIOGRAPHY (cont.)
58.  Young, D. C. and Scott, C. B., "Wet-Process Poly-
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                             465

-------
                 BIBLIOGRAPHY  (cont.)
68.  Partante, Robert, "A Guide to Treatment Costs,"
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77.  Jenkins, George F.,  "Process Wastes from Chemicals
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                             466

-------
                  BIBLIOGRAPHY (cont.)
78.  Bosworth,  D. A.,  "Installed Costs of Outside Piping,"
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                              467
                                      * U. S. GOVERNMENT PRINTING OFFICE , 1970 O - 384-098

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