POLLUTION PREVENTION IN PUBLICLY
OWNED TREATMENT WORKS
PROCEEDINGS FROM STATE/POTW
GRANT RECIPIENTS WORKSHOP IN
RALEIGH , N.C.
FEBRUARY 6, 7,1992
PREPARED BY
POLLUTION PREVENTION DIVISION
OFFICE OF POLLUTION PREVENTION AND TOXICS
U.S. ENVIRONMENTAL PROTECTION AGENCY
FEBRUARY 1992
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Forward
The Environmental Protection Agency awarded grants to five states
in FY 91 to develop and implement pilot projects which will demonstrate
how publicly owned treatment works at the municipal and state level can
integrate pollution prevention into their programs. Grants were
awarded to Utah, New Mexico, Minnesota, Massachusetts, and North
Carolina.
In order to provide information on current activities in this area and
to establish a pilot project network, a workshop was held on February 6
and 7,1992 in Raleigh, North Carolina. Invited to participate in the
workshop were the five state grant recipients, the municipalities
participating in the project, EPA Regional staff from MWPP , pre-
treatment and pollution prevention programs and headquarters staff from
the Office of Water and the Office of Pollution Prevention and Toxics.
A total of 35 people attended the workshop.
This report summarizes the two-day workshop and identifies some
of the major issues brought out by the participants.
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PARTiaPANTS
POTW's
Florence Reynolds, Salt Lake City, UT
Bob Hogrefe, City of Albuquerque, NM
Debbie LaVergne, Millbury, MA
Michael Downey, Springfield, MA
Crystal Couch, Winston-Salem, NC
Navneet Tiku, St. Paul, MN
State Representatives
Mary Deloretto, Dept of Environmental Quality, UT
Paul Richard, Office of Technical Assistance, MA
Kevin McDonald, Office of Waste Management, MN
Trevor Clements, Dept of Environment, Health and Natural Resources, NC
Stephanie Richardson, Dept of Environment, Health and Natural Resources, NC
Julia Storm, Dept of Environment, Health and Natural Resources, NC
Lindsay Mize, Dept of Environment, Health and Natural Resources, NC
Mahin Talebi, Orange County, CA
Vic Young, Waste Reduction Resource Center
EPA Regions
Joseph Canzano, Region I
Alicia Suarez, Region II
Ben Chen, Region IV
Pete Smith, Region V
Harold Thompson, Region VIII
EPA Headquarters
Deborah Hanlon, Pollution Prevention Division
Lena Hann, Pollution Prevention Division
Valerie Martin, Office of Water
Mary Settle, Office of Water
Wendy Bell, office of Water
Walter Brodtman, Office of Water
(Phone Numbers and Addresses in Appendix b)
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POLLUTION PREVENTION IN PUBLICLY OWNED
TREATMENT WORKS
Workshop Proceedings
CONTENTS
Section I
Section II
Section III
Section IV
Section V
Section VI
Introduction
Project Issues
Future Funding Opportunities
Measuring Progress and Results
Obstacles/Incentives
Publicizing Programs
Resources Required To Implement Programs
POTW's Resource Needs
States
EPA Regions
EPA Headquarters
Five State Pilot Project Descriptions
Utah
New Mexico
Minnesota
Massachusetts
North Carolina
POTW Programs
Orange County
Appendices
a. Meeting Agenda
b. List of Attendees
c. Wastewater Pollution PreventionCase Studies
from the Pollution Prevention Information
Clearinghouse
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Section 1 Introduction
Background
EPA, states and municipalities have made significant progress over the last 20
years in improving the quality of the environment through the implementation of
the Clean Water Act requirements. Billions of dollars have been spent in the
nation's wastewater treatment infrastructure resulting in substantial improvements
in water quality.
Today however, we are faced with new challenges in the areas of municipal
growth, newly regulated pollutants and more stringent effluent limits. These
challenges, we believe, must be addressed by placing an emphasis on pollution
prevention rather than on the treatment and control of wastewaters or on the
expansion of the POTW.
As the federal government's role in funding municipal wastewater treatment
ends, there is both the need and the opportunity to adopt pollution prevention
measures to meet the expanding demands and to prepare for new federal and state
requirements. Therefore, a primary focus of EPA's program is to encourage and
support states and municipalities in developing pollution prevention programs.
To this end, the Office of Pollution Prevention and Toxics and the Office of
Water have initiated a pilot pollution prevention grant program for publicly owned
treatment works. Five states were awarded grants up to $100K, to demonstrate how
pollution prevention could be promoted through pre-tr-eatment programs and
MWPP.
Purpose and Description of Workshop
On February 6 and 7, 1992 the Pollution Prevention Division in conjunction
with the State of North Carolina conducted a workshop for the participants in the
program. Attendees included the five state grant recipients, one or more of the
states' POTW's, EPA MWPP regional coordinators and headquarters Office of Water
and Pollution Prevention Division staff.
The purpose of the workshop was to develop a" network of individuals
interested in promoting pollution'prevention in POTW's and to share information
on progress, obstacles, and resource needs. Agenda topics included discussions on
future program funding opportunities, measuring progress, publicizing programs
and identifying obstacles and solutions. Participants also identified resource needs
from the local, state and EPA Regional perspectives.
This report has been developed to provide a communication link between all
interested parties and to assist in the dissemination of current information and
activities regarding pollution prevention in Publicly Owned Treatment Works.
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Section II Pilot Program Issues
Recognizing the need to identify and explore new methods for achieving
prevention in local pre-treatment and MWPP programs, four issues were addressed
in brainstorming sessions during this workshop. This section describes the
suggestions and outcome of these group sessions.
Issue 1. Future Funding Opportunities
The state's pilot projects are the result of Federal Assistance Grants, however
states are encouraged to begin to explore opportunities for continued funding of the
pollution prevention programs. The alternative financing mechanisms that were
identified by the participants include the following:
1. User and pollution discharge fees
2. Penalty fines
3. Environmental taxes
4. Bonds, lotteries and state development funds
5. Clean Water Act Funds 205-j, 106
6. Trade Associations
7. Industry sponsors
8. Environmental groups and foundations
9. Revolving Loan funds
For analysis of various funding opportunities for environmental programs,
readers are directed to obtain a copy of the National Governors Association Report
Funding Environmental Programs: An Examination of the Alternatives, published
by the NGA, 1989. Washington DC.
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Issue 2. Measuring Progress and Results
Measuring progress and results of the pollution prevention effort must be
considered in the design of the Pollution Prevention pilot project. Numerically
measuring progress can be achieved through the following activities:
1. Baseline sampling and defining critical parameters.
Sampling must be done at the facility (IU), at the influent and effluent point at the
POTW. Samples should measure quantity in pounds and in quality, constituents.
2. TRI Pollution Prevention and Release data
3. Economic front end loading
4. Hydraulic and organic loading. Measure with city water bills and quantify plant
life extensions.
5. Industry retention
6. Fines, violations.
7. Identify how the violator gets into compliance; source reduction, treatment etc.
8. Data comparison where is it going.
9. Disclosure of sewered hazardous waste.
10. Tech transfer of successful methodologies
11. Reduction of end-of-pipe treatment and control capitol expenditures
12. Reduction of sludge generated at POTW
13. Reduction in wastewater generated per unit product.
14. Energy costs at POTW are reduced.
Issue 3. Obstacles/Solutions/Incentives
Traditionally, owners and operators of POTW's as well as state and federal
regulators have placed an emphasis on pollution control rather than on
conservation and prevention. POTW's have had pre-treatment programs,
including sampling efforts, inspection and enforcement programs , MWPP, sludge
management programs and various water conservation efforts.
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Today there is greater concern on developing a complementary environmental
protection strategy based on conservation of natural resources and on preventing
pollution at the source. This strategy represents not only a major shift in the way a
company will do business, but also poses substantial challenges for governments.
Some of the major obstacles facing POTW's in the adoption of pollution prevention
programs as identified by the participants in the meeting include the following:
1. Lack of information and data on technologies that work
2. Concentration based effluent limits
3. Lack of money and training
4. Inplace equipment produces barriers to innovation
5. Financial disincentives for IU
6. Commercial products that are counterproductive
7. Reduced income to POTW
8. No directive (mandate) from EPA to develop program
9. Existing city codes and ordinances inhibit p2
10. Conflicting regulations
Solutions and incentives for POTW's to adopt Pollution Prevention Programs
include such things as:
1. Provide education and training to industry, government etc.
2. Good technical information and case studies
3. EPA assistance and incentives throughout all programs, audits etc.
4. Develop mass based effluent limits
5. Rewrite EPA H20 Guidelines incorporating P2
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Issue 4. Publicizing Programs
Publicizing programs and the results of pollution prevention efforts are
important to obtain necessary political and public support. Suggestions
from the participants of this workshop for publicizing programs include:
1. Workshops and conferences in the community
2. Mass mailings, H20 Bills etc.
3. Newsletters, papers, radio, TV
4. Working with legislators and:
a. Economic development agencies
b. AMSA
c. League of Municipalities
d. lobbyists
e. League of Woman Voters
f. WEF
5. Utilize Public Affairs Offices
6. Attention to legislators' industries
7. Tours/outreach programs
8. Invite public to meetings and hearings
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Section III Resources Required To Implement
Programs
Aside from receiving Federal dollars to implement their programs, POTW's,
States,EPA Regions and Headquarters all have other significant resource needs vital
to the development and implementation of their projects. Though some of these
resource needs are shared commonly among the groups, their are certain resources
that are specific to the individually target audiences.
Representatives from the POTW municipalities and POTW's listed their
resource needs to implement the pollution prevention program. POTW
resource needs include:
1. Information exchange network (ask EPA to provide mini-exchange in PIES).
2. Specific pollution prevention information on industries.
3. Pollution prevention training.
4. Examples of local government ordinances (mass based effluent guidelines).
5. Management support.
6. Outreach component.
7. Support from industry and community for the program.
8. Trade associations support.
9. Help in providing new funding sources if discharge fees are reduced as a
result of implementing a pollution prevention option.
EPA is exploring the possibility of developing a mini-exchange for POTW's on its
Pollution Prevention Informative Clearinghouse.
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States
The 5 States were asked to list their resource needs. The following items were
discussed:
1. Clear directive from EPA to allow for the incorporation of pollution
prevention into media specific grant programs, permit and enforcement
programs.
2. Ability to use funds from Clean Water Act; Section 106, 104, for pollution
prevention programs.
3. Provide Best Management Practice guidelines and NPDES language to
promote pollution prevention
4. Create options other than just Enforcement
5. Develop a source reduction compliance schedule
6. Need flexibility from EPA to do pollution prevention in the regulations
7. Significant non-compliance (SNU) regulations are barriers. Need to let
the State and Locals have flexibility on what and who to report publicly thus
encouraging visits and technical assistance to industry.
8. Less focus on bean counting and more focus on the non-regulatory,
educational and technical assistance efforts.
9. Training to integrate pollution prevention into specific program
sectors (pretreatment inspection and operating training).
10. flexibility in determining when to do sampling.
11. Empower the pretreatment inspectors to be able provide pollution
prevention information through an Office of Water Inspector policy.
12. Put pollution prevention into permits. Industry should be required to have
an assessment done.
13. Develop methodologies to measure progress.
14. Need EPA guidance to emphasize and integrate pollution prevention
coordinators in each program office.
15. Need to incorporate pollution prevention into new guidance manuals for
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municipalities;
pollution compliance inspection
audits
EPA
EPA Regional and Headquarters needs were identified by the participants. The
following items were listed:
1. Equivalent of bean credit for pollution prevention in enforcement
settlements.
2. Pollution prevention incorporated into penalty policies.
3. Pollution prevention needs to be addressed not only as cross-media, but
cross-agency.
4. Resource database (outreach and training on the Pollution Prevention
Information Clearinghouse).
5. Communication channel dedicated to pollution prevention in POTW's.
6. EPA needs to provide training for its consultants, contractors and operation
specialists.
7. Evaluate the financial repercussions on POTW's from industries
practicing pollution prevention.
8. Have POTW's involved in the development of guidances.
9. EPA needs to establish a system to provide for better internal
communication.
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Section IV
Pollution Prevention in Publicly Owned
Treatment Works: Project Descriptions
1. Utah and Salt Lake City
2. New Mexico and Albuquerque
3. Minnesota and St. Paul/Minneapolis
4. Massachusetts Critical Mass Project
5. North Carolina Program
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Pollution Prevention in Publicly
Owned Treatment Works
Grant Summaries
Five States were awarded Pollution Prevention in POTW Grants in FY 91 by
EPA's Office of Pollution Prevention. The purpose of these grants are to
demonstrate how a municipal POTW ,through its pretreatment program and its
facility operations can promote source reduction activities in industrial and
business dischargers. Activities funded under this grant will include such things
as conducting energy audits of specific POTW's, providing education and
technical assistance to industrial dischargers and establishing water conservation
programs in the community. The demonstrations will result in the development
of a national pollution prevention in POTW's program plan The projects will be
discussed at the 92 National pretreatment conference. The States reveiving the
grants include the following:
1. State of North Carolina, Department of Environment, Health, and
Natural Resources.
Contact: Trevor Clements 919 733-5083
Linda Roderick 919 733-7015
Goal: To Incorporate Pollution Prevention in Pretreatment Program Statewide
Activities will include the following:
1. Create a state level program structure to enhance coordination and
communication between the States Pollution Prevention Pays Program and the
states pretreatment program.
2. Establish pollution prevention technical assistance programs at a large and
small POTW and set up challenge grants for additional programs.
3. Identify specified pollution prevention solutions for targeted POTW problems.
4. Provide Education and training for POTW staff and industrial
dischargers.
2. Utah Department of Environmental Quality
Contact: Mary De Loretto 801 538-6146
Florence Perez 801 799-4040
Goal: Incorporate Pollution Prevention in State MWPP Program and in the City
of Salt Lake City POTW.
Activities will include the following:
1. Expand MWPP to incorporate water conservation and pollution prevention
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technical assistance to industry to extend life of POTW.
2. Target metal platers and other high health and ecological risk areas through
pretreatment program.
3. Establish strict mass based local limits for SLC POTW
4. Target solvents for reduction and initiate awards programs
3. Minnesota Office of Waste Management
Contact Kevin McDonald 612 640-5744
Goal: Develop a pollution prevention program at the Metropolitin Waste Control
Commission.
Activites that will be conducted with this grant include:
1. Integrate PP into all state POTW's using Minneapolis as a demonstration
project and model.
2. Target specific industrial dischargers and pollutants
3. Develop training and conduct workshops for POTW's and industry.
4. Massachusetts Office of Technical Assistance
Paul Richards 617 727-3260
Critical Parameters Pollution Prevention in POTW's Project
Goal: To assist POTW's statewide in utilizing pollution prevention opportunities
to address problems which relate to critical parameters for operations of POTW's
Activites include
1. Conducting surveys of POTW's approaching critical parameters and establish
baseline measurements
2. Use pollution prevention approaches to reduce loadings
3. Demonstrate how pollution prevention approach can address problems faced
by POTW's.
5. New Mexico Environment Department
Sante Fe, NM Contact: Alex Puglisi 505 827-2799
Project Description: This project will demonstrate source reduction in the City of
Albequerque's POTW. The project will include educational and techncial
assistance to industrial dischargers and will identify and target specific
contaminants of concern.
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POLLUTION PREVENTION THROUGH
POTWS
Utah Division of Water Quality
Mary DeLoretto, Pretreatment Coordinator
Salt Lake City Corporation
Florence Reynolds, Water Quality Administrator
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Achieve PP/WM from POTW Users by
conducting wastewater assessments
promoting water conservation
conducting waste minimization
assessments
- establishing stringent mass and
technology based local limits
- providing information, education
and technical assistance
- targeting metal finishers
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PROJECT TRANSFERABILITY
Moderate sized metropolitan city
Semi-arid/rapid growth area
No pollution prevention legislation
Pilot and transfer results to many
similar cities/states
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ACTIVITIES
Education Initiative
Expand Chemical Clearinghouse
Metal Finishers Initiative
IU Awards System Expansion
City Owned Facilities Waste
Minimization Initiative
Project Result Dissemination Initiative
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MEASURES
Overall reduction in multi-media
discharges of pollutants
-(Requires establishing a baseline)
Establishment of POTW PP capacity
within DWQ and SLC
-(Testing knowledge before and
after education initiatives)
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EDUCATION INITIATIVE
Pollution Prevention Specialist
DWQ/SLC Staff Workshop
Metal Finishers Workshop
General Industrial/Commercial
Workshop
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PROJECT RESULT DISSEMINATION
INITIATIVE
Annual Regional Pretreatment
Coordinators Meeting
Annual Utah WPCA Conference
Metal Finishers Association
State Water Pollution Publications
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SCHEDULE
Sep 91 - Initiate project
Nov 91 - Initiate development of City-Owned facilities
waste minimization plan
Dec 91 - Prepare Request-for-Proposal and solicit
pollution prevention specialists
Jan 92 - Establish criteria for IU pollution prevention
awards
Feb 92 - Establish criteria for baseline for pollution
reduction; Hire pollution prevention specialist
contractor
Apr 92 - Hold DWQ/SLC staff training workshop; Test
knowledge before and after to assess pollution
prevention awareness
May 92 - Initiate pollution prevention assessments at
industrial facilities, to be ongoing from then
on
Jul 92 - Conduct industrial pollution prevention
workshop, targeting metal finishers and
electroplaters; Test knowledge before and
after to assess PP awareness
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Aug 92 - Implement chemical clearinghouse expansion
Sep 92 - Conduct industrial pollution prevention
workshop for the general industrial and
commercial community; Test knowledge
before and after
Get 92 - Initiate analyses to determine program success
Jan 92 - Prepare final report on program success
Apr 93 - Disseminate report information; Present
findings at annual UWPCA meeting
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CITY WASTE MINIMIZATION PROGRAM
SOLVENT RECOVERY Current usage minimized
PROGRAM ALTERATION
With the cooperation of the new administration and all city
departments identification of the major concerns, and
development of a waste minimization plan.
INITIATION
Documentation of current usage of all materials that may be
environmentally damaging. Development of alternate materials
and practices.
POTENTIAL OBJECTIVES
Road Salting Procedures and Salt Storage
Airport Deicing Procedures
Heavy Duty Equipment Maintenance Procedures
Fire Department Training Practices
Paint and Paint Cleanup Procedures
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WASTE MINIMIZATION PROGRAM
INDUSTRIAL AWARD PROGRAM
Eligibility: all permitted industry
Criter ia; 95 % of all tests in compliance
submission of all required reports
spill prevention and control plan
effort and cooperation
employee training
environmental concern
1989 7 award recipients
1990 6 award recipients (1 new)
1991 5 award recipients (all new)
WASTE MINIMIZATION PROGRAM
Eligibility: all firms within the city, with or without waste flow
Criteria: Introduction of a policy or program which minimizes
the use or disposal of waste materials.
demonstrable
practical
applicable to other firms in some way
Initial awards will be made in 1992.
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NEW MEXICO WATER POLLUTION PREVENTION PROPOSAL
Background
The New Mexico Environment Department (NMED) has already initiated
a number of water pollution prevention efforts in conjunction with
Region 6 of the U.S. Environmental Protection Agency (EPA).
Current efforts are oriented toward the framework of a pilot
program, IMPAC, developed and implemented in 1989 and 1990. IMPAC
(Improving Municipal Performance by Addressing Capacity) is a
compliance maintenance program with a focus on the ability or
publicly owned treatment works (POTWs) to meet the provisions of
the federal Clean Water Act. It is designed to assist
municipalities identify and address those performance limiting
factors which have been found to adversely impact the ability of
POTWs to effectively treat municipal wastewater and produce
compliant effluent..
The NMED is proposing to utilize $100,000.00 in federal assistance
during FY 91 to expand the scope of New Mexico's Water Pollution
prevention program to include activities which encourage waste
minimization and source reduction. A recent report prepared for
the NMED on hazardous waste minimization program planning indicated
that there is a significant potential for hazardous waste reduction
in several of the major industrial categories present in New
Mexico. Several industries surveyed had already undertaken
important preliminary steps in the waste minimization process. The
NMED hopes to encourage and foster continued efforts by industry in
this arena.
The NMED initiative will focus on implementing waste minimization
and source reduction strategies at the local level. In order to
accomplish this, the Department will work closely with the City of
Albuquerque's Industrial Pretreatment Program in establishing a
pilot program to encourage waste minimization at permitted
industries. The City of Albuquerque is the largest municipality in
New Mexico's in terms of both population and industrial base.
Twenty-nine of the state's fifty largest industries are either
located in Albuquerque or utilize the city's sewer system for the
disposal of their effluent. Therefore, any program targeted at New
Mexico's industrial base will have its most widespread impact in
Albuquerque. Additionally, the city has a widely recognized
industrial pretreatment program and well established contacts with
local industry.
Description
The Albuquerque Industrial Pretreatment Program already
successfully regulates the introduction of many toxic contaminants
into the city's POTW's by mandating the pretreatment of potentially
hazardous pollutants. However, most industrial pretreatment
systems transfer a portion of wastewater pollutants to other
environmental media while lowering the concentration of toxic
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constituents in the waste stream that enters the sewer. Toxic
pollutants still go to the sewer, albeit in lower amounts, and to
other environmental media such as the air or toxic waste landfills.
Often, there is no real net reduction in the amount of toxic
pollutants discharged to the environment. Additionally, new state
water quality standards and federal requirements have imposed new
regulatory and financial pressures on POTW s , such as Albuquerque,
in meeting more stringent discharge requirements on both the
effluent discharged from their treatment facilities and the sludge
produced at those facilities. Since Albuquerque is implementing
mechanisms to compost and distribute their wastewater sludge, the
presence of toxic contaminants in this media is also of increasing
concern to city officials.
The continued fast paced and constant growth which confronts
Albuquerque presently and in the coming decades, makes hazardous
waste minimization and source reduction the most viable and
economical way for the city to respond to potential new hazardous
pollutant loads placed on its POTW. The implementation of a waste
minimization program will assist Albuquerque in meeting the toxic
effluent discharge limitations of its National Pollutant Discharge
Elimination System permit while allowing continued industrial
growth within the city. It will also assist the city in producing
an environmentally safe sludge which can be distributed for
beneficial use. Overall, the possible positive impacts to the
environment are significant.
enient at ion
The majority ($70,000) of the requested $100,000 federal grant will
be transferred to the City of Albuquerque through a Memorandum of
Understanding (MOU) for the implementation of a hazardous waste
minimization program. This transfer of funds has been selected for
several reasons:
1) waste minimization programs aimed at industrial
wastewater discharges have been found to be highly
effective when implemented at the local level;
2) Albuquerque has a well established Industrial
Pretreatment program which provides an effective
framework for the establishment and implementation of a
waste minimization program;
3) personnel in the Albuquerque Industrial Pretreatment
Program are aware of the needs and waste disposal
problems of local industry;
4) the city is already implementing measures to identify and
eliminate "problem" toxic waste discharges; and
5 ) the city has several resources at its disposal which can
be utilized to match and support any waste minimization
efforts .
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The city will utilize the federal funds to hire the personnel and
furnish any resources necessary to work with local industry in
exploring and implementing measures which will reduce the amounts
of hazardous or toxic discharges to the Albuquerque POTW. This
personnel will be hired directly by the City or indirectly through
contracts with consultant firms specializing in waste minimization
techniques. The City of Albuquerque will furnish a number of in-
kind services to match the amount of the federal grant. These
services may include but are not limited to services such as:
1. the monitoring of industries known or suspected to
discharge toxic or hazardous constituents to the city's
POTW;
2. enforcement actions taken, or surcharges implemented, to
induce industries to reduce the amounts of toxic or
hazardous wastes they discharge into the POTW;
3. technical advice or assistance provided to industry on
matters relating to the pretreatment, minimization, or
elimination of toxic waste discharges;
4. activities involved in identifying and eliminating
toxicity in the wastewater received by the Albuquerque
POTW such as Toxicity Reduction Evaluations;
5. laboratory analyses performed to identify or quantify the
concentrations of toxic or hazardous constituents in
industrial wastewater discharges; and
6. the purchase of equipment necessary to perform the above
listed tasks.
The waste minimization program implemented through the Albuquerque
Industrial Pretreatment Program will be structured to achieve the
following objectives:
Educational Outreach which will provide hazardous waste
minimization information to industry;
Technical Assistance to help companies identify and
evaluate site-specific opportunities for hazardous waste
minimization;
Identification and Targeting of specific discharges for
waste reduction in accordance with their potential impact
on the ability of the Albuquerque POTW to produce a
compliant effluent and safe sludge; and
Consideration of Regulatory Alternatives which establish
indirect inducements or direct requirements to promote
waste minimization (i.e., mass balance discharge limits,
more stringent local limits, etc...)
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MINNESOTA PROPOSAL
MINNESOTA
OFFICE
OF WASTE
MANAGEMENT
Metropolitan
Waste Control
Commission
Pollution Prevention in
Publicly-Owned Treatment
Works Grant Program
July 26, 1991
POLLUTION PREVENTION
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I. EXECUTIVE SUMMARY
The Minnesota Office of Waste Management (OWM) and the
Metropolitan Waste Control Commission (MWCC) propose to develop
and implement a pollution prevention program at the MWCC. The
program seeks reductions, through pollution prevention, of
pollutants and wastewaters discharged to MWCC's wastewater
treatment system. Additionally, OWM and MWCC intend to
disseminate project experiences to other publicly-owned treatment
works (POTWs).
The MWCC is the largest POTW in Minnesota, with a staff of over
1,000. The MWCC serves 105 communities and approximately 750
industrial dischargers. The OWM is the lead agency for
implementing pollution prevention in Minnesota, with a staff of 5
in its Toxic Pollution Prevention Program. The OWM's Minnesota
Technical Assistance Program (MnTAP), with a staff of 15,
provides nonregulatory pollution prevention assistance to
Minnesota businesses and organizations. MnTAP will play a role
in providing training and delivering technical assistance to
industry under this proposed grant project.
Major proposed activities include establishing a multi-media
pollution prevention training program for POTW staff, providing
on-site technical assistance and referrals for industrial
dischargers, establishing a plan for integration of pollution
prevention into MWCC programs, measuring progress, coordinating
with other state programs, and soliciting industry and public
input.
Activities under this proposed two-year grant would start on
January 1, 1992 and extend through December 31, 1993. Training
workshops are planned for April 1992, August 1992, and March
1993. An internal MWCC pollution prevention staff committee
would be established in February 1992 and will meet monthly.
Quarterly meetings with other state pollution prevention programs
would be scheduled. Input from industry and the public would be
provided at monthly meetings.
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II. GOALS AMD OBJECTIVES
1. overall Goals
A. Establish Metropolitan Waste Control Commission (MWCC)
programs and activities to prevent pollution at its source of
generation.
B. Reduce, through pollution prevention methods and
technologies, pollutants and wastewaters discharged to the
wastewater treatment system.
C. Explore opportunities to realize the potential benefits of
multi-media pollution prevention activities, such as:
* Reducing the risks inherent in the management of waste
streams and residues that result from traditional control
methods;
* Avoiding the transfer or "shifting" of pollutants from one
environmental medium to another (e.g., water to air); and
> Addressing dispersed sources of contaminants.
2. Specific Objectives
A. Develop and begin implementation of a comprehensive plan to
integrate pollution prevention into MWCC programs and activities.
B. Train staff from MWCC and other Minnesota publicly-owned
treatment works (POTWs) to promote source reduction as a
preferred strategy, and to assist businesses in identifying and
implementing pollution prevention opportunities.
C. Coordinate pollution prevention activities at Minnesota POTWs
with other programs in the state.
D. Provide information and referrals for technical assistance to
businesses discharging wastewater and pollutants to the sewer
system.
E. Develop pollution prevention activities targeted at specific
dischargers and/or waste streams.
F. Using existing data sources, develop measures to determine
progress in pollution prevention.
G. Design pollution prevention actions with industry and public
input and solicit the involvement of these groups during program
delivery.
H. Encourage other Minnesota POTWs to initiate activities based
on MWCC's pollution prevention program.
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III. SPECIFIC ACTIVITIES AMD PROGRAM ELEMENTS
1. Provide multi-media pollution prevention training
A. Workshops
> WORKSHOP #1: Pollution prevention concepts,
background on pollution prevention efforts, future
directions, supplementing treatment and control with.
prevention, prevention activities in MN and in other
states, MN Toxic Pollution Prevention Act, Federal
Pollution Prevention Act, SARA Title III, Section 313
introduction to MNTAP and OWM
(Audience: MWCC pretreatment program staff, MWCC
staff committee members, other MN POTW staff, MPCA
industrial wastewater staff, representatives from
metro county hazardous waste programs).
» WORKSHOP #2: Integrating prevention into pretreatment
inspections and other POTW programs, identifying
pollution prevention opportunities, promoting the
prevention approach, coordinating with MnTAP assistance
activities, prevention success stories, industry
pollution prevention plans and annual progress reports
(Audience: same as Workshop #1)
* WORKSHOP #3: Roundtable/Forum with POTW staff and
industrial users on the topic of pollution prevention;
Forum designed to share ideas and experiences on
pollution prevention; items addressed in Workshops #1 &
#2 may also be covered
(Audience: participants from Workshops #1 & #2,
other POTW staff, and interested industrial users
of sewage treatment plant system)
B. MWCC will develop training materials for each workshop
C. Possible tours of successful industry pollution
prevention programs and outstate sewage treatment
authorities undergoing efforts to integrate pollution
prevention into programs
2. Provide on-site technical assistance and referrals
MWCC Pretreatment Program Staff will:
A. Promote pollution prevention and provide information to
industry based on skills developed in training
B. Identify opportunities to prevent pollution during
inspections
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C. Refer industry to MnTAP and other contacts for further
assistance
D. Promote the availability of MnTAP information
clearinghouse
3. Establish staff committee to integrate prevention into MWCC
programs
The Staff Committee will:
A. Recommend pollution prevention policy statement to MWCC
management and Board
B. Identify opportunities to integrate pollution prevention
into programs (e.g., inspections, rulewriting, policy
decisions, interpretation of existing regulations,
household hazardous waste and water conservation,
enforcement and agreements/settlements, fee structure)
C. Recommend a clearly defined MWCC pollution prevention
program
D. Develop implementation plan to establish program
E. Identify target industrial activities and facilities
(e.g., specific waste streams, processes, businesses that
lack information, problem cross-media transfers,
opportunities for multi-media coordination with other
media-specific programs)
F. Oversee grant project
G. Review/comment on semi-annual and final grant reports
4. Measure progress
A. Develop method for measuring progress
B. Analyze existing data sources: MWCC monthly discharge
reports, TRI, hazardous waste disclosures, and other
relevant databases to measure progress
C. Cross reference databases and perform other data quality
activities to identify discrepancies
D. Consider mail survey to solicit feedback and information
on needs
E. Document progress in semi-annual and final grant reports
5. Coordinate with other programs in state
MWCC will:
A. Meet quarterly to communicate with other pollution
prevention programs in Minnesota (OWM, MnTAP, MPCA, metro
counties, Emergency Response Commission)
B. Continue to participate on OWM's Pollution Prevention
Task Force
C. Participate at OWM's annual Pollution Prevention
Conference
D. Develop fact sheets and other materials for dissemination
to other POTWs
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Proposal of Massachusetts Office of Technical Assistance for Pollution Prevention in Publicly Owned
Treatment Works Grant.
Title: Critical Parameters Project
Summary
This proposal is to conduct a program to assist POTWs in Massachusetts in utilizing pollution prevention
techniques to address problems which relate to critical parameters for operation of the POTW. Critical
parameters are those measures for which loadings to the POTW are approaching or exceeding 35% capacity,
necessitating capital expenditures to enlarge the system; those environmental parameters which if exceeded can
have a substantial economic effect on the POTW, such as prohibiting the marketing or reuse of sludge; or those
parameters of design capacity which when exceeded could cause the POTW to be in violation of its own National
Pollution Discharge Elimination System permit.
The Office of Technical Assistance (OTA) would conduct a survey of POTWs affected by loadings approaching
critical parameters and fund environmental evaluations to establish baseline measurements. OTA would then
draw upon in-state, national or international sources to supply pollution prevention technical assistance to address
the identified problems at these POTWs and conduct trials of innovative approaches to reducing loadings,
working with POTW and state environmental officials. Such work would include integration of compliance in
all media, promotion of water conservation in addition to source reduction of pollutants, and pilots of changes
in regulatory procedures. The effort would also address contributions to loadings from non industry sources as
well, for example; households, nonpoint sources, and agriculture.
OTA would then fund environmental evaluations of loadings to compare to the baselines set earlier. OTA would
also set aside money tc be awarded in the second year of the project to a select number of POTWs to continue
work begun as part of the critical parameters project, to ensure the continuation of the pollution prevention
effort at those POTWs which demonstrate commitment, understanding, and progress in the use of pollution
prevention principals and techniques. OTA would act to facilitate coordination by POTWs, local, state and
federal officials, and community and industry groups.
At the end of the first year, OTA would create a series of case studies documenting the work done with POTWs
to demonstrate what can be achieved by the application of pollution principles to problems POTWs face. As
a condition of the award of funds for special projects in the second year, documentation of work would be
required, resulting in additional case studies by the POTWs themselves, reviewed by OTA. OTA would also
create videotape documentation of each case.
Background
The Massachusetts Office of Safe Waste Management (OSWM, which was renamed the Office of Technical
Assistance in 1990) began working with POTW pretreatment programs in 1989 as part of its Small Quantity
Generator program. Several POTWs joined the office in holding a series of workshops designed to promote
source reduction and good management of hazardous wastes by pollution sources not usually visited by any
POTW enforcement officer (e.g.; schools, printers, typesetters, medical facilities). As a result of this program
OTA's project manager was made an honorary member of a newly created organization, the Massachusetts
Pretreatment Forum (MPF), which is a self-help group of pretreatment officers. OTA has continued working
with POTWs, organizing with POTWS three annual fora on silver recovery techniques, and has conducted a
series of talks to MPF members on recognizing pollution prevention opportunities when inspecting facilities.
OTA also conducted a program in conjunction with the state's environmental enforcement agency, the
Department of Environmental Protection,^ bring source reduction practices to the Worcester region, to try out
multi-media inspections, and to forge cooperative efforts between OTA's technical assistance program and the
enforcement program. This program, the Central Mass Pollution Prevention Project, funded by an EPA grant
and commonly known as the Blackstone Project, has demonstrated not just the success of a multi-media
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POTWs. He has also been a visible advocate for pollution prevention at the MPF, and has been a member of
the state's Toxics Use Reduction Advisory Board. He would be eminently suitable to oversee the critical
parameters program, with the assistance of Rick Reibstein. Rick was the originator of the Office of Safe Waste's
POTW program, and has worked with MPF members for over two years. He is an attorney and has been doing
source reduction and toxics use reduction counseling for over three years. With Nikki Roy and Lee Dane,
formerly of DEP and OSWM, he developed the original idea for the Blackstone Project.
Paul is currently assigned to expanding OTA's work to the Western region of the state, where very little has been
done to date. Rick is currently overseeing the Merrimack Project, which will be located in the northeastern part
of the state. OTA members Rich Bizzozero and Mitch Kennedy are assigned to the Southeast region, and Joe
Paluzzi is continuing the Central Mass Pollution Prevention project described above.
The critical parameters project money would be used to hire an assistant to Paul Richard, who could work in
any region where necessary, coordinating with the other programs. This person would also be detailed to work
for periods of time at specific POTWs once a POTW has committed to work on an identified project. Some
money would be used either to fund environmental sampling by POTWs or to hire certified analysts to do the
sampling and lab work. Other money would be used to pay for technical assistance projects. Such money could
be used, for example, to rent wet vacuum machines to demonstrate to a food processor an alternative to simply
washing down floors, (t could also be used to fly in experts from other states or countries, or to visit such sites
where innovative approaches are being applied. It might be used to generate informational materials or fund
a conference or public event to educate pollution dischargers. The exact budget for the expenditure of the non-
personnel funds will depend on the results of the evaluation of critical parameters and the research to discover
appropriate techniques to address critical problems has been accomplished. The following spending plan,
therefore, sets aside a certain amount of funding for as yet undetermined specific items.
In the second year, OTA will announce that $12,000 is available in a competitive award for those POTWs that
wish to conduct special projects that utilize pollution prevention principles or techniques to address problems
concerning critical parameters.
Sept. 1991 - Sept 1992
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Critical Parameters Project Outline: Warren, Massachusetts
BACKGROUND: Warren, a rural community of 4,500, is located in the central region of Massachusetts. The
major industrial discharger (user) to the POTW is a textile company.
The wastewater treatment plant servicing the town became operational on September 16, 1989. The cost
of construction for the plant was ten million dollars. Construction was 75% federally funded and a 15% state
match with the town funded the remaining 10%. Yearly operational and maintenance costs are 5250,000. A
three member Board of Commissioners administers the operation of the plant. Staffing consists of three full-
time operators. The treatment plant consists of both primary and secondary treatment. Secondary treatment
is achieved by rotating biological contactors. Design flow for the plant is 1.5 MGD with an average flow of .55
MOD.
The plant discharges into the Quaboag River, a class B Massachusetts river. N.P.D.E.S. limitations
established for the plant are for conventional pollutants such as B.O.D., suspended solids, chlorine and fecal
coliform. Additional requirements are quarterly testing for both acute and chronic toxicity. The last two
analyses for toxicity failed to meet minimum survival rates. Continued failure to meet survival rates will result
in the mandatory requirement that the plant perform a Toxic Reduction Evaluation (TRE). The estimated cost
for this evaluation is 570,000 based on preliminary work ddne by the town's consulting engineer. Once the TRE
source is identified, the town would be required to reduce the toxicity through many options. The most common
are implementing a pretreatment program or imposing limits directly against an industrial user. For the user
this usually means adding end of pipe treatment to meet the new limits.
The environmental and economic needs facing Warren are typical of many small Massachusetts towns.
The results from this study should prove that both needs can be met without extensive end of pipe treatment and
heavy costs being placed on either the rate payers or the industrial user.
PROJECT GOALS: Reduce the toxicity of the final effluent through pollution prevention practices at the major
industrial user. Pollution prevention practices include source reduction, on-line recycling, chemical substitutions,
improved housekeeping and maintenance practices. Implementation of these practices will be accomplished by
voluntary participation from the Office of Technical Assistance (O.TA.), the Local Board of Sewer
Commissioners-POTW plant operator, and the major industrial user. The results of these efforts will be
evaluated from a sampling program established at the POTW,
PROJECT WORK:
1. O.TA. will gain voluntary support from the town, the POTW, and the major industrial user.
2. The group will develop and implement a sampling program at the treatment plant. This program will
establish baseline levels and detect waste load reductions as they occur. The program will include analytical
testing requirements. Once requirements are established the work group will determine those tests to be sent
to an outside laboratory and those to be done in house by the POTW.
3. O.TA. and the company will develop a systematic approach to evaluating pollution prevention
opportunities at the plant. Once done, options will be rated according to ease and some implementation will
begin. Any prevention projects requiring additional resources will be evaluated and effected according to grant
resources and or available state T.U.R. program resources.
4. O.TA. will attempt to facilitate the implementation of quality pollution prevention teams at the
industrial user. The goal is to develop whole facility support from the employees.
5. Specialty workshops already developed as part of the O.TA. Fall River initiative will be made
available to the industrial user.
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6. L'nivcrsily resources will be applied where needed.
PROJECT NEEDS:
1. A commitment 1'rom all parties to work cooperatively to achieve project goals.
2. Schedule of progress for implementation of the project. The schedule will include milestone events.
meeting dates, etc.
3. Laboratory facilities to support the POTVV laboratory including containers, samplers, etc.
4. University intern students to assist in the project.
5. Develop resource material from national databases and other state pollution prevention programs.
6. Data manaccment: for the sampling program and to track any cost saving the industrial user
experiences as a result of pollution prevention projects.
COST: Project Grant Project Match
In kind services
Staffing S 10.000 $5000 (O.T.A. and POTW)
Laboratory Si0,000 STOOO (in house)
Resources
workshops
printed materials
experts
bench scale $5,000 Company Match (?)
Travel/Other... $5,000
Summary:
Reports will be completed and sent to O.T.A. before June 1, September I, December 1, 1992 and March
1, 1993. These reports will be designed as progress reports. The final report will document the results of the
project. It will be evaluated for pollution prevention effectiveness and waste load reductions to the P.O.T.W.
The final report will incorporate recommendations made by the group rating the project on its environmental,
economic, technical and political merits.
The work plan is designed to be used as a guide for the project. It is possible that other influences
could result in the need to modify the plan. If necessary, O.T.A., The Board of Sew^er Commissioners-POT\V
operator and the Industrial User will adjust the program to meet the underlining goals of the project. If any
major changes occur to this workplan O.T.A. will notify Deb Hanlin, the grant administrator of EPA.
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CRITICAL PARAMETER PROJECT
NON-POINT SOURCE PILOT WORK PLAN
PURPOSE:
The City of Springfield plans to develop and implement a pollution
prevention pilot program to reduce the non-point source pollutant
load to the City's wastewater treatment plant. The pilot will be
divided into stages that will include measuring non-point pollution
from several sources, evaluating the effect of those pollutants on
the wastswater treatment plant, developing a pollution prevention
outreach education program to reduce those pollutant loads, and
post outreach monitoring of the non-point sources to evaluate the
effectiveness of the program.
BACKGROUND:
The City of Springfield operates a 67 million gallon per day (mgd)
regional wastewater treatment plant (SRWTP) serving eight
municipalities with a population of about 250,000. The treatment
facility is the largest activated sludge facility in New England
and is located on Bondi Island in Agawara, Massachusetts. From the
1940s until the 1970s the Bondi Island facility was one of two
plants that treated the City's wastewater using grit removal an el-
primary settling. The plant was upgraded to a regional secondai
treatment facility in 1977, adding mechanical aeration, air
floatation thickening and Zimpro sludge heat treatment. Presently
the sludge is belt filtered and composted. The treatment plant
maintains consistent compliance with its NPDES permit for discharge
to a Class B waterway and the Massachusetts Land Application of
Sludge and Septage Regulations for a Type II sludge.
In accordance with EPA pretreatment regulations, the City
implemented an Industrial Pretreatment Program (IPP) in 1986 to
control and limit the discharge of industrial wastes to the SRWTP.
The industrial community is highly diversified and includes 52
Significant Industrial Users (SIUs) contributing about 8 mgd of
industrial wastewater. The program required the SIUs to install,
operate, and maintain a continuous wastewater monitoring station
for the purpose of determining pretreatment compliance. A
networked, personal computer system evaluates industry compliance
and treatment process operation, and generates enforcement notices
and annual IPP cost recovery bills. The IPP was audited by the
Environmental Protection Agency (EPA) in 1989 and found in
compliance with the conditions of the National Pretreatment
Program.
The IPP investigated the effects of conservative toxic pollutants
on the SRWTP during 1990 and 1991. The SRWTP has approximately K
tons of biomass under aeration to absorb the impact of a toxi
pollutant discharge and an additional 179 tons of biomass in the
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clarifiers and return channels to reseed the aeration basins. The
data indicated that the SRWTP biomass was not inhibited by the load
of antimony, arsenic, beryllium, cadmium, copper, chromium, nickel,
lead, selenium, silver or zinc, and that those metals did not pass-
through the SRWTP in toxic concentrations to the receiving stream,
In addition, the SRWTP passed the four quarterly effluent bioassays
that were recently mandated under the plant's revised 1991 NPDES
permit.
The SRWTP plans on producing Massachusetts Type I sludge for
composting and marketing as a soil conditioner. Three metals,
cadmium, copper and nickel were present in the SRWTP sludge in
concentrations that exceed 80% of the Type I sludge limits and were
identified as critical parameters that must be controlled to meet
the compost marketing goal. Cadmium was identified as the
restricting pollutant that prevents the sludge from being
classified as Type I. Cadmium was effectively controlled at the
industrial point sources, and presently exhibits a higher load from
non-industrial and/or non-point sources than from industrial point
sources.
Approximately 1/3 of the City's sewer system is a combined sanitary
and storm sewer system that discharges to the SRWTP. The storm
sewer portion of that system serves commercial, industrial and
residential areas that generate pollution from loading docks,
parking areas, streets, driveways and lawns. No pollutant load
data is available on the City's non-point sources, and flow
estimates are based on pavement area and previous inflow and
infiltration studies. It is believed that the residential and non-
point source cadmium load restricts the SRWTP sludge distribution
and marketing options.
PROJECT:
The City of Springfield will work with the Office of Technical
Assistance (OTA) and conduct a pollution prevention pilot
consisting of monitoring, educational outreach and evaluation. The
effect of point source pollutants on the SRWTP is well documented,
therefore the project will focus on non-point source pollutants
that impact the SRWTP sludge. The project will quantify the non-
point source pollutant load of cadmium, copper and nickel to the
SRWTP by monitoring selected sections of the combined sewer system.
Based on the monitoring data the City will coordinate a pollution
prevention educational outreach project targeted at the storm sewer
users in the study areas. The City will repeat monitor the storm
sewer in each study area at the completion of the outreach program
to evaluate the effect of pollution prevention education on the
load of non-point source pollutants to the SRWTP. The City will
draw on the resources of three Department of Public Works
divisions: the IPP, the SRWTP and Engineering Division.
The Engineering Division will identify three storm sewer monitoring
areas consisting of residential, commercial/light industrial and
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documenting all activities associated with the project and will
report to the IPP management or delegate.
The project is scheduled to extend over a two year period and the
research intern position will be budget for a $10,000 per year
stipend. The SRWTP will provide a work area for the intern, the
IPP will provide most of the material support and the grant will
provide the stipend. A preliminary budget is delineated in Table
1. A job number system will be established by the IPP to track all
contractual service, labor and material costs for the project.
REPORTS:
A project schedule will be developed by the IPP for submission to
the OTA and Environmental Protection Agency (EPA). Progress
reports will be filed with OTA by the IPP on May 15, August 15,
November 15, and February 15. OTA will incorporate the information
from those reports and submit progress reports to the EPA on June
1 , September 1, December 1 and March 1. A final report will be
developed by the IPP and the OTA upon completion of the evaluation
phase and recommendations will be made to EPA on non-point source
pollution prevention.
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i Piiot Pollution Prevention Project
01
recycled
antifreeze
recycled
silver
reclaimed
-------
The State of North Carolina's
Pilot Approach to
POTW Pollution Prevention
Presentedat EPA Grant Recipients Roundtable Meeting
Februarys, 1992
Raleigh, NC
-------
ibJ
ra
Major Project Goals:
Create State-level Program
Infrastructure
Establish Local-level
Program Structure
Execution of Pollution
Prevention Problem-solving
Provide for Information
Transfer
-------
1. Create State-level
Program Infrastructure:
Enhance & improve cooperative efforts
between two established, successful
programs
Integrate PP evaluation techniques into
pretreatment program elements
Lay groundwork for new program elements
such as TRAP
Provide example for other states
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2. Establish Local-Level
Program Structure:
Establish pilot PP program at a large POTW
Develop model PP program designed to
meet needs of a small POTW
Establish additional POTW programs
through the award of challenge grants
-------
nJ
3. Execution of Pollution
Prevention Problem-Solving
Address specific pollution problem in
model applications
Develop mechanisms for identifying and
reducjng uncontrollable sources through
pollution prevention techniques
-------
4. Provide for Information
Transfer:
Document pilot program experiences
Produce and distribute guidance materials
describing! the development of POTW
Pollution Prevention programs at the State
& Local Level
Produce and distribute guidance for
specific industries and/or specific waste
types regarding PP techniques and their
implementation
-------
ItLJ
State Staff devoted to Project
From Pretreatment Program: Project
Manager and part-time services of State
Coordinator and Environmental Engineer
From Pollution Prevention: One full-time
Environmental Engineer and part-time
services of Program Director and
Environmental Chemist
Both programs will contribute clerical
assistance
-------
QTRLY Status Report:
State hired engineering staff
Negotiating contract with
large POTW
Reviewing existing info for
specific problem
-------
Cd Report Elledge May 1990 - April, 1991
Controllable
Metal Finishing
Electroplater
(10 -ftunlt-HesT)
Uncontrollable
Industrial
Commercial
Domestic
Septage
Permitted Max
Flow (MGD)
klo.
.211
7.190
Cd (Max)
.26
Average
Flow (MGD) Cone, ftig/1)
.1290
7.1974
11.61
.0036
* .0568
.0109
003
.088
Ibs.
.0374
.5006
.2904
.0026
Influent
Effluent
30
30
18.94
18.94
.0061
.0036
.964 41* R.
.569
* Arithmetic Average for this category of facility during this time fram - not flow weighted.
-------
Section V Program Example
1. Sanitation District of Orange County
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HIGHLIGHTS OF WASTE MINIMIZATION
AT
THE COUNTY SANITATION DISTRICTS
. > r. / ' O
)'..,'..< ."." ' / 7/25/91
'<-*'
-------
INTRODUCTION TO THE COUNTY SANITATION DISTRICTS
OF ORANGE COUNTY
Service Territory
439 Square Miles
29 Cities
9 Districts
Number of Permittees:
Class I = 429
Class II = 337
Class III « 215
Others = 53
Total = 1034
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INTRODUCTION TO THE COUNTY SANITATION DISTRICTS
OF ORANGE COUNTY
(CONTINUED)
Industrial Source Control
1954 First Ordinance
1970 Industrial Waste Division Established
1976 First Waste Minimization Outreach
and Ordinance Revision to Include
Heavy Metal Limits
1983 Ordinance Revision to Include
Enforcement of EPA's Federal
Categorical Limits
1984 Industrial Pretreatment Program
Approved by EPA
1989 Waste Minimization Policy Approved
by Board of Directors
Ordinance was revised
Industrial Waste Division was renamed
to Source Control Division
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INTRODUCTION TO THE COUNTY SANITATION DISTRICTS
OF ORANGE COUNTY
(CONTINUED)
Treatment Plants
Treatment Plant No. 1:
Location - Fountain Valley
Present Average Capacity - 97 MGD
Masterplanned Expansion By Year 2020:
219 MGD Average / o - \^ T /,-./« dr <
408 MGD Maximum
V f < iv»v < ' /
Treatment Plant No. 2:
! » I'j U"* * \
Location - Huntlngton Beach
Present Average Capacity 180 MGD
Masterplanned Expansion By Year 2020:
180 MGD Average
360 MGD Maximum
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WASTE MINIMIZATION ACTIVITIES
AT THE COUNTY SANITATION DISTRICTS
OF ORANGE COUNTY
TIER1
1984 - 1991
Enforcement of Mass Emission Rates
Promoting Wastewater Reduction
Promoting Better Housekeeping
Enforcing Waste Minimization, and
Permittee Assistance
Multi-Agency Coordination
Field Inspector Training
Workshops and Speakers
Mass Mailings
Information Clearinghouse
Results
TIER 2
1992 and Beyond
Advanced Planning
Enforcement and Implementation
Workshops
Multi-Agency Coordination
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TIER 1 - WASTE MINIMIZATION ACTIVITIES
1984 - 1991
ENFORCEMENT OF MASS
EMISSION RATES
JlAs/ol
[,(<.
^4
PROMOTING WASTEWATER
REDUCTION
'7
To control and reduce the quantity of toxic
materials discharged by permittees to the
Districts' sewer system and to prevent dilution,
mass emission limits (instead of concentration
limits) were determined and enforced based on
the standard water usage at each permittee's
facility.
As part of the pretreatment program, the
Districts required the permittees to have flow
restrictors or control valves to assure
wastewater reduction and avoid dilution. The
permittees' facilities are inspected and checked
for water conservation control equipment at least
annually.
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TIER 1 - WASTE MINIMISATION ACTIVITIES
1984-1991
(CONTINUED)
PROMOTING BETTER
HOUSEKEEPING AND
INSTALLATION OF BASIC
WASTE MINIMIZATION
EQUIPMENT
ENFORCING WASTE MINIMIZATION,
AND PERMITTEE ASSISTANCE
Through permitting and enforcement activities,
the Districts promoted and Implemented good
housekeeping practices and Installation of waste
minimization equipment (such as waste
segregation, installation of dragout tanks/trays,
spray rinses, and flow restrlctors) to reduce the
volume of waste generated and the cost of the
pretreatment-system and user charges
(economic incentive).
All permittees in violation with discharge
limits are required to Implement waste
minimization techniques and are provided
advice, checklists, and information In
conjunction with enforcement activities.
Permit application supplements containing plant-
wide and process-specific waste minimization
checklists will be implemented shortly.
Selected Source Control Division staff respond
to all permittee inquiries.
6
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TIER 1 - WASTE MINIMIZATION ACTIVITIES
1984 - 1991
(CONTINUED)
MULTI-AGENCY
COORDINATION
FIELD INSPECTOR
TRAINING
WORKSHOPS AND SPEAKERS
A multi-agency county task force on
waste minimization provides Interagency contact and
coordination of workshops and technology transfer.
The Districts are voluntarily participating In a four-
county, Technical and Educational Assistance Model
Project" which Is demonstrating multi-agency
coordination of waste minimization promotion.
A training program for field Inspectors is
being developed Into ten 2-hour sessions. A
multimedia oriented training Is planned for
implementation in late 1991.
Three workshops organized In cooperation with the
University of California on "Industrial Wastewater
Treatment and Waste Reduction". A workshop on
"Switching from Solvents to Water-Based Cleaning
Processes" was sponsored.
Speakers at industry association meetings to discuss
Industrial waste ordinance and promote waste
reduction.
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TIER 1 - WASTE MINIM TION ACTIVITIES
1984-1*31
(CONTINUED)
MASS MAILINGS
INFORMATION
CLEARINGHOUSE
RESULTS
Mass mailings are made to notify permittees of
government grant funds available and upcoming
meetings, conferences, and workshops on Industrial
waste minimization.
A library and supporting computer
database of over 300 publications on waste
minimization have been assembled for Districts' staff
and permittees' reference.
Reduction of toxics by the Source Control program
and enforcing mass emission rates have been so
effective that for the last three years, the InfluflQ
metals to the Districts' plant meet the effluent
standards.
The Influent heavy metals have been reduced about
50% during the past five years.
Over 95% of all the metal finishers and categorically
regulated Industries have flow restrlctors or control
valves to reduce the water usage and Installed the
basic waste minimization equipment to reduce the
volume of hazardous wastes and wastewater
discharge to the sewer system.
8
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TIER 2 - WASTE MINIMIZATION ACTIVITIES
1992 AND BEYOND
ADVANCED
PLANNING
ENFORCEMENT &
IMPLEMENTATION
Determine pollutants of concern.
Determine sources (industrial, commercial, domestic).
Evaluate pollutant management alternative:
Minimization of waste materials.
Conversion off hazardous waste into non-hazardous or
less hazardous waste.
Perpetual storage.
Evaluate economic feasibility of pollutant management
alternative and available techniques.
Evaluate effectiveness.
Establish preferred waste management alternative.
Establish pollution prevention strategies (waste
minimization techniques, product bans, recovery systems)
and standards for Implementation.
Enforce pollution prevention standards to the applicable
sources through the permitting process.
Mandate installation of waste minimization equipment.
Mandate
reuse/recycle of material and process wastewater.
Mandate product bans and material substitution.
Mandate extended water conservation for commercial and
domestic sources, if necessary.
9
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TIER 2 WASTE MINIML^FION ACTIVITIES
1992 AND BEYOND
(CONTINUED)
WORKSHOPS
Workshops for promoting advanced technologies for waste
reduction will be held in cooperation with University
Institutes, Industrial/commercial communities, the U.S. EPA
pollution prevention technology transfer and Information
exchange, and Industrial associations.
MULTI-AGENCY
COORDINATION
The pollution prevention strategies and advance planning
will be coordinated within a multi-agency task force as
needed. Multi-agency cooperation on advanced planning
studies and technology transfer will be a goal.
10
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APPENDICES
a. Agenda
b. List of Attendees
c. Case studies from PPIC
-------
Pollution Prevention in Publicly Owned
Treatment Works
EPA Grant Recipients Roundtable Meeting
DATE: February 6 and 7, 1992
TIME: 9:00am-4:00pm
LOCATION: State of North Carolina Archibald BIdg.
512 N. Salisbury St., Raleigh, N.C.
The purpose of this meeting is to develop a network of people and agencies that are
interested in promoting pollution prevention in POTW's, pre-treatment programs
and MWPP. The attendees will share ideas, problems, and goals associated with this
pilot project.
AGENDA
Feb. 6
Morning
1. States will describe the pilot programs. Each of the five grant recipient will
have 20 minutes to discuss their approach to this project. The first quarterly report
will be presented orally by state participants . Q&A /discussions
9:00-9:30 Welcome and Introductions Deborah Hanlon
9:30-10:00 Utah P2 Program Mary DeLaretto
10:-10:30 New Mexico Alex Puglisi
break
10:45-11:15 Minnesota Kevin McDonald
11:15-11:45 Massachusetts Critical Mass P2 Paul Richards
11:45-12:15 North Carolina Trevor Clements
Lunch Break
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Afternoon
2. Examples and case studies from other POTW's and state programs that provide
pollution prevention technical assistance will be presented. Participants will share
ideas on how Regions and states can assist in training, coordination, and in
conducting joint inspections.
1:30-2:00 Sanitation District of Orange County Mahin Talibei
2:00-2:30 Case Study from North Carolina Stephanie Richardson
Break
3:00-4:00 -Group Problem Solving and Discussion Hanlon
Discussion issues: Future funding options
Measuring progress and results
Publicizing programs
Feb. 7
Morning
1. EPA will discuss reporting requirements and expectations. Participants will
discuss needs and availability of resources. EPA Project Officer, regional
coordinators, State Pollution Prevention Programs, MWPP and Pre-treatment
program coordinators will share perspectives on this project.
9-10 What are your resource needs? What resources are available?
PPIC, Grant Programs, etc. Hanlon, Hann,
Southeast Waste Reduction Cente Bob Carter
10-12:00 EPA HQ and Regions/Perspective on Grant Projects:
MWPP Valerie Martin
Pre-treatment
Permits Wendy Bell
Enforcement Walter Brodtman
Reporting Requirements Lena Hann
Lunch
1:30-3:00 Tour of Raleigh POTW
*Agenda subject to change
-------
Lindsay Mize
oil ice of Waste Reduction
Dept of Environment Health and Natural Resources
PO Box 27687
Raleigh, NC 27611-7687
919-571-4100
Florence Reynolds
Salt Lake City Corporation
1530 S. West Temple
Salt Lake City, UT 84915
Paul Richard
Office of Technical Assistance
Executive Office of Environmental Affairs
Room 1904, 100 Cambridge St
Boston, MA 02202
617-727-3260 ext 692
Stephanie Richardson
Office of Waste reduction
Dept of Environment Health and Natural Resources
PO Box 27687
Raleigh, NC 27611-7667
919-571-4100
Mary Settle
US EPA (WH-546)
Office of Water
401 M St SW
Washington. DC 20460
202-260-5810
Pete Smith
US EPA Region 5
77 West Jackson Blvd
Chicago. IL 60604
312-886-2000
Julia Storm
Department of Environment Health and Nat Resources
Division of Environmental Management
PO Box 29535
Raleigh, NC 27626
919-733-5083
Alicia Suarez
US EPA Region 2
26 Federal Plaza
Room 837
New York, NY 10278
212-264-9204
Mahin Talebi
Sanitation District of Orange County
PO Box 8127
Foutain Valley. CA 92728
714-267-9500
Harold Thompson
US EPA Region 8 (8WM-MF)
999 18thSt, Suite 500
Denver, CO 80202-2405
303-293-1560
Navneet Tiku
Metropolitan Waste Control Commission
230 E. 5th St
St. Paul, MN 55101
612-772-7016
Vic Young
Waste Reduction Resource Center
3825 Barrett Dr
Raleigh, NC 27609
800-476-8686
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Wendy Bell
US EPA (EN-336)
401 M St. SW
Washington, DC 20460
202-260-9534
Walter Brodtman
US EPA (EN-338)
401 M St Sw
Washington. DC 20460
202-260-5998
Joseph Canzano
US EPA Region 1 (WCM-510)
JFK FederalBuilding
Boston, MA 02203
617-565-3554
Ben Chen
US EPA Region 4 (4WMD)
345 Courtland St, NE
Atlanta, GA 30365
404-347-3633
favor Clements
5ept of Environment Health and Nat Resources
ivision of Environmental Management
0 Box 29535
ialeigh, NC 27626
(19-733-5083
Crystal Couch
Industrial Waste Control
2799 Griffith Road
Winston-Salem, NC 27103
919-765-0134
Mary DeLoretto
Division of Water Quality
department of Environmental Quality
fatt Lake City. UT 84114-4870
601-538-6146
Michael Downey
SRWRP
1600 E. Columbus Ave
Springfield, MA 01103
Deborah Hanlon
US EPA (PM-222B)
Pollution Prevention Division
401 M St. SW
Washington, DC 20460
202-260-2726
Lena Hann
US EPA (PM-222B)
Pollution Prevention Division
401 M St, SW
Washington, DC 20460
202-260-2237
Bob Hogrefe
City of Albuquerque
4201 2nd St SW
Albuquerque, NM 87105
505-873-7087
Debbie LaVergne
UBWPAD
Route 20
Millbury, MA 01527
508-755-1286
Valerie Martin
US EPA (WH-547)
Office of Water
401 M St, SW
Washington, DC 20460
202-260-7265
Kevin McDonald
Office of Waste Management
Hazardous and Problem Wastes
1350 Energy Lane
St. Paul, MN 55108
612-649-5744
-------
Following are some of the more than 120 case studies on the PIES
database dealing with wastewater:
-------
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Reuse of Water in a Woollen mill
2.0 SIC Code: 2299, Textile Goods, NEC
3.0 Name & Location of Company: Shanghai Second Woollen Mills,
Shanghai, China
4.0 Clean Technology Category
This technology involves the recycling and reuse of wastewater
5.0 Case Study Summary
5.1 Process and Waste Information: Coloured wastewater
effluents from two workshops at a woollen mill were
treated using dissolved air flotation and biological
towers. Decolorization was achieved by coagulation and
adsorption with activated carbon. After biological
treatement and decolorization, the wastewater was diluted
with 20% tap water. This water was used to prepare
dyeing liquors. A neutral dye and a mordant dye were
selected. The dyeing recipe w adjusted to account for
the effect of hexavalent chromium ion present in low
concentrations in the reuse water.
5.2 Scale of Operation: Information not provided
5.3 State of Development: Pilot stage field experiments were
performed
5.4 Level of Commercialization: Information not provided
5.5 Balances and Substitutions:
Material Category Quantity Before Quantity After
Waste Generation: N/A N/A
Feedstock Use:
A12(S04)3 120 ?/day 156 ?/day
Activated Carbon - 300 ?/day
Water Use: 1450 m3/day 300 m3/day
4207/day 6507/day
6.0 Economics
6.1 Investment Costs: Information not provided
6 2 Operational and Maintenance Costs: Operational use of
activated carbon reported to cost 12 Yuan/day (1974) . An
increase in energy use resulted in a net cost increase of
23 Yuan/day. Wastewater treatment costs increased by 46
-------
Yuan/day. Costs of A12(SO4)3 increased by 13 Yuan/day.
6.3 Payback Time: Information not provided
7.0 Cleaner Production Benefits: Economic benefits were calculated
to be 90 Yuan/day (1974) and resulted form the decreased use
of tap water.
Use of the technology minimizes discharges of coloured
wastewater
8.0 Obstacles, Problems and/or Known Constraints
Economic feasibility of the technology depends on the
availability of activated carbon, and the lack of costs
associated with carbon regeneration in this case.
9.0 Date case study was performed: 1974 and 1976
10.0 Contacts and Citation
10.1 Type of Source Material: Conference Proceedings
10.2 Citation: A Study on Reuse of Water in a Woollen Mill.
Hu Hiajue et al. Purdue Universty Conference on
Industrial Waste Treatment
10.3 Level of Detail of Source Material: Additional
information is available in the source material
10.4 Industry/Pr.ogram Contact and Address: Industry contact
not provided
10.5 Abstractor and Address: Reformatted: Isaac Diwan, SAIC,
8400 Westpark Dr., McLean, VA 22102
11.0 Keywords
11.1 Waste Type: Coloured water
11.2 Process Type/Waste Source:
11.3 Waste Reduction Technique:
11.4 Other Keywords:
12.0 Assumptions: None
13.0 Peer Review: Unknown
KEYWORDS: CLOURED WATER, WASTEWATER REUSE, TEXTILES
**********!
**********
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Displaying item number 78
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Water Conservation in a Textile Industry.
2.0 SIC Code: 22, Textile Mill Products
3.0 Name and Location of Company: Binny Textile Mills, Madras,
India.
4.0 Clean Technology Category: This case study focusses on reuse
of wastewaters and water conservation.
5.0 Case Study Summary:
5.1 Process and Waste information: Four areas within the
facility are the major wastewater producers: (1) process
and treatment department; (2) captive power generation
unit (coal fixed thermal power station); (3) sizing
department; and (4) yarn dyeing and printing department.
The following changes were undertaken to conserve water
and reduce wastewater generation.
Reuse of pressure filters backwash water. Suspended
solids that can easily settle are the main pollutants in
pressure filter backwash water. By collecting the
backwash water in a pond, with a minimum hydraulic
retention time of 12 hours, the supernatant freed from
the suspended solids can be reused for gardening
purposes. Periodically, the retained suspended solids
are removed from the pond and disposed of a solid waste
in a landfill site. The net effect is conservation of 20
cubic meters/day of fresh water, which the facility used
for gardening purposes.
Reuse of wastewater from the dyeing and finishing
department. About 1,200 cubic meters/day of fresh water,
including the evaporation loss, was used for quenching
hot ash from the boiler house prior to its disposal.
Laboratory experiments confirmed that it is feasible to
reuse hard to treat wastewater from the dyeing department
for ash quenching in lieu of fresh water. Due to
adsorption of colors and dyes on the ash particles, there
is a approximately a 20% reduction in BOD content in the
reused dye department wastewater. Approximately 1,200
cubic meters per day of fresh water was conserved, with
a reduction of 552 kg. BOD/day.
Reuse of wastewater from the sizing department. In order
to avoid spontaneous combustion and to reduce the fines
loss, freshwater was used to wet coal in the yard. By
-------
collecting in a pond the low volume, high organic
strength wastewater from the sizing department, all of
the wastewater could be reused for coal wetting.
Appropriate facilities must be available at the pond to
avoid septicity. Wastewaters from the sizing department
were completely reused and 27 cubic meters per day of
fresh water were conserved.
5.2 Scale of Operation: Unknown.
5.3 Stage of Development: The technology was fully
implemented.
5.4 Level of Commercialization: Not applicable.
5.5 Material/Energy Balances and Substitutions:
6.0 Economics*
6.1 Investments Costs: Investment costs include the facility
for pH neutralization pumps and pipeline costs.
6.2 Operational & Maintenance Costs: Savings and reduction
in the capital investment is Rs. 7 lakhs annually, and
annual O&M costs are Rs. 6 lakhs. Annual savings for 300
workings days per year for purchase of fresh water from
the municipal corporation totalled Rs. 4 per cubic meter.
6.3 Payback Time: Not reported.
7.0 Cleaner Production Benefits: Wastewater reused equals 2,690
cubic meters per day and freshwater consumption was reduced
1.227 cubic meters per day. "The overall reduction in
wastewater quantity and BOD load were 31% and 25%
respectively.
8.0 Obstacles, Problems, and/or Known Constraints: Not available.
9.0 Date Case Study Was Performed: 1984
10.0 Contacts and Citation
10.1 Type of Source Material: Unpublished materials.
10.2 Citation: Mr. L. Paneerselvam, Director (PC), National
Productivity Council, Lodhi Road, New Delhi no 003,
India.
10.3 Level of Detail of Source Material: Unknown.
10.4 Industry/Program Contact and Address: Unknown.
10.5 Abstractor Name and Address: Mary L. Wolfe, Science
-------
Applications International Corporation, 8400 Westpark
Drive, McLean, VA 22102.
11.0 Keywords
11.1 Waste type: Wastewater.
11.2 Process Type/Waste Source: Textile Mill Products, SIC
Code 22.
11.3 Waste Reduction Technique: Wastewater Reduction.
11.4 Other Keywords:
12.0 Assumptions: The information in this case study was derived
from abstracts provided by the United Nations Environment
Program (Paris). This abstract was prepared directly from the
abstract without access to the case study cited.
13.0 Peer Review:
(*) - Disclaimer: Economic data will vary due to economic
climate, varying governmental regulations, and
other factors.
KEYWORDS: Wastewater, Textile Mill Products, SIC Code 22,
Wastewater Reduction
**********
Displaying item number 79
**********
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Elimination of the Problems of Sulfides by Chemical
Substitution in the Textile Industry
2.0 SIC Code: 22, Textile Mill Products
3.0 Name and Location of Company: Century Textiles and Industries
Limited, Worli, Bombay 400 025, India.
4.0 Clean Technology Category: This case study presents chemical
substitutions for sulphur dyes.
5.0 Case Study Summary:
5.1 Process and Waste Information: Sulphur dyes are water
insoluble and must be converted into a water soluble
(leuco) form before application to textile materials.
The traditional method is treatment with an aqueous
solution of sodium sulfide. Since the leuco compounds
-------
have an affinity for cellulosic fibers and are sensitive
to atmospheric oxygen, they must be applied from the
aqueous solution. After the dye has been absorbed on the
fiber surface, the reduced form of the dye must be
reconverted into the water insoluable form. Generally,
this is carried out through exposure to air or by using
a chemical oxidizing agent.
Black dye is an important member of the sulfur series due
to its fastness in washing and light and its low cost as
compared to other synthetic dyes. It is converted using
the process described above. The facility encountered
difficulties, however, when the State pollution control
board established a 2 ppm maximum sulfide content for
treated effluent from textile mills.
Rather than attempt to reduce the sulfide in the
effluent, the facility sought options to reduce or
replace the sodium sulfide. During studies conducted by
the facility, it was discovered that an alkaline solution
of glucose can satisfactorily reduce the sulfur colors,
enabling the facility to substitute the glucose solution
for the sodium sulfide. Because the glucose solution
prepared in the studies would be cost prohibitive, the
facility sought an inexpensive source of glucose. This
lead to the use of liquid glucose, a by-product of the
starch industry.
The facility replaced 100 parts sodium sulfide (50%) with
61 parts liquid glucose (80% solids) and 26 parts caustic
soda in its sulfur black color dye operations. The
. facility continued to have difficulties with this mixture
because the thick glucose solution required special
arrangements for emptying drums. The operation was still
cost intensive.
The facility finally substituted an alkaline solution
from sugar reduction for the sodium sulfide. A by-
product containing 50% reducing sugars was
technologically and financially feasible. The facility
substitutes 100 parts sodium sulfide (50%) with 65 parts
of the product (containing 50% reducing sugars) plus 25
parts caustic soda. Dye qualities were equivalent to the
standard process for depth of shades, fastness, and other
properties.
5.2 Scale of Operation: Unknown.
5.3 Stage of Development: The technology is fully
implemented.
5.4 Level of Commercialization: The substitute materials are
commercially available.
-------
5.5 Material/Energy Balances and Substitutions:
6.0 Economics*
6.1 Investments Costs: No capital expenditure was involved.
6.2 Operational & Maintenance Costs: Not provided.
6.3 Payback Time: Not applicable.
7.0 Cleaner Production Benefits: The facility met the mandatory
effluent level for sulfide and eliminated the foul smell of
sulfide in the workplace.
8.0 Obstacles, Problems, and/or Known Constraints: The high cost
of glucose was the main constraint in making the technology
have practical applications. Further, the glucose solution
required special handling when drums were emptied and solution
replacement was cost intensive. These problems were resolved
by the use of suitable by-products containing reducing sugars.
9.0 Date Case Study Was Performed: 1990.
10.0 Contacts and Citation
10.1 Type of Source Material: Unpublished materials.
10.2 Citation: Mr. Mahesh A. Sharma, Chief Chemist, Century
Textiles and Industries Limited, Worli, Bombay 400 025,
India.
10.3 Level of Detail of Source Material: Unknown.
10.4 Industry/Program Contact and Address: See citation.
10.5 Abstractor Name and Address: Mary L. Wolfe, Science
Applications International Corporation, 8400 Westpark
Drive, McLean, VA 22102.
11.0 Keywords
11.1 Waste type: Wastewater.
11.2 Process Type/Waste Source: Textile Mill Products, SIC
Code 22.
11.3 Waste Reduction Technique: Chemical Substitution
11.4 Other Keywords:
12 0 Assumptions: The information in this case study was derived
from abstracts provided by the United Nations Environment
Program (Paris). This abstract was prepared directly from the
abstract without access to the source material cited.
-------
13.0 Peer Review:
(*) - Disclaimer: Economic data will vary due to economic
climate, varying governmental regulations, and
other factors.
KEYWORDS: Wastewater, Textile Mill Products, SIC Code 22, Chemical
Substitution
Displaying item number 80
**********:
**********
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Dye-bath Reuse in Carpet Dyeing
2.0 SIC Code: 2273, Carpets and Rugs; 22, Textile Mill Products
3.0 Name and Location of Company: Bigelow, USA
4.0 Clean Technology Category: Recycle and Reuse
5.0 Case Study Summary:
5.1 Process and Waste Information: Carpets were dyed with
conventional procedures and then with dye-bath reuse.
Data on pollution reduction showed significant
improvements due to dye-bath reuse. Dyeings' in Bigelow
production runs were done on two different shades and
styles of carpet. A pair of conventional atmospheric
becks were used and dye-bath was pumped back and forth
between them. Over twenty reuse cycles could be
obtained.
5.2 Scale of Operation: Unknown.
5.3 Stage of Development: The technology was fully
implemented at the facility.
5.4 Level of Commercialization: Not applicable.
5.5 Material /Energy Balances and Substitutions:
6.0 Economics*: A savings of $60,000 per pair of becks.
7.0 Cleaner Production Benefits: The consumption of dyes was
reduced, thereby lowering the cost of effluent treatment.
8.0 Obstacles, Problems, and/or Known Constraints: None reported.
9.0 Date Case Study Was Performed: 1983
-------
10.0 Contacts and Citation
10.1 Type of Source Material: Journal.
10.2 Citation: Berganthal, J. et. al., "The Case for Direct
Dye-bath Reuse," Carpet and Rug Industry, October 1984,
p. 16.
10.3 Level of Detail of Source Material: Unknown.
10.4 Industry/Program Contact and Address: Unknown.
10.5 Abstractor Name and Address: Mary L. Wolfe, Science
Applications International Corporation, 8400 Westpark
Drive, McLean, VA 22102.
11.0 Keywords
11.1 Waste type: Dye; Wastewater.
11.2 Process Type/Waste Source: Carpets and Rugs, SIC Code
2273; Textile Mill Products, SIC Code 22.
11.3 Waste Reduction Technique: Reuse, dye bath reuse.
11.4 Other Keywords:
12.0 Assumptions: The information in this case study was derived
from abstracts provided by the United Nations Environment
Program (Paris). This abstract was prepared directly from the
abstract without access to the journal article cited. It is
not known if the economic data is based on annual savings.
13.0 Peer Review:
(*) - Disclaimer: Economic data will vary due to economic
climate, varying governmental regulations, and
other factors.
KEYWORDS: Dye; Wastewater, Carpets and Rugs, SIC Code 2273;
Textile Mill Products, SIC Code 22, Reuse, dye bath reuse.
**********
Displaying item number 81
**********
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Nordic Project on Water Used Reduction in Textile
Industries
2.0 SIC Code: 22, Textile Mill Products
-------
3.0 Name and Location of Company: 15 textile facilities in
Denmark, Finals, Norway, and Sweden.
4.0 Clean Technology Category
Process/Equipment Modification: This technology involves the
introduction of automatic water stops to encourage water
conservation.
5.0 Case Study Summary:
5.1 Process and Waste Information: Between. 1976 and 1981, a
Nordic, "water care" project was launched to examine
avenues of water conservation in textile industries in
Denmark, Finland, Norway, and Sweden.
The following changes were reported for batch operations:
* Winch dyeing: By dropping the dye batch and
avoiding overflow rinsing, water consumption could
be reduced 25%.
* High and Low Pressure Jet Dyeing: Approximately
50% of water consumption could be reduced by
replacing the overflow with batchwise rinsing.
* Beam Dyeing: Avoiding overflow during soaking and
rinsing can reduce water consumption by
approximately 60%.
* Jig Dyeing: Switching to stepwise rinsing from the
overflow practice resulted in water consumption
reductions of 15%-79%.
* Cheese Dyeing Apparatus: A water consumption
reduction of 70% can be expected with the use of an
intermittent rinsing procedure.
For continuous operations, a savings of 20%-30% was
reported by the introduction of automatic water stops.
Counter current washing was found to be most effective.
Horizontal washing equipment was found to deliver the
performance of two vertical washing machines for the same
water consumption.
5.2 Scale of Operation: Initially, laboratory studies were
carried out to ascertain potential possibilities.
Approximately 25 setups were installed at 15 textile
plants.
5.3 Stage of Development: At the time the case study was
reported, the technology was in the pilot stage.
5.4 Level of Commercialization: It is unknown whether the
technology was commercially available at the time of the
-------
case study.
5.5 Material/Energy Balances and Substitutions:
6.0 Economics:
6.3 Payback Time: The only technology with a known payback
time is beam dyeing, which has a payback time of about
four months.
7.0 Cleaner Production Benefits: Substantially reduced fresh
water consumption and reduced cost of effluent treatment
plant.
8.0 Obstacles, Problems, and/or Known Constraints.: None reported.
9.0 Date Case Study Was Performed: 1976
10.0 Contacts and Citation
10.1 Type of Source Material: Conference Proceedings.
10.2 Citation: H. Asnes, "Reduction in Water Consumption in
the Textile Industry," IFATCC Conference, London, 1978.
10.3 Level of Detail of Source Material: Unknown.
10.4 Industry/Program Contact and Address: Unknown.
10.5 Abstractor Name and Address: Mary L. Wolfe, Science
Applications International Corporation, 8400 Westpark
Drive, McLean, VA 22102.
11.0 Keywords
11.1 Waste type: Wastewater.
11.2 Process Type/Waste Source: Textile Mill Products, SIC
Code 22.
11.3 Waste Reduction Technique: Wastewater Reduction,
Equipment Modification.
11.4 Other Keywords:
12.0 Assumptions: The information in this case study was derived
from abstracts provided by the United Nationals Environment
Program (Paris) . This abstract was prepared directly from the
abstract without access to the conference proceedings cited.
13.0 Peer Review:
I*) - Disclaimer: Economic data will vary due to economic
(*} Disclaimer. climatBi varying governmental regulations, and
-------
other factors.
KEYWORDS: Wastewater, Textile Mill Products, SIC Code 22,
Wastewater Reduction, Equipment Modification.
Displaying item number 82
**********
***** DOCNO: DOCUMENT NOT AVAILABLE *****
1.0 Headline: Heat Recovery in Textile Industry.
2.0 SIC Code: 2259, Knitting Mills NEC; 22, Textile Mill Products
3.0 Name and Location of Company: Ellen Knitting Mills, Spruce
Pine, North Carolina, USA.
4.0 Clean Technology Category: This case study presents heat
recovery technology.
5.0 Case Study Summary:
5.1 Process and Waste Information: The temperature of the
dye bath water, which was discharged to the municipal
sewer system, was 123 Deg. F. The water temperature
cause breakage of the terra cotta sewer piping. To
alleviate this problem, heat recovery was required.
Spent dye water is discharged into a holding vat from
which it enters a stainless steel heat exchanger. The
exchanger is composed of five 50-foot long, eight-inch
diameter pipes. Inside each pipe is a bundle of smaller
tubes that allow heat transfer. Heat recovered from the
water is used to preheat incoming feed water from the dye
tubes from 55 Deg. F to about 105 Deg. F. The preheating
operation saves about 52,000 gallons of fuel oil per
year.
5.2 Scale of Operation: Unknown.
5.3 Stage of Development: The technology is fully
implemented at the facility.
5.4 Level of Commercialization: Unknown.
5.5 Material/Energy Balances and Substitutions:
6.1 Investments Costs: In 1981, the company invested
$100,000 in a heat exchange system.
-------
6.2 Operational & Maintenance Costs: Not reported.
6.3 Payback Time: Not reported.
7.0 Cleaner Production Benefits: The facility reduced its fuel
oil use.
8.0 Obstacles, Problems, and/or Known Constraints: Unknown.
9.0 Date Case Study Was Performed: 1981
10.0 Contacts and Citation
10.1 Type of Source Material: Government publication.
10.2 Citation: Profits of Pollution Prevention: A Compendium
of North Carolina Case Studies, North Carolina Department
of Natural Resources and Community Development, North
Carolina.
10.3 Level of Detail of Source Material: Unknown.
10.4 Industry/Program Contact and Address: Unknown.
10.5 Abstractor Name and Address: Mary L. Wolfe, Science
Applications International Corporation, 8400 Westpark
Drive, McLean, VA 22102.
11.0 Keywords
11.1 Waste type: Wastewater.
11.2 Process Type/Waste Source: Textile Mill Products, SIC
Code 22.
11.3 Waste Reduction Technique: Heat Exchange.
11.4 Other Keywords:
12.0 Assumptions: The information in this case study was derived
from abstracts provided by the United Nationals Environment
Program (Paris). This abstract was prepared directly from the
abstract without access to the publication cited.
13.0 Peer Review:
(*) - Disclaimer: Economic data will vary due to economic
climate, varying governmental regulations, and
other factors.
KEYWORDS: Wastewater, Textile Mill Products, SIC Code 22, Heat
Exchange.
********!
**********
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Displaying item number 83
***** DOCNO: 400-121-A *****
1.0 Headline: Zinc Recovery in the Rayon Industry in Netherlands.
2.0 SIC Code: 22, Textile Mill Products
3.0 Name and Location of Company: Enka B.V., Velperweg,
Kleefsewaard at Arnheim, Netherlands.
4.0 Clean Technology Category: This case study addresses recovery
of zinc.
5.0 Case Study Summary:
5.1 Process and Waste Information: The main production steps
in the rayon industry are (1) the reaction of cellulose
with sodium hydroxide, followed by pressing and grinding;
(2) the reaction of sodium-cellulose with carbon
disulfide; (3) the creation of a solution of reaction
product in water, called viscose; (4)the spinning of
viscose by injection through a spinning head into a
spinning bath, where the viscose is transformed into
cellulose yarn by coagulation; and (5) finishing of rayon
tire cord by washing, lubrication, and drying.
During the spinning process, zinc sulphate is used to
slow down the formation of the yarn. This is necessary
in order to obtain the desired strength and elongation of
the yarn. The wastewater from the spinning process
contains mainly sulfuric acid, sodium sulphate, and zinc
salts. This wastewater is treated in the biological
wastewater treatment plant. Removal of zinc++ is
effected by precipitating it to form inert zinc sulfides.
The biological sludge containing this zinc sulfide is
dumped on the land. For the wastewater, the discharge
draft standard for zinc in some areas of the Netherlands
is 20 kg/day. The maximum allowable amount of zinc in
any given sample of wastewater effluent is 3 mg/liter.
Over a 24-hour period the maximum allowable zinc content
in the wastewater effluent is 2 mg/liter.
The low-waste technology concerns the recovery and
recycling of zinc from the acid effluent of the rayon
spinning process. The zinc++ containing acid effluent is
treated with a mixture of D.E.H.P.A. (10%) and solvesso
150 (90%) . The ratio of acid effluent to organic solvent
is generally less than one. Treatment occurs in a tank
fitted with agitators. The dispersed water and organic
solvent is transported to a separation tank in order to
-------
obtain separation between water and the organic phase.
The extraction process is carried out in three steps with
counter-flow of the effluent and the organic solvent.
The reaction product of zinc++ and D.E.H.P.A. dissolves
in the organic phase. This organic phase has to be
stripped in order to recover the zinc++.
In order to obtain high efficiency of zinc++ removal, the
pH of the water phase must be controlled by addition of
sodium hydroxide. During the first extraction step the
pH is greater than 2.8 and afterwards it is greater than
3.0. The zinc++ removal efficiency is generally more
than 98%. The zinc-free water phase is neutralized and
charged together with 10 times the amount of caustic
wastewater in the wastewater treatment plant. The
effluent from the wastewater treatment plant is dumped
together with three times the amount of other wastewater
into open water.
To recover the zinc++ from the organic extraction
solvent, the solvent is stripped with a water-based
solution of sulfuric acid (20%) and a flocculent. This
is, however, a one-step process. During stripping, the
zinc++ is re-worked as zinc sulphate. It dissolves in
the waster phase. This solution is used again in the
spinning process. The addition of a flocculent is
essential in order to obtain high efficiency of zinc++
recovery and to prevent large losses or organic solvent.
This flocculent neutralizes the cation-active substances.
The zinc++ recovery efficiency is about 100%.
5.2 Scale of Operation: The plant maximum capacity for
treatment is 40 cubic meters of effluent per hour.
5.3 Stage of Development: The technology is fully
implemented.
5.4 Level of Commercialization: Unknown.
5.5 Material/Energy Balances and Substitutions: Figures
based on tone of rayon tire cord production in the
effluent discharge.
6.0 Economics*
6.1 Investments Costs: While the total investment for the
conventional process is 2,000,000 Fl, the investment for
the low-waste technology is 5,600,000 Fl. The cost of
rayon tire cord per year increases from 70 Fl for the
conventional method to 85 Fl for the low-waste
technology. Zinc recovery results in savings of 225,000
Fl per year.
-------
6.2 Operational & Maintenance Costs: Unknown.
6.3 Payback Time: Unknown.
7.0 Cleaner Production Benefits: Because the zinc removal
efficiency is high, there are economic benefits as well as
regulatory benefits.
8.0 Obstacles, Problems, and/or Known Constraints: Not available.
9.0 Date Case Study Was Performed: 1982
10.0 Contacts and Citation
10.1 Type of Source Material: United Nations document.
10.2 Citation: United Nations Economic and Social Council,
Economic Commission for Europe, Compendium on Low- or
Non-Waste Technology, Monograph ENV/W) .2/5/Add.l21, May
1985.
10.3 Level of Detail of Source Material: Unknown.
10.4 Industry/Program Contact and Address: Unknown.
10.5 Abstractor Name and Address: Mary L. Wolfe, Science
Applications International Corporation, 8400 Westpark
Drive, McLean, VA 22102.
11.0 Keywords
11.1 Waste type: Wastewater.
11.2 Process Type/Waste Source: Textile Mill Products, SIC
Code 22.
11.3 Waste Reduction Technique: Wastewater Reduction, Reuse,
Recovery.
11.4 Other Keywords:
12.0 Assumptions: The information in this case study was derived
from abstracts provided by the United Nations Environment
Program (Paris) . This abstract was prepared directly from the
abstract without access to the document cited.
13.0 Peer Review:
(*) - Disclaimer: Economic data will vary due to economic
climate, varying governmental regulations, and
other factors.
KEYWORDS: Wastewater, Textile Mill Products, SIC Code 22,
Wastewater Reduction, Reuse, Recovery.
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Displaying item number 84
Document No.: 327-005-A-OOO
1.0 Headline: Cadmium Waste Management Progam Utilizes Good
Operating Practices to Reduce Generation of Metal Hydroxide
Sludge at A Plating Facility
2.0 SIC Code: 3471, Electroplating, Plating, Polishing,
Anodizing and Coloring
3.0 Name & Location of Company
Bass Plating Company
Old Windsor Road
Bloomfield, Connecticut
4.0 Clean Technology Category: The technology involves
implementation of good operating practice and waste
minimzation options such as increasing drip times, elevating
plating bath temperatures, improving drip containment and
redesigning plating racks.
5.0 Case Study Summary
5.1 Process and Waste Information: The company specializes
in zinc, cadmium, nickel-cadmium, and tin plating and
passivating. Metal hydroxide sludge is generated from
the three plating lines which all contain cadmium. The
company conducted a waste minimization assessment at
the facility.
Many of the low-cost, good operating practice and waste
minimization options identified were implemented.
These included increasing drip times, elevating plating
bath temperatures, improving drip containment and
redesigning plating racks.
5.2 Scale of Operation: The company employs 35 people.
5.3 Stage of Development: The options identified above
have been implemented. Other options have been
identified which may be implemented in the future.
5.4 Level of Commercialization: The technology is fully
commercialized.
5.5 Material/Energy Balances and Substitutions:
Information not provided.
-------
6.0 Economics*
6.1 Investment Costs: The cost was reported as $12,000.
6.2 Operational & Maintenance Costs: Savings in operating
expenses were reported as $96,100 per year.
6.3 Payback Time: Payback period is 5.8 months.
7.0 Cleaner Production Benefits: 120 tons of metal hydroxide
sludge were expected to be generated in 1989, representing a
15% decrease in sludge generation in 1988.
8.0 Obstacles, Problems, and/or Known Constraints: None
reported.
9.0 Date Case Study Was Performed: The project was completed in
June 1989.
10.0 Contacts and Citation
10.1 Type of Source Material: Technical assistance program
summary
10.2 Citation: ConnTAP Matching Challenge Grants - 1988-89,
Connecticut Hazardous Waste Management Service, pp. 4-
5. "Summary Report, Cadmium Waste Management Program,
Bass Plating Company," Bass Plating Company, June,
1989.
10.3 Level of Detail of the Source Material: Additional
information is available concerning the funding of this
project.
10.4 Industry/Program Contact and Address: Rocco
Mastrobattista, Project Manager, Bass Plating Company,
Old Windsor Road, Bloomfiled, CT 06002, (203) 243-
2557.
11.0 Keywords
11.1 Waste type: wastewater, plating baths
11.2 Process type/waste source: electroplating, zinc
plating, cadmium plating, tin plating, passivating, SIC
Code 3471
11.3 Waste reduction technique: drip confinement, process
redesign, equipment modification
11.4 Other keywords:
12.0 Assumptions
-------
None
13.0 Peer Review: .Unknown
(*) - Disclaimer: Economic data will vary due to economic
climate, varying governmental regulations and other factors.
KEYWORDS: wastewater, plating baths, electroplating, zinc plating,
cadmium plating, tin plating, passivating, SIC Code 3471, drip
confinement, process redesign, equipment modification
r*******************************************
Displaying item number 85
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Document No.: 327-005-A-OOO
1.0 Headline: Pilot Scale Test of "lonnet" Electrolytic
Recovery Unit Plates Out Nickel from Wastewater
2.0 SIC Code: 3471, Electroplating, Plating, Polishing,
Anodizing, and Coloring
3 . 0 Name & Location of Company
Pioneer Industries, Inc.
700 Lordship Blvd.
Stratford CT 06497
4.0 Clean Technology Category: A pilot scale test of an
"lonnet" electrolytic recovery unit was conducted to plate
out nickel from wastewater.
5 . 0 Case Study Summary
5.1 Process and Waste Information: The facility performs
contract plating, utilizing both rack and barrel
techniques and works with nickel and gold
electroplating and electroless nickel plating. A pilot
scale test of an "lonnet" electrolytic recovery unit
was conducted to plate nickel out of wastewater. The
metal-bearing stream enters the unit and is channeled
downward through a eries of electrolytic chambers each
containing an anode and a cathode. The metal ions
readily adhere to the cathode due to an increase in
mass transfer efficiency. Solids which accumulate
during the electrowinning process are swept to the cell
bottom and contained for draining. The lonnet cell can
be used for batch recovery or continuous treatment.
The wastewater was processed through the recovery unit
-------
until it contained less than 20 ppm of nickel. The
wastewater was then further processed using existing
technology before being discharged.
5.2 Scale of Operation: The company employs ten people.
5.3 Stage of Development: The technology was tested in a
pilot scale demonstration.
5.4 Level of Commercialization: The technology is
commercially available.
5.5 Material/Energy Balances and Substitutions:
Information not provided.
6.0 Economics*
6.1 Investment Costs: The cost of the system is $11,900.
6.2 Operational & Maintenance Costs: Savings are $17,000
in waste treatment costs.
6.3 Payback Time: Payback time is 8.4 months.
7.0 Cleaner Production Benefits:
If a full-scale electrolytic recovery unit were installed,
the generation of metal hydroxide sludge and the need for
off-site disposal would be eliminated.
8.0 Obstacles, Problems, and/or Known Constraints:
None mentioned
9.0 Date Case Study Was Performed: The project was completed in
September 1989.
10.0 Contacts and Citation
10.1 Type of Source Material: Technical assistance program
summary.
10.2 Citation: ConnTAP - Matching Challenge Grants, 1988-
89, Connecticut Hazardous Waste Management Service, pp.
6-7. "Electrolytic Recovery of Nickel from an
Electroplating Process, Project P500," Precision Metal
Finishing, Inc., September 1989.
10.3 Level of Detail of the Source Material: A diagram of
the lonnet cell is given in the source document.
10.4 Industry/Program Contact and Address: Jeff Collins,
-------
Prject Manager, Pioneer Industries, Inc. 700 Lordship
Blvd., Stratford, CT 06497, (203) 378-6116.
11.0 Keywords
11.1 Waste type: wastewater, metal-bearing wastes
11.2 Process type/waste source: electroplating, nickel
plating
11.3 Waste reduction technique: electrolytic recovery,
lonnet cell
11.4 Other keywords: pilot scale test
12.0 Assumptions
None
13.0 Peer Review: Unknown
(*) - Disclaimer: Economic data will vary due to economic
climate, varying governmental regulations and other factors.
KEYWORDS: wastewater, metal-bearing wastes, electroplating, nickel
plating, electrolytic recovery, lonnet cell, pilot scale test
**********!
**********
Displaying item number 86
**********:
**********
Document No.: 327-005-A-OOO
1.0 Headline: Waste Minimization Study Identifies Alternatives
for Reducing Wastes at a Metal Finishing Plant
2.0 SIC Code: 3471, Electroplating, Plating, Polishing,
Anodizing and Coloring
3.0 Name & Location of Company
Seaboard Metal Finishing Co., Inc.
50 Fresh Meadow Road, West Haven, CT 06516
4.0 Clean Technology Category: A waste minimization study,
including performing a mass balance and waste inventory,
identified alternatives for future implementation.
5.0 Case Study Summary
-------
5.1 Process and Waste Information: The facility has six
process plating lines, including copper, automatic
nickel, barrel copper/nickel, bulk chrome, hard chrome
and rack nickel/chrome plating. The resulting F006
sludge requires off-site disposal.
A waste minimization study of the six electroplating
lines was conducted. A mass balance was determined by
analyzing the discharges for metals and determining an
average discharge rate. A waste inventory was peformed
and critical sources of waste were identified. Waste
minimization alternatives were analyzed for technical
feasibility and cost effectiveness. The proposed
alternatives included recycling rinsewaters, automating
plating lines, installing evaporation technology and
additional rinse tanks with reduction of countercurrent
flow.
5.2 Scale of Operation: The facility employs 45 plant
personnel.
5.3 Stage of Development: The proposed alternatives had
not been implemented at the time the case study was
written.
5.4 Level of Commercialization: The technology is
commercially available.
5.5 Material/Energy Balances and Substitutions:
Information not available.
6.0 Economics*
6.1 Investment Costs: The cost is estimated at $13,500 for
several new rinse tanks and evaporation unit.
6.2 Operational & Maintenance Costs: Annual savings of
more than $15,000 are anticipated.
6.3 Payback Time: The payback period is estimated at 1.2
years.
7.0 Cleaner Production Benefits: If the alternatives were
implemented, a reduction of 75% would be achieved for
copper, hexavalent chromium, cyanide, and nickel wastewater.
About 16 tons of F006 sludge, now requiring off-site
disposal, would be eliminated.
8.0 Obstacles, Problems, and/or Known Constraints: None
mentioned.
9.0 Date Case Study Was Performed: The project was completed in
April 1989.
-------
10.0 Contacts and Citation
10.1 Type of Source Material: Technical assistance program
summary
10.2 Citation: ConnTAP Matching Challenge Grants - 1988-89,
Connecticut Hazardous Waste Management Service, pp. 8-
9. "Waste Minimization Study." YWC, Inc., April 1989.
10.3 Level of Detail of the Source Material: No additional
information is provided.
10.4 Industry/Program Contact and Address: John Conroy,
Project Manager, Seaboard Metal Finishing Co., Inc., 50
Fresh Meadow Road, West Haven, CT 06516 (203) 933-
1603.
11.0 Keywords
11.1 Waste type: wastewater, plating baths
11.2 Process type/waste source: electroplating, nickel
plating, chrome plating
11.3 Waste reduction technique: waste minimization study,
bath recycling, flow reduction evaporation
11.4 Other keywords:
12 . 0 Assumptions
None
13.0 Peer Review: Unknown
(*) - Disclaimer: Economic data will vary due to economic
climate, varying governmental regulations and other factors.
KEYWORDS: wastewater, plating baths, electroplating, nickel
plating, chrome plating, waste minimization study, bath recycling,
flow reduction evaporation
Displaying item number 87
**********
Document No.: 327-005-A-OOO
1.0 Headline: Evaporative Recovery Systems Evaluated for
-------
Reducing Volume of Hazardous Wastewater
2.0 SIC Code: 3842, Orthopedic, Prosthetic, and Surgical
Appliances and Supplies
3.0 Name & Location of Company
Davis & Geek
Danbury, CT
4.0 Clean Technology Category: The technology involves use of
an evaporative recoery system to reduce hazardous waste
produced from a silk dying process.
5.0 Case Study Summary
5.1 Process and Waste Information: The facility
manufactures surgical equipment, such as arthroscopic
and ophthalmologic devices. A silk dying process is
used which generates hazadrous wastewater.
Two evaporative methods for wastewater reduction were
investigated. A "CALFRAN" cold evaporation unit, which
operated under a vacuum of 10 to 20 torr, and a
"SAMSCO" hot evaporation unit, which is a natural gas
fired air assisten water evaporator, were considered.
The "SAMSCO" system was selected due to a lower capital
expenditure, higher annual savings, low maintenance,
flexibility to add capacity and fewer state permit
requirements.
5.2 Scale of Operation: Information not provided.
5.3 Stage of Development: The system was selected but had
not been purchased or installed at the time of the case
study.
5.4 Level of Commercialization: The equipment is
commercially available.
5.5 Material/Energy Balances and Substitutions:
Information not provided.
6.0 Economics*
6.1 Investment Costs: The investment cost is $68,000.
6.2 Operational & Maintenance Costs: Savings of $51,000
are anticipated.
6.3 Payback Time: The payback period is estimated as 2.1
years.
-------
7.0 Cleaner Production Benefits: The installation of the system
is expected to reduce the volume of hazardous wastewater in
need of disposal by at least 152,000 gallons per year.
8.0 Obstacles, Problems, and/or Known Constraints:
None
9.0 Date Case Study Was Performed: The project to assess the
systems was completed-in November 1989.
10.0 Contacts and Citation
10.1 Type of Source Material: Technical assistance program
summary.
10.2 Citation: ConnTAP Matching Challenge Grants - 1988-89,
Connecticut Hazardous Waste Management Service, pp. 16-
17. "Engineering Report for Silk Dye Waste Reduction
Project," American Cyanamid Company, Davis and Geek
Division, November 1989.
10.3 Level of Detail of the Source Material: Additional
information is available on the SAMSCO system.
10.4 Industry/Program Contact and Address: Joseph
Lacalamito, Project Manager, American Cyanamid Company,
Davis and Geek Division, 1 Casper Street, Danbury, CT
06810, (203) 743-4451.
11.0 Keywords
11.1 Waste type: wastewater
11.2 Process type/waste source: silk dying, SIC Code 3842
11.3 Waste reduction technique: evaporation, hot evaporator
11.4 Other keywords: volume reduction
12.0 Assumptions
13.0 Peer Review
(*) - Disclaimer: Economic data will vary due to economic
climate, varying governmental regulations and other factors.
KEYWORDS: wastewater, silk dying, SIC Code 3842, evaporation, hot
evaporator, volume reduction
Displaying item number 88
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**********
Document No.: 222-003-001
1.0 Headline An adsorbent-based system for effective removal of
low concentration toxic metals from rinse waters has been
developed and tested in the metal plating industry.
2.0 SIC Code: 3471, electroplating, surface finishing, metal
finishing
3.0 Name & Loca'tion of Company
Aluminum Company of America
Alcoa Technical Center
Alcoa Center, PA 15069
4.0 Clean Technology Category
A specialty activated Mg-Al oxide adsorbent, which acts as
an inorganic anion exchange material, is a used as a
wastewater treatment technology.
5.0 Case Study Summary
5.1 Process and Waste Information: The metal finishing
industry performs a wide variety of chemical
operations. Important among these are metal surface
preparation and plating operations. Surface
preparation often consists of chemical etching and
conversion coating with solutions of chromium salts.
The plating operations include both conventional
electroplating processes and electroless chemical
plating of metal films such as Ni-P, Cu, Co, etc. The
testing of a Mg-Al oxide adsorbent-based process which
effectively removes toxic metals from metal finishing
rinse waters is presented in this case study.
The adsorbent was tested in the laboratory on
individual samples from customer's wastewater streams.
Two tests were conducted: a powder treatment study and
a granular column study. Then pilot scale trials were
done to obtain material consumption and economic data.
Testing was done on electroless plating rinses,
hexavalent chromium rinses, and cyanide plating rinses.
5.2 Scale of Operation: The scale of operation of the
plants from which the water was tested was not
described.
5.3 Stage of Development: This treatment method has been
laboratory tested and pilot field tested. The
adsorbent is fully developed.
5.4 Level of Commercialization: The new adsorbent is
-------
trademarked as Alcoa SORBPLUS Adsorbent.
5.5 Material/Energy Balances and Substitutions:
Quantity Quantity
Material Category Before After
Waste Generation:
rinsewater N/A
This study tested the effectiveness of various adsorbent doses by
determining the associated element concentrations in the
laboratory and in pilot field tests. Therefore, a material
balance within a specific facility is not possible. The study
provides the concentrations associated with different adsorbent
doses.
6.0 Economics*
6.1 Investment Costs: not provided
6.2 Operational & Maintenance Costs: not provided
6.3 Payback Time: not provided
7.0 Cleaner Production Benefits The Mg-Al oxide adsorbent is a
non-toxic, non-corrosive inorganic chemical. The key
benefit of the adsorbent is the selective adsorption of
toxic .stream contaminants. The adsorbent is highly
effective at removing chelated nickel, copper or cobalt from
electroless plating baths or rinses; hexavalent chromium
from chrome plating or chromate conversion coating
rinsewaters; and metal complexed cyanides from cyanide
plating rinsewaters.
This treatment technology requires very low capital
investment and low maintenance (figures not provided).
Furthermore, it is feasible to recycle the treated rinse
water which can actually improve the overall system
performance.
8.0 Obstacles, Problems, and/or Known Constraints Spent
adsorbent will have to pass the Toxic Characteristic
Leaching Procedure (TCLP) before being disposed of in a
landfill.
9.0 Date Case Study Was Performed
not provided
10. Contacts and Citation
10.1 Type of Source Material: EPA Conference Proceedings
-------
10.2 Citation: American Electroplaters and Surface
Finishers Society, Inc., and the Environmental
Protection Agency; "12th AESF/EPA Conference on
Environmental Control for the Surface Finishing
Industry; January, 1991; pp. 257-268.
10.3 Level of Detail of the Source Material: Additional
detail is provided on the results of each rinse tested,
including the adsorbent doses, the concentrations of
chemicals in the rinsewater before and after
introducing the adsorbent.
10.4 Industry/Program Contact and Address: not provided
10.5 Abstractor Name and Address: Maria Leet, SAIC, 7600
Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords
11.1 Waste type: rinsewater, plating baths
11.2 Process type/waste source: electroplating, surface
finishing, SIC Code 3471
11.3 Waste reduction technique: wastewater treatment,
adsorption
11.4 Other keywords:
12.0 Assumptions
Although ALCOA is listed above in Section 3.0 as the
facility, the laboratory testing was conducted on
rinsewaters from customer companies. It was not stated
where the pilot field testing was conducted.
13.0 Peer Review
Unknown
(*) - Disclaimer: Economic data will vary due to economic
climate, varying governmental regulations and other factors.
KEYWORDS: rinsewater, plating baths, electroplating, surface
finishing, SIC Code 3471, wastewater treatment, adsorption
*****************************************************************
**********
Displaying item number 89
*****************************************************************
**********
Document No.: 222-003-001
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1.0 Headline A Metal Finishing Plant Tested Silver Reduction
Process To Replace The Existing Treatment Plant and Also Tested
On-site Silver Reclamation To Replace Off-site Reclamation.
2.0 SIC Code: 3471, electroplating, surface finishing
3.0 Name & Location of Company
not specified
4.0 Clean Technology Category; The clean technologies initiated
in the case study consisted of the modification of air-
knives, electrolytic recovery cells and flow restrictors to
reduce silver drag-out and the installation of reverse
osmosis units as in-line reuse systems.
5.0 Case Study Summary
5.1 Process and Waste Information: Two examples of waste
minimization at a metal finishing plant are presented
in this case study. In the first example, the rinse-
wastewater treatment plant was frequently violating the
discharge standard for silver. The major sources of
the silver were rinses following silver-cyanide plating
in the reel-to-reel lines. The plant evaluated whether
or not to modify the treatment system or introduce
waste minimization in the production line. A strategy
to reduce silver drag-out was initiated, including:
efficient air-knives installed at the rinse tanks, more
efficient electrolytic recovery cells installed on the
dead rinses following the silver plating baths, and
flow restrictors installed on all rinses.
In the second example, to replace off-site silver-
reclamation, on-site silver reclamation was initiated
to reclaim silver from the silver dead rinses. This
in-line reuse system consisted of 6 reverse osmosis
units. The installation would involve conversion of
the dead rinse and Dl-Water rinse stations to a two-
stage counter flow rinse, conductivity control of DI
Water supply, and recirculation pumps for rinsing to
reduce the flow rate.
5.2 Scale of Operation: Information not provided.
5.3 Stage of Development: The clean technologies are fully
developed.
5.4 Level of Commercialization: The clean technologies are
fully commercialized.
-------
5.5 Material/Energy Balances and Substitutions:
Quantity Quantity
Material Category Before After
Waste Generation:
silver drag-out reduction:
rinse-wastewater 240,000 gpd 155,000 gpd
silver concentration
in influent 5 mg/1 0.5 mg/1
silver concentrations
in effluent N/A below 0.15
mg/1
6.0 Economics*
6.1 Investment Costs: In the first example, the capital
investment for the silver drag-out reduction was.
$12,000.
The capital cost to install the reverse osmosis units
was estimated at $525,000.
6.2 Operational & Maintenance Costs: Information not
provided.
6.3 Payback Time: without expanding the capacity of the
plant, the payback period for installing the capacity
of the plant, the payback period for installing waste
minimization in the production line was projected to be
less than one month.
The marginal payback period for the in-line reuse
system as compared to the existing off-site reclamation
was projected as 5 months.
7.0 Cleaner Production Benefits: For the first example, the
operating savings of silver drag-out reduction versus
treatment is $470,000 per year. For the first six months
after implementation of the reduction process, all discharge
standards were being met.
In the second example, the net savings of the in-line reuse
system versus the off-site reclamation were estimated at
$825,000. According to laboratory tests, more than 90%
recovery is feasible with the reverse osmosis units.
8.0 Obstacles, Problems, and/or Known Constraints There are
-------
fiscal and organizational limits to implementation of waste
minimization for these processes. The silver drag-out
reduction program required considerable attention from
production Q/A personnel. Despite initial improvements from
waste discharge standards, by the end of a year, silver
violations had returned to their former level. This was due
to significant changes in production and inadequate new
treatment plant and not continue with the waste minimization
efforts.
Due to the large capital cost needed for the in-line-reuse
system, the facility also decided not to adopt the in-line
system.
9.0 Date Case Study Was Performed
Information not provided.
10. Contacts and Citation
10.1 Type of Source Material: EPA Conference Proceedings
10.2 Citation: American Electroplaters and Surface
Finishers Society, Inc., and the Environmental
Protection Agency; "12th AESF/EPA Conference on
Environmental Control for the Surface Finishing
Industry"; January, 1991; pp. 59-69.
10.3 Level of Detail of the Source Material: Further detail
is provided on the silver drag-out reduction strategy
and additional cost data is provided.
10.4 Industry/Program Contact and Address: John Rosenblum,
Rosenblum Environmental Engineering, 3502 Thorn Road,
Sebastopol, CA 95472. Mazen J. Naser, Plating and
Waste Management Consulting, 96 Lycett Circle, Daly
City, CA 94015.
10.5 Abstractor Name and Address: Maria Leet, SAIC 7600
Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords
11.1 Waste type: rinsewater, wastewater
11.2 Process type/waste source: electroplating, SIC Code
3471, electroplating baths
11.3 Waste reduction technique: reuse, reclamation, reverse
osmosis, electrolytic recovery, process modification,
-------
silver recovery drag-out reduction.
11.4 Other keywords: economics, payback period, economic
evaluation, return on investment.
12.0 Assumptions
None
13.0 Peer Review
Unknown
(*) - Disclaimer: Economic data will vary due to economic
climate, varying governmental regulations and other factors.
KEYWORDS: rinsewater, wastewater, electroplating, SIC Code 3471,
electroplating baths, reuse, reclamation, reverse osmosis,
electrolytic recovery, process modification, silver recovery
drag-out reduction, economics, payback period, economic evaluation,
re
Displaying item number 90
**********
Document No.: 222-003-001
1.0 Headline Use of Simple Material Balances Solves Problems in
A Circuit Board Manufacturer's Waste Water Treatment Plant.
2.0 SIC Code: 3672, printed circuit board manufacturing, 3471,
electroplating, surface finishing
3.0 Name & Location of Company
Teradyne Connection Systems
4 Pittsburgh Avenue
Nashua, NH 03062
4.0 Clean Technology Category
After conducting a material balance, the company implemented
technologies including process modification, equipment
redesign, and water conservation. Recycling, incineration,
minimizing landfilling, equipment modification, on-site
treatment, ion exchange, neutralization, electrolytic
recovery were also used as clean technologies.
5.0 Case Study Summary
-------
5.1 Process and Waste Information: This circuit board
manufacturing facility used conventional precipitation
for waste treatment. After monitoring the compliance
data from the waste treatment effluent with respect to
copper concentration, it became evident that the system
was incapable of providing repeatable results. There
were copper spikes in the effluent that were apparently
caused by non-settleable particles in the clarification
process.
A water material balance was conducted to verify the
flow rates from the process area and the flow rates
into the waste treatment area. To reduce the hydraulic
loading on the waste water treatment system, non-
contact cooling water and scrubbing water were
eliminated by installing closed loop systems.
Equipment washdowns were also reduced 80% by installing
automatic shut offs on the washdown hoses and devising
and implementing strict water conservation
specifications. In addition, to reduce the water flow
rate supplying the process equipment, rinsing
specifications were determined and flow restrictors
were installed. Electronic controls were also
installed to shut down the water flow to production
equipment when unattended.
A material balance of hazardous waste was also used to
attempt to understand the type and amount of waste
material that was being disposed of from the waste
treatment process. Strategic plans for waste
management were then made, including: recycling,
incinerating all organic material, and minimizing or
eliminating materials that are landfilled. Therefore,
two changes were made in waste handling at the
facility: (1) a sludge dehydrator was installed to
increase the solids content of the F006 metal hydroxide
sludge and reduce the amount of material that is
disposed of at hazardous waste landfills and (2) the
copper pyrophosphate material was to be treated in-
house and not shipped off-site for disposal.
To minimize hazardous waste generation, ion exchange
can be coupled with electrolytic recovery. A material
balance was used to investigate the feasibility of such
a system. Depending on the concentration of the
process waste water entering the collection system,
either conventional treatment (precipitation), or
neutralization should be used. It was discovered that
one line entering the collection system, which has a
flow rate of 15.5 gpm, would benefit from an ion
exchange/electrolytic recovery system.
-------
5.2 Scale of Operation: There are 275 employees. Water
usage at the facility is 100,000 gpd.
5.3 Stage of Development: The technology is fully
developed.
5.4 Level of Commercialization: Information not provided.
5.5 Material/Energy Balances and Substitutions:
Material Category
Waste Generation:
copper pyrophosphate
Assumptions
below)
metal hydroxide sludge
Feedstock Use:
Quantity
Before
2,764 Ibs
410,000 IbS
25% solids
N/A
Quantity
After
2,500 Ibs (see
12.0
101,675 Ibs
95% solids
N/A
Material Category
Quantity
Before
Quantity
After
Water Usage:
Process rinsewater 176 gpm
Mechanical scrubber water 118 gpm
Non-contact cooling water 42 gpm
Equipment washdowns 10 gpm
106 gpm
-0-
-0-
-0-
Energy Use: N/A N/A
6.0 Economics*
6.1 Investment Costs: Information not provided
6.2 Operational & Maintenance Costs: Information not
provided
6.3 Payback Time: Information not provided
-------
7.0 Cleaner Production Benefits
Process water flow rates were reduced approximately 40%.
The results of the flow rate reduction proved effective in
increasing the repeatability of the effluent stream and
resulted in a treatment confidence level of 99.45%.
The installation and operation of the sludge dehydrator
increased the solids content of the F006 sludge from 25 to
95% and decreased the volume by 75% which reduced disposal
by 308,325 pounds per year. In addition, by drying the
sludge, the leaching capability and thus the toxicity is
reduced.
The process to treat the copper pyrophosphate was designed
and installed in-house. This reduced the outside waste
disposal by approximately 2700 Ibs per year.
Subsequent to a materials balance of the hazardous waste,
for a relatively small capital investment, a significant
portion of the metal hydroxide sludge generation could be
shifted to the production of non-hazardous metal products.
8.0 Obstacles, Problems, and/or Known Constraints
Information not provided
9.0 Date Case Study Was Performed
The date was not provided, however, the case study was
published in a January 1991 document.
10. Contacts and Citation
10.1 Type of Source Material: EPA Conference Proceedings
10.2 Citation: American Electroplaters and Surface
Finishers Society, Inc., and the Environmental
Protection Agency; "12th AESF/EPA Conference on
Environmental Control for the Surface Finishing
Industry"; January, 1991; pp. 113-129.
10.3 Level of Detail of the Source Material: No further
details were provided on material balances, and flow
charts of the plant processes.
10.4 Industry/Program Contact and Address: David A. Wood,
P.T., Teradyne Connection Systems, 4 Pittsburgh Avenue,
Nashua, NH 03062.
10.5 Abstractor Name and Address: Maria Leet, SAIC, 7600-A
Leesburg Pike, McLean, VA 22043-4317.
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11.0 Keywords
11.1 Waste type: waste water, sludge, metals, copper
11.2 Process type/waste source: SIC Code 3672, printed
circuit board manufacturing, SIC Code 3471,
electroplating, surface finishing
11.3 Waste reduction technique: ion exchange, electrolytic
recovery, process modification, equipment redesign
11.4 Other keywords: wastewater reduction, materials
balance
12.0 Assumptions
13.0 Peer Review
Unknown
(*) - Disclaimer: Economic data will vary due to economic
climate, varying governmental regulations and other factors.
KEYWORDS: waste water, sludge, metals, copper, SIC Code 3672,
printed circuit board manufacturing, SIC Code 3471, electroplating,
surface finishing, ion exchange, electrolytic recovery, process
modification, equipment redesign, wastewater reduction, mater
**********
Displaying item number 91
**********1
**********
Document No.: 222-003-001
1.0 Headline The Removal of Certain Metals Can Be Accurately
Monitored with Oxidation Reduction Potential (ORP) Probes in The
Metal Plating Industry
2.0 SIC Code: 3471, electroplating, surface finishing
3.0 Name & Location of Company
Nalco Chemical Company
Naperville, Illinois
4.0 Clean Technology Category
The clean technology used in these metal plating plants is
precipitation. This case study evaluated Oxidation
-------
Reduction Potential (ORP) probes to measure metals removal.
5.0 Case Study Summary
5.1 Process and Waste Information: A research study was
done to evaluate Oxidation Reduction Potential (ORP)
probes as sensors in metal ion precipitation at Nalco
Chemical Company. Wastewater samples were tested using
this method from four plants including, two printed
circuit board plants, a zinc plating plant and a brass
plating plant.
5.2 Scale of Operation: Information not provided
5.3 Stage of Development: The use of ORP probes as process
sensors in ion precipitation is still in the testing
phase.
5.4 Level of Commercialization: ORP probes are fully
commercialized as they are commonly used in the plating
industry to automate control of cyanide destruction and
chromium (VI) reduction processes.
5.5 Material/Energy Balances and Substitutions:
Quantity Quantity
Material Category Before After
Waste Generation:
Feedstock Use: N/A
Water Use:
Energy Use:
-------
6.0 Economics*
6.1 Investment Costs: Information not provided.
6.2 Operational & Maintenance Costs: Information not
provided
6.3 Payback Time: Information not provided
7.0 Cleaner Production Benefits
Removal of certain metals can be accurately monitored with
ORP probes. In laboratory studies, marked response of ORP
was seen at the equivalence point (dosage corresponding to
metal ion disappearance) for a copper-bearing wastewater, a
synthetic copper-nickel wastewater, and a copper-zinc
wastewater. ORP responds to the disappearance of certain
metal ions such as copper and nickel, that are active at the
electrode.
8.0 Obstacles, Problems, and/or Known Constraints
In one sample of circuit board plating wastewater, the
presence of an interference predicted severe product
overfeed and under ORP control. The need for waste stream
equalization or removal of the suspect stream from the
continuous process was suggested.
9.0 Date Case Study Was Performed Information not provided
10. Contacts and Citation
10.1 Type of Source Material: EPA Conference Proceedings
10.2 Citation: American Electroplaters and Surface
Finishers Society, Inc., and the Environmental
Protection Agency; "12th AESF/EPA Conference on
Environmental Control for the Surface Finishing
Industry"; January, 1991; pp. 309-316.
10.3 Level of Detail of the Source Material: Specific
details of the experimental procedure and the responses
of the ORP probe to metals removal are provided.
10.4 Indus try/Program Contact and Address: Kristine s.
Siefert and Kerstin Lampert, Nalco Chemical Company,
Naperville, Illinois.
10.5 Abstractor Name and Address: Maria Leet, SAIC, 7600-A
Leesburg Pike, McLean, VA 22043-4317.
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11.0 Keywords
11.1 Waste type: wastewater
11.2 Process type/waste source: electroplating, plating,
SIC Code 3471, printed circuit board manufacturing,
zinc plating, brass plating
11.3 Waste reduction technique: metal ion precipitation,
metal recovery
11.4 Other keywords: oxidation reduction potential (ORP)
probes
12.0 Assumptions
None
13.0 Peer Review
Unknown
(*) - Disclaimer: Economic data will vary due to economic
climate, varying governmental regulations and other factors.
KEYWORDS: wastewater, electroplating, plating, SIC Code 3471,
printed circuit board manufacturing, zinc plating, brass plating,
metal ion precipitation, metal recovery, oxidation reduction
potential (ORP) probes
Displaying item number 92
**********
Document No.: 222-003-001
1.0 Headline: Metal Recovery Systems Installed in an
Electroplating Facility Reduces Waste Generation, and Disposal
Costs, and the Potential for Wastewater Treatment Upsets
2.0 SIC Code: 3471, electroplating, surface finishing
3.0 Name & Location of Company: Von Duprin, Incorporated,
Indianapolis, Indiana.
4.0 Clean Technology Category
The metal recovery systems involve spray rinses, a
reciprocating bed ion-exchange system, atmospheric
evaporation, a stagnant rinse, and reverse osmosis.
5.0 Case Study Summary
5.1 Process and Waste Information: Von Duprin conducts
-------
automated hoist rack plating of copper cyanide, satin and
bright nickel, decorative chromium, brass cyanide and
barrel plating of alkaline non-cyanide zinc.
Previously implemented waste reduction measures include
the following: modifying rack designs to minimize
cupping; adjusting automatic hoist parameters to include
extended drip times; using two-stage and three-stage
counterflow rinses; using stagnant baths for recovery of
dragout from bright nickel and chrome baths; using
alkaline non-cyanide zinc bath to minimize use of
cyanides; and eliminating vapor degreasing.
New technically and economically optimal processes
selected for the facility include five metal recovery
system:
(1) Cyanide copper - The chosen technology includes
a combination of spray rinses to minimize dragout and
atmospheric evaporation to allow space in the bath for
added water. These technologies result in maximum
recovery of solution with minimal capital and operating
costs. They also result in less operator and maintenance
attention than other minimization options. However,
because of the use of the atmospheric evaporator on a
cyanide bath, there is an increased rate of buildup of
potassium carbonate in the bath.
(2) Nickel - Installation of a reciprocating bed
ion-exchange system for recovery and reuse of a nickel
chloride/nickel sulfate mix was recommended. Nickel can
be recovered from both the satin and bright nickel baths
without fear of bath contamination associated with
recovery of bath brighteners. The reciprocating bed
design offers the direct ability to reuse recovered
solution without further processing to remove excess
water. Although the system has a relatively high capital
cost, the payback period on the capital investment was
less than two years.
(3) Chrome - A combination of spray rinsing,
atmospheric evaporation and a stagnant rinse to minimize
dragout and recover solution captured in the first rinse
was selected. This system greatly improved recovery with
a minimal capital investment. The system is also
applicable to atrivalent chrome processing. The system,
however, causes the buildup of impurities from reuse of
the dragout. The ability of the existing tank steam
coils to handle the heat loss from the evaporator was
also found to be a problem after the system was
installed.
(4) Brass - Reverse osmosis to capture dragout and
return to clean water for rinsing was selected. This
-------
system allows for closed-loop rinsing which eliminates
cyanide discharges. This does have a high capital and
operating costs. Buildup of carbonates is also a
concern, but this has not been observed at the plant.
(5) Non-cyanide alkaline zinc: Reverse osmosis
captures dragout from this barrel line and atmospheric
evaporators make room in the bath for reuse of all of the
recovered solution. This allows for a closed-loop system
thus eliminating zinc discharge. Reverse osmosis also
allows for recovery and reuse of the zinc, unlike ion
exchange systems, which were designed to recover a zinc
metal which would be shipped off-site. The main
disadvantage was the lack of vendor in-plant experience
with the system.
In addition to the five processes described above,
process water for bath makeup and rinsing in the plating
area was upgraded through the installation of a reverse
osmosis water treatment system. In addition, water use
was achieved through reactive rinsing. Rinsewater from
acid activation steps was pumped to rinse parts after
alkaline steps.
5.2 Scale of Operation: Information not provided
5.3 Stage of Development: While all systems are not fully
operational on a continual basis, some reduction in
sludge volumes has been seen. Metal usage in the third
quarter of 1990 was less than half of that in the first
quarter of 1990.
5.4 Level of Commercialization: The clean technologies are
fuXly commercialized.
5.5 Material/Energy Balances and Substitutions:
Quantity Quantity
Material Category Before After
Waste Generation: N/A N/A
Feedstock Use: N/A N/A
Water Use: N/A N/A
Energy Use: N/A N/A
6.0 Economics*
6.1 Investment Costs: Costs were not provided although costs
were considered in their evaluation of selecting waste
reduction processes. For example, it was stated that the
reciprocating bed design has a "relatively high capital
cost".
6.2 Operational & Maintenance Costs: Costs were not provided
although costs were considered in the selection of waste
-------
reduction processes.
6.3 Payback Time: The reciprocating bed ion-exchange system
for recovery and reuse of a nickel chloride/nickel
sulfate mix has a payback period of under two years.
7.0 Cleaner Production Benefits
The systems provide a cost-effective means to reduce waste
generation and disposal costs, enhance community and customer
relations, and reduce the potential for wastewater treatment
upsets. Significant reductions in metals and cyanides are
expected to result and metal usage by the plant is already
decreased over 50%. Drastic reductions in sludge volume are
expected when the zinc recovery system operates consistently
and bath dumping is minimized.
8.0 Obstacles, Problems, and/or Known Constraints
Some .of the problems related to each process are discussed
above in Section 5.1.
During the installation of the equipment, there were some
problems, including a lack of constant adequate water pressure
to feed the reverse osmosis unit, resulting in system
shutdowns. During the installation of the nickel recovery
ion-exchange system, piping contractors inappropriately
mounted several transfer pumps outside of the diked area
provided for the equipment. The major problems associated
with the ion-exchange system included the control logic, which
had to be modified to allow smooth operation, and the
variations rinse conductivities, which was resolved by
reducing the acid amounts and adjusting the conductivity
control loop.
To install the brass and zinc reverse osmosis systems,
substantial time was spent cleaning rinse tanks to remove
hardness salts which could foul the reverse osmosis membranes.
Extra costs were incurred to provide additional electrical
noise isolation to protect system components.
Several problems were found in the first few months of
operation of the reverse osmosis systems. A diatomaceous
earth (DE) prefilter included in the zinc system repeatedly
became plugged with a hard deposit that also clogged the
piping to the DE filter. This clogging caused several failed
prefilter pumps. It was determined that it was a result of
calcium carbonate in the system, coming from the use of
insufficient quality water before installation of softeners
and reverse osmosis membranes on the water supply. The
calcium carbonate also apparently passed through the DE
filter, plugging one set of reverse osmosis membranes.
9.0 Date Case Study Was Performed
-------
The case study was conducted in 1989-1990. Dates of
installation of technologies was not provided.
10. Contacts and Citation
10.1 Type of Source Material: EPA Conference Proceedings
10.2 Citation: American Electroplaters and Surface Finishers
Society, Inc., and the Environmental Protection Agency;
"12th AESF/EPA Conference on Environmental Control for
the Surface Finishing Industry; January, 1991; pp. 51-57.
10.3 Level of Detail of the Source Material: Additional
information is available concerning the equipment and its
operation.
10.4 Industry /Program Contact and Address: James Smith and
Michael Bayman, Von Duprin, Inc., Indianapolis, IN.
Daniel Reinke, Capsule Environmental Engineering, Inc.
10.5 Abstractor Name and Address: Maria Leet, SAIC, 7600-A
Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords
11.1 Waste type: wastewater, rinsewater
11.2 Process type/waste source: electroplating, SIC Code
3.471, plating baths
11.3 Waste reduction technique: evaporation, ion-exchange,
metals recovery, drag-out recovery, reverse osmosis,
closed-loop recycling, rinsing techniques
11.4 Other keywords: wastewater reduction
12.0 Assumptions
None
13.0 Peer Review: Unknown
(*) - Disclaimer: Economic data will vary due to economic climate,
varying governmental regulations and other factors
KEYWORDS: wastewater, rinsewater, electroplating, SIC Code 3471,
plating baths, evaporation, ion-exchange, metals recovery, drag-out
recovery, reverse osmosis, closed-loop recycling, rinsing
techniques, wastewater reduction
Displaying item number 93
-------
**********
Document No.: 222-003-001
1.0 Headline
Closed-loop Recycling Reduces Metal Finishing Wastewater
Discharges
2.0 SIC Code: 3471, electroplating, surface finishing
3.0 Name & Location of Company
Pratt & Whitney Aircraft, North Haven, CT
4.0 Clean Technology Category
Striving toward zero discharge, a closed-loop recycling system
using good operating practices has been installed.
5.0 Case Study Summary
5.1 Process and Waste Information: This facility produces
major metal-finished rotating parts such as discs, hubs,
and shafts. In 1987, they were discharging approximately
1,000,000 GPD of treated wastewater, 400,000 of which was
generated by metal-finishing operations. Implementation
of a "zero discharge" program involved 6 phases.
In Phase One good operating practices were defined.
These include defining minimum water quality standards;
using countercurrent rinses to reduce water usage; using
continuous process purification versus batch purification
to maintain consistent process quality (i.e., dummy
plating and carbon and particulate filtration); using on-
line process monitors to control solution additions;
optimizing process solutions to control dragout;
optimizing preplate rinsing to control dragin of
contaminants; installing automatic level controls on all
heated processes; training operators to understand proper
rinsing and work transfer techniques to reduce dragout
and dragin; and treating small concentrated batches as
opposed to high volume dilute wastestrearns.
Phase Two is to implement Phase One. Phase Three is
designed to verify closed-loop technology on a single
process. This was conducted on an existing nickel
plating process encompassing a Woods nickel strike and
four sulfamate nickel plating tanks.
Phase Four incorporates good operating practices and
closed-loop technologies in the design of planned and
appropriated new plating lines. Mew plating lines,
encompassing (l) nickel and chromium plating, (2)
cadmium, chromium, and nickel stripping, and (3) titanium
-------
descaling were already on the drawing boards. Initial
plans were revised to incorporate countercurrent rinses,
ion exchange (nickel strike, nickel strip, cadmium strip,
and chromium strip); atmospheric evaporation (hard
chromium, and sulfamate nickel); and deionized water in
all critical rinses and softened water in all noncritical
rinses and noncritical evaporation makeup.
Phase Five was to install the plating lines. Phase
Six involved renovating remaining existing processes,
including cadmium cyanide plating and chromating.
5.2 Scale of Operation: The facility encompasses 1,000,000
square feet. It was discharging 1,000,000 GPD of treated
wastewater, 400,000 GPD of which was generated from metal
finishing operations.
5.3 Stage of Development: Implementation of Phase Three is
fully developed and was completed in August, 1989. The
plating lines (Phase Five) are also completely developed
and were installed by October, 1990.
5.4 Level of Commercialization: The new processes are fully
commercialized.
5.5 Material/Energy Balances and Substitutions:
Material Category Qty. Before Qty. After
Waste generation: N/A N/A
Feedstock Use: N/A N/A
Water Use: Shown in process schematics
Energy Use: N/A N/A
6.0 Economics*
6.1 Investment Costs: Information not provided
6.2 Operational & Maintenance Costs: Information not
provided
6.3 Payback Time: The anticipated payback time is less than
two years.
7.0 Cleaner Production Benefits
The metal finishing contribution to the total wastestream
volume has been reduced from 40% to 5%.
Raw material costs have been reduced by approximately
90%. Transportation and disposal costs and associated
liabilities have also been reduced by the same order of
magnitude due to the decreased sludge production and decreased
shipments of concentrated solution wastes to a treatment
facility. Product quality has also improved and operator
acceptance has been very good despite initial skepticism.
-------
8.0 Obstacles, Problems, andyor Known Constraints
None mentioned
9.0 Date Case Study Was Performed
The date the case study was not provided, however, the initial
conception for the zero-discharge plan began in 1987.
10. Contacts and Citation
10.1 Type of Source Material: EPA Conference Proceedings
10.2 Citation: American Electroplaters and Surface Finishers
Society, Inc., and the Environmental Protection Agency;
"12th AESF/EPA Conference on Environmental Control for
the Surface Finishing Industry; January, 1991; pp. 75-89.
10.3 Level of Detail of the Source Material: Additional
details on the process description, nickel concentration,
conductivity, workload and water usage are provided in
graphs.
10.4 Industry/Program Contact and Address: Industry contact
not provided.
10.5 Abstractor Name and Address: Maria Leet, SAIC, 7600-A
Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords
11.1 Waste type: wastewater, metal finishing wastes,
rinsewater
11.2 Process type/waste source: electroplating, SIC Code 3471
11.3 Waste reduction technique: closed-loop recycling,
counter-current rinsing, ion exchange, evaporation,
housekeeping
11.4 Other keywords: wastewater reduction
12.0 Assumptions
None
13.0 Peer Review
Unknown
(*) - Disclaimer: Economic data will vary due to economic climate,
varying governmental regulations and other factors
KEYWORDS: wastewater, metal finishing wastes, rinsewater,
electroplating, SIC Code 3471, closed-loop recycling,
-------
counter-current rinsing, ion exchange, evaporation, housekeeping,
wastewater reduction
**********
Displaying item number 94
**********
Document No.: 222-003-001
1.0 Headline
Printed Circuit Board Manufacturer Reduces Air Emissions,
Wastewater Discharge, Sludge, and Chemical Wastes through
Process Changes, Equipment Modifications, and Recycling
2.0 SIC Code: 3672, printed circuit board manufacturing; 3471,
electroplating, surface finishing
3.0 Name & Location of Company
Bull HN Information Systems Inc., Brighton, MA.
4.0 Clean Technology Category
The technologies include: changing from solvent-based to
aqueous-based processes; recycling through ion exchange;
installing filter presses into the effluent waste treatment
process to reduce sludge volume; and recycling of waste
chemicals.
5.0 Case Study Summary
5.1 Process and Waste Information: This printed circuit
board manufacturer produces four types of waste: air
emissions, wastewater discharge, sludge, and chemical
disposals. The company is attempting to reduce and
recycle these emissions.
Air emissions: The facility previously used 1,1,1-
trichloroethane and methylene chloride as stripping and
cleaning agents. The solvent-based stripping process was
converted to an aqueous base stripping process by
substituting aqueous materials for the chlorinated
solvents.
Wastewater discharge: The wastewater treatment
system installed in the 1970's consisted of one giant
tank for neutralizing wastewater. Several problems arose
with this system because the system could not
satisfactorily remove all insoluble contaminants due to
equipment corrosion. The equipment began to malfunction
due to age.
-------
A new industrial wastewater treatment system was
installed consisting of three parts: segregated rinse
waters (allowing recycling through ion exchange),
combined rinse waters (treated through a large ion
exchange system and discharged directly to the sewer),
and effluent treatment systems which concentrate metal
bearing solution streams from ion exchange backwash.
Regenerant wastes combined with metered bath dumps are
also treated through two identical conventional effluent
treatment systems.
Sludge disposal: In the 1970's, the by-product of
the effluent waste treatment process was the
precipitation of metal hydroxides or "sludges." The old
system produced a large volume of sludge which was
difficult to dewater and had to be manually collected.
After the installation of several plate and frame filter
presses in the new effluent treatment system and the use
of coagulation and flocculation, the operation improved
considerably and the sludge volume was significantly
reduced.
Chemical Disposal: Previously, chemical wastes were
transported, treated, and disposed of off-site. Most of
the waste is now either treated on site or returned to
the manufacturer who in turn recycles the chemical.
5.2 Scale of Operation: The industrial wastewater treatment
system can process nearly 250,000 gallons of combined
treated rinse and wastewater per day.
5.3 Stage of Development: Conversion to aqueous-based
stripping was completed in 1987. The installation of the
wastewater treatment system was completed in 1984.
5.4 Level of Commercialization: The processes are fully
commercialized.
5.5 Material/Energy Balances and Substitutions:
Material Category Qty. Before Qty. After
Waste generation: N/A N/A
Feedstock Use: N/A N/A
Water Use: N/A N/A
Energy Use: N/A N/A
6.0 Economics*
6.1 Investment Costs: Conversion to the aqueous-based
stripping process cost $1.8 million (1987 dollars). The
cost of installing the wastewater treatment system was
greater than $2.5 million.
.6.2 operational & Maintenance Costs: Information not
provided.
-------
6.3 Payback Time: Information not provided.
7.0 Cleaner Production Benefits
Greater than 20% of the company's industrial waste water is
recycled. The sludge volume was "significantly" reduced.
Chemical recycling reduced trucking-out of wastes by 90%.
8.0 Obstacles, Problems, and/or Known Constraints
Information not provided.
9.0 Date Case Study Was Performed Information not provided.
10. Contacts and Citation
10.1 Type of Source Material: EPA Conference Proceedings
10.2 Citation: American Electroplaters and Surface Finishers
Society, Inc., and the Environmental Protection Agency;
"12th AESF/EPA Conference on Environmental Control for
the Surface Finishing Industry;" January, 1991; pp. 91-
99.
10.3 Level of Detail of the Source Material:
Additional information is provided on equipment and
future steps to be taken by the facility..
10.4 Industry/Program Contact and Address:
Solomon Roditi, Bull HN Information Systems, Inc.,
Brighton, MA.
10.5 Abstractor Name and Address: Maria Leet, SAIC, 7600-A
Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords
11.1 Waste type: sludge, organic chemicals, volatile organic
compounds, wastewater
11.2 Process type/waste source: printed circuit board
manufacturing, SIC Code 3672, electroplating, SIC Code
3471
11.3 Waste reduction technique: process redesign, equipment
modification, recycling, ion exchange,
11.4 Other keywords: sludge, volume reduction
12.0 Assumptions
None
13.0 Peer Review: Unknown
-------
(*) - Disclaimer: Economic data will vary due to economic climate,
varying governmental regulations and other factors
KEYWORDS: sludge, organic chemicals, volatile organic compounds,
wastewater, printed circuit board manufacturing, SIC Code 3672,
electroplating, SIC Code 3471, process redesign, equipment
modification, recycling, ion exchange, sludge, volume reduction
**********
Displaying item number 95
*****************************************************************
**********
Document No.: 222-003-001
1.0 Headline: Treatability and Pilot Tests have Successfully
Reduced Effluent Toxicity from a Metal Finishing Facility
2.0 SIC Code: 3471, electroplating, surface finishing
3.0 Name & Location of Company
Har-Conn Chrome Company
603 New Park Avenue
West Hartford, CT 06110
4.0 Clean Technology Category
The company initiated a toxicity reduction program including
a pilot study that incorporated pH adjustment (to pH 11) for
metals precipitation, followed by filtration and final pH
adjustment. In addition, as part of a waste minimization
program, water conservation efforts have begun and pollution
prevention techniques, including evaporation, ion exchange,
electrowinning, and recovery of metals, are being or will be
installed to enhance the reduction of toxic effluents from the
facility.
5.0 Case Study Summary
5.1 Process and Waste Information:
Har-Conn conducts the following metal finishing
operations: cleaning (acid and alkaline), electroplating
(chromium, nickel, copper, cadmium, tin and silver),
electroless plating (silver), anodizing (titanium and
aluminum), phosphating (zinc and manganese), and
chormating. Rinsewater from these operations are
discharged to a treatment system which consists of
cyanide destruction, chrome reduction, pH adjustment,
equalization and pressure filtration.
-------
A toxicity reduction program was initiated in August 1989
and was continuing at the time this case study was
prepared. A successful pilot study was conducted that
incorporated elevated pH adjustment for metals
precipitation, filtration and final pH adjustment.
Microfiltration is currently being evaluated as a means
of upgrading the current pressure filtration system.
Har-Conn is also undertaking the first phase of a
comprehensive waste minimization program. The purpose of
this program is to identify, evaluate and implement
applicable techniques for the conservation and/or
recovery of process chemicals and water. The first phase
consists primarily of water conservation efforts. As an
initial step, the company has installed flow restrictors
on all running rinses. In addition, conductivity
controllers were being installed at various areas of the
plant to reduce rinsewater discharge rates. To further
reduce flow rates, a portion of the final effluent will
be recycled for use in non-critical rinsing applications.
This will be done after an upgraded treatment system is
installed.
A second phase of waste minimization is planned to reduce
releases of toxic metals. The company plans to implement
(1) process techniques to reduce chemical drag-out and
(2) evaporation, ion exchange and electrowining
technologies for point source treatment and recovery of
chemicals. Based on results of toxicity evaluation
procedures, source reduction efforts will initially
concentrate on cadmium and copper. Nickel, although
relatively less toxic than these metals, will also be
included in these efforts due to its high contribution of
the total metals load and potential for economic recovery
of nickel salts.
5.2 Scale of Operation:
Approximately 60,000 gallons per day of effluent are
discharged from the facility.
5.3 Stage of Development:
The pilot study for metals precipitation and filtration
has been completed. Under the waste minimization
program, flow restrictors have been installed and
conductivity controllers were being installed at the time
of the case study report. The evaporation, ion exchange
and electrowinning technologies have not yet been
implemented.
5.4 Level of Commercialization: Information not provided.
-------
5.5 Material/Energy Balances and Substitutions:
Quantity Quantity
Material Category Before After
Waste Generation: 90,000 gpd 60,000 gpd
rinsewater rinsewater
(Aug, 1990) (Sept, 1990)
Feedstock Use: N/A N/A
Water Use: N/A N/A
Energy Use: N/A N/A
6.0 Economics*
6.1 Investment Costs: Information not provided.
6.2 Operational & Maintenance Costs: Information not
provided.
6.3 Payback Time: Information not provided.
7.0 Cleaner Production Benefits
Toxicity has been reduced through the treatability of
rinsewater by pH adjustment and filtration. The installation
of flow restrictors on running rinses has reduced water use at
the facility by 33%. In addition, conductivity controllers
which were being installed at the time of the case study, are
expected to reduce the rinsewater discharge rate from 60,000
to 45,000 gpd. Recycling of rinse waters should reduce
effluent flow to less than 30,000 gpd. Finally, there is the
potential for economic recovery of nickel salts.
8.0 Obstacles, Problems, and/or Known Constraints
To achieve compliance with the chronic toxicity limits, flow
reduction and waste minimization efforts aimed at point source
reduction of specific toxic metals will be required.
9.0 Date Case Study Was Performed: Information was not provided.
The case study was presented at a Conference in January 1991.
10. Contacts and Citation
10.1 Type of Source Material: EPA Conference Proceedings
10.2 Citation: American Electroplaters and Surface Finishers
Society, Inc., and the Environmental Protection Agency;
"12th AESF/EPA Conference on Environmental Control for
the Surface Finishing Industry;" January, 1991; pp. 101-
111.
10.3 Level of Detail of the Source Material: Additional
toxicity data are provided.
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10.4 Industry/Program Contact and Address: Scott Backus, Vice
President, Har-Conn Chrome Co., 603 NewPark Avenue, West
Hartford, CT 06110; Bill Willams, P.E., Vice President,
Paul Schaffman, Project Engineer, Consulting-
Environmental Engineers, Inc., 100 Shield Street, West
Hartford, CT 06110.
10.5 Abstractor Name and Address: Maria Leet, SAIC, 7600-A
Leesburg Pike, Falls Church, VA 22043.
11.0 Keywords
11.1 Waste type: rinsewater, metals,
11.2 Process type/waste source: electroplating, metal
finishing, SIC Code 3471
11.3 Waste reduction technique: toxics reduction, filtration,
ion exchange, precipitation, source reduction, water
conservation, evaporation
11.4 Other keywords: wastewater reduction
12.0 Assumptions
13.0 Peer Review
Unknown
(*) - Disclaimer: Economic data wi'll vary due to economic climate,
varying governmental regulations and other factors
KEYWORDS: rinsewater, metals, electroplating, metal finishing, SIC
Code 3471, toxics reduction, filtration, ion exchange,
precipitation, source reduction, water conservation, evaporation,
wastewater reduction
Displaying item number 96
Document No. 453-001-A-OOO
1.0 Headline: Recovery and Use of Methane From Sugar Beet
Processing Effluent
2.0 SIC Code: 2063, Beet Sugar
3 . 0 Name and Location of company
British Sugar pic
Oundle Road
Peterborough PE2 9QU, England
-------
4.0 Clean Technology Category
This technology uses an anaerobic stage to recover
methane from sugar beet effluent for use as a process
fuel.
5.0 Case Study Summary
5.1 Process and Waste Information: The facility
processes sugar beets generating a wastewater effluent
with a high chemical oxygen demand. Traditionally, this
effluent was dealt with aerobically by a water treatment
plant and its organic content wasted. The clean
technology was to add an anaerobic stage to the water
treatment section to convert the organic content of the
effluent to usable methane. The fermentation takes place
in the digestion vessel, the off-gas consists largely of
methane with some carbon dioxide. Key features of the
process are the pre-heating of the incoming stream using
low-grade heat, careful control of the pH and the
recirculation of sludge. The methane provides process
heat to dry the pulp for use as an animal feed.
5.2 Scale of Operation: British Sugar operates 12 beet
factories and employs 3,000 people. The Peterborough
facility produces 100,000 tons of sugar per year.
5.3 Stage of Development: The technology is fully
implemented.
5.4 Level of Commercialization: No information
provided.
5.5 Material/Energy Balances and Substitutions: No
information provided.
6.0 Economics*
6.1 Investment Costs: The capital cost of the
technology is 750,000 English Pounds.
6.2 Operational and Maintenance Costs: Annual savings
in lower sewage charges are 26,000 English Pounds and
8,000 English Pounds in electricity cost savings. The
value of recovered gas is 25,000 English Pounds.
6.3 Payback Time: Payback time is 12 years.
7.0 Cleaner Production Benefits
The technology resulted in reduced chemical oxygen demand
in the wastewater effluent. Recovery and use of methane
from organic matter in the waste water effluent were
achieved. Lower operating costs and energy conservation
-------
were added benefits of the technology.
3.0 Obstacles, Problems and/or Known Constraints
None were identified.
9.0 Date Case Study Was Performed
Unknown.
10.0 Contacts and Citation
10.1 Type of Source Material: Government Publication.
10.2 Citation: Clean Technology, Environmental
Protection Technology Scheme, Department of the
Environment, 2 Marsham Street, London SW1P 3EB, 1989,
p. 21.
10.3 Level of Detail of the Source Material: No
additional detail is provided.
10.4 Industry/Program Contact and Address: Mr. J.N.
Smith, Chief Safety and Environment Officer, British
Sugar pic, Oundle Road, Peterborough PE2 9QU, England,
Telephone (0733) 63171.
10.5 Abstractor Name and Address: John Houlahan,
Science Applications International Corporation, 7600-A
Leesburg Pike, Falls Church Virginia 22043.
11.0 Keywords
11.1 Waste type: chemical oxygen demand, wastewater
effluent, sugar beet processing effluent
11.2 Process type/waste source: sugar products,
agricultural processing
11.3 Waste reduction technique: anaerobic digestion
11.4 Other keywords: methane, United Kingdom, SIC 2063
12.0 Assumptions
It is assumed that the economics cited in the source
document are on a per plant basis and not the total of
all 12 British Sugar plants.
13.0 Peer Review
Unknown.
(*) - Disclaimer: Economic data will vary due to
-------
economic climate, varying governmental
regulations and other factors.
KEYWORDS: chemical oxygen demand, wastewater effluent, sugar beet
processing effluent, sugar products, agricultural processing,
anaerobic digestion, methane, United Kingdom, SIC 2063
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