INTERIM EFFLUENT GUIDANCE
FOR NPDES PERMITS
OFFICE OF PERMIT PROGRAMS
U. S. ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D. C. 20460
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I UNITED STATES ENVIRONMENTAL PROTECTION AGENCY
WASHINGTON, D.C. 20460
OFFICE OF
ENFORCEMENT AND GENERAL COUNSEL
MEMORANDUM
TO : All Regional Permit Program Directors
FROM : Office of Permit Programs, Washington, D. C.
SUBJECT : Updated Effluent Guidance Materials
The attached guidance package consists of two parts:
1. Instruction and limitations which apply to permit appli-
cations in all industrial categories. In general this is
the guidance you received in our January 2, 1973, memorandum;
there have been some additions and deletions.
2. Updated and streamlined guidance documents in a standardized
format, to replace the guidance documents which you received
at intervals since June 1972. Previous effluent guidance
documents are superceded. Explanatory data and references
have been deleted and will be made available in separate
back-up documents. Sampling and monitoring instructions
also have been deleted. Specific guidance for monitoring
and self reporting has been provided in draft form 3/9/73.
The Effluent Guidelines Division, Office of Air and Water Programs and
the Permit Program Staff, Office of Enforcement and General Counsel, have
reviewed the effluent guidance documents and have concurred in the
technical applicability of these documents for interim use in the issuance
of permits under Section 402, until effluent guidelines are promulgated under
Section 304, but only within the limitations set forth in the Deputy
Administrator's memo of February 28, 1973, which has been cited in each case
in the guidance under the title "Application of Limitations".
As pointed out in our memo of January 2, 1973, this guidance applies
primarily to major or significant dischargers. Considerable care and
discretion must be used in the application of this guidance to minor or
less significant discharges.
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There may be individual cases outside the areas indicated below where
a determination of best practicable control technology currently available
for the industrial facility in question can be made with a high degree
of confidence, through reliance on the interim effluent guidance together
with an evaluation of the particular conditions in existence at the
facility. Decisions to issue permits in such cases should be made with
caution and on a limited basis. Subject to the foregoing, the following
guidance documents may be used in accordance with the caveats and qualifications
cited.
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TABLE OF CONTENTS
General Effluent Guidance for all
Industrial Categories 1
Aluminum Industry 11
Beet Sugar Industry 15
Beverage Industry 17
Cane Sugar Refining Industry 23
Canned and Frozen Fruits and Vegetables Industry 27
Cement, Lime, Gypsum and Flat Glass Industry 31
Coal Industry 37
Dairy Industry 45
Fertilizer Industry 49
Inorganic Chemicals Industry 57
Insulation Fiberglass Industry 121
Meat Products Industry 63
Metal Finishing Industry 69
Mining and Milling Industry 75
Motor Vehicles Industry 79
Petroleum Refining Industry 83
Plastic Materials and Synthetics Industry 91
Pulp and Paper Industry 101
Raw Cane Sugar Industry 1°5
Iron and Steel Industry 107
Textile Industry
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General Effluent Guidance for All
Industrial Categories
The following guidance on special technical considerations in the
application of limitations, and on effluent limitations for specific
parameters, is to be used as appropriate in writing permits for
applications in all industrial categories.
General
The guidance documents were developed to cover, as specifically as
possible, the identified industrial categories. The numbers previously
developed and the information contained herein were meant to apply
generally to the industrial category but more specifically to "major",
"large", or more significant dischargers. Additional information on other
considerations (i.e., economic, age) will be forthcoming. This should not
materially effect your priorities. However, should a problem arise that requires
additional consideration, please contact the appropriate headquarters
individual. You will find, as you probably already have, that the guidance
does not lend itself to all situations involving "special" problems of
age and economic impact, etc., for a given category.
£H
The normal range in which all discharges should fall is generally
accepted to be between a pH of 6 and a pH of 9. Any discharge outside
of this range should be well justified and should consider such things
as the addition of total dissolved solids from neutralization and the
buffering capacity of the receiving water. If the pH of the discharge
is significantly different than the pH of the receiving water within
the 6.0 to 9.0 range and the discharge is a significant portion of the
receiving water, toxic effects due to pH fluctuations within this range
can be shown. Therefore, it is imperative that the discharge be evaluated
carefully even within the range of 6.0 to 9.0, (e.g., 7.0 +_ 0.5).
Coliform
This is a significant parameter for mixtures of industrial wastewater
and sewage and may be significant for certain industrial wastewaters
alone. Because of the sewering of most plants, the absence of sewage
should be established by dye test. If sewage is present, the following
effluent limit should be imposed:
"Organisms isolated in the fecal coliform test shall not
exceed 1000 organisms per 100 ml."
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Total Dissolved Solids
Total dissolved solids have not been limited in the individual guidance
documents. There is technology available for the removal of total
dissolved solids when receiving water quality so dictates.
Oil and Grease
Permit conditions for petroleum-based Oil and Grease, based on the
Standard Methods (13th Edition, Method 137) are to reflect an achievable
concentration of 10 mg/1 as the basis for determining limitations.
This limitation should be imposed where appropriate across industrial
categories. If petroleum-based oil and grease is not present in the
characteristic discharge, the limitation may be eliminated. Oil and
grease analysis may also be used to detect oily materials of animal
and vegetable origin. The limitation of oil and grease in these
instances should be applied with caution. Vegetable or animal based
oil and grease is generally less significant than petroleum based
oil and grease at the same levels.
Toxicity
National standards for toxicity limitations via bioassay procedures have
not been set. Certain States require bioassay procedures which will be
incorporated in our discharge permits when those states include the
requirement as part of certification under Section 401. A list of toxic
substances and standards will be promulgated under Section 307 of the Act.
Heavy Metals
A general limitation of 1 mg/1 maximum total dissolved heavy metals
should not be imposed across the board. The figure is, however
a good point of reference when establishing limits for a discharge involving
a number of dissolved heavy metals which could present a hazard to water
quality due to synergistic toxic effects.
Utility Discharges, Thermal Energy
For practical purposes, thermal limitations are most significant when
applied to once through non-process contact cooling water, and treated
effluent. This includes both manufacturing industry and power generating
industry.
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The industrial effluent limitation guidance addresses "process wastewaters"
only, which have come into intimate contact with raw material, products,
byproducts, etc., and include all wastewaters containing significant amounts
of non-thermal pollutants. Typically, these streams require biological
or physical treatment to reduce the content of specific constituents.
When the resulting "treated effluent" contains thermal energy, additional
considerations and limitations may be necessary.
Included in this definition of "process wastewaters" are cooling tower
blowdown, boiler water blowdown, water treatment plant backwashings
and once through process contact (e.g., barometric condenser) cooling
water. However, limitations to be applied to constituents of these
components of "process waters" are generally not contained in existing
guidance.
Relative to pollutant reduction in utility water components of "process
wastewaters", each case should be evaluated individually. Further
definition of "best practicable control technology currently available"
in this area has been undertaken by contract studies under Effluent
Guidelines Division of Office of Water Programs.
The combination of cooling water and treated process water effluent
prior to introduction into the receiving water is permissible. In
instances where monitoring of the combined flows will not provide adequate
information because of a concentration below a detectable limit, monitoring
may be required prior to the combination of process flows and non-contact
cooling water flows. Where once through non-contact cooling water is
collected with process wastewaters in combined sewers, no allowance may
be given that would condone the dilution of the plant raw waste load and
result in a higher pollutant discharges allowance.
Once-through cooling water that does not come into contact with process
material (shell and tube heat exchangers) discharging into segregated
sewers may be excluded from the accounting of pollutants (excepting
thermal) limited in the permit where source of water is the receiving
stream. In such cases, thermal considerations should be applied taking
into account applicable Water Quality Standards and using the guidance
afforded in the Thermal Technical Manual forwarded earlier in draft form.
Monitoring for possible contamination should be required, especially
where saline cooling water is used. Due to the corrosive properties
of saline water, corrosion products may be significant. The logic for
excluding once through non-contact cooling water from pollutant limitation
accounting is based upon net/gross considerations relative to influent
constituents, and upon the 'practicability1 of treatment to reduce very
low pollutant levels":
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Typically large quantities of water relative to process
leakage result in concentrations not appreciably higher
than supply water characteristics, and so low as to produce
dubious analytical results.
Unless a specific violation of Water Quality Standards results,
such low concentrations would not ordinarily be expected to have
a significant or adverse impact on the receiving water.
In the absence of adverse impact (i.e., violation of Water
Quality Standards) on the receiving water, the benefit of
treating such large quantities of water (especially for
net pollutant reduction) does not justify the cost.
Color
Color is generally an aesthetic problem. Where a specific problem is
evident, limitations may be set on a case-by-case basis based upon
receiving water quality.
Net and Gross
Generally a discharger is not responsible for pollutants entering
with his water supply if he takes water from the same source into
which he is discharging. If his source is other than the receiving
stream, he is to be charged with the gross discharge.
Unless industry specifically requests application of net considerations
in writing, or unless the difference between net and gross is of major
significance to a discharger, the permit should be written on a gross
basis with no stipulation for influent values. Where the differences
between net and gross application of effluent guidance is of relatively
minor significance but industry requests application of net values, the
supply water waste loading should be stipulated based on presentation of
existing data (i.e., adjust limitation accordingly and write permit in
gross terms.) Limitations that are established for materials that are
normally expected to be "concentration controlled" (e.g., TSS and BOD)
may not need total credit for influent levels (a well designed clarifier
will generally produce a quality effluent - 20 mg/1 ss - regardless of
source of suspended solids). Where application of net values is of
great significance to the dischargers, permit requirements for sampling
the influent wasteloadings must be included.
Pollutants that are removed in the treatment of water in an industrial
facility (e.g., silt removal, filter backwash) may not be returned to
the receiving water. Once a pollutant is removed by the discharger it
may not be reintroduced. In this situation net/gross considerations
will be applied downstream of any pretreatment steps.
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Disposal of Pollutants into Wells
If an applicant for a permit proposes to dispose of pollutants into
wells as part of a program to meet the proposed terms of a permit,
additional terms and conditions should be specified in the permit
which either prohibit the proposed disposal or control the disposal
so as to prevent pollution of ground and surface waters and to
protect the public health and welfare. The Administrator's decision
statement number five, February 6, 1973, "Environmental Protection
Agency Policy on Subsurface Emplacement of Fluids by Well Injection"
should be consulted and complied with.
Standard Conditions
The provided standard permit conditions will be included in each permit
in the order and language given. Additional conditions necessary to
meet state certification requirements will follow the standard special
conditions in the permit. State requirements which exceed national
requirements will generally be adopted for National Pollutant Discharge
Elimination System permits written for discharges in the State. Please
note, however, that only those State requirements included in the
certification (Sec. 401 of the Act) must be adopted. Recommendations
can be accepted for cause. In this manner, terms and conditions of dubious
legal or technical validity, or that would tend to impede enforcement may
possibly be screened out.
Limitations
Permits are to be written with limitations in terms of kilograms (pounds)
of each pollutant per day excepting in certain industries (such as mining
operations and utility discharges) where wastewater generation is not
related to production levels. The monthly operating average effluent
limitation, in kilograms (pounds) per day, should be calculated using the
production basis multiplied by the appropriate effluent level as specified
in the guidance. It is not our intent to specifically limit water use in
the permit unless the flow is so high as to cause a scouring problem in
ti.e receiving water. Once a permit has been issued based on the use of
effluent volume, production levels, and attainable abatement technology,
the discharger may meet his requirement via any combination of effluent
volume and concentration providing he does not violate water quality standards
in so doing. If a discharger drastically reduces his water usage he may
augment receiving water diffusion capacity to prevent localized toxic effects
or take advantage of improved treatability to reduce pollutant discharge,
at his option, within the life of the permit.
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The basis for limitations shall be:
1. Monthly average, expressed in kilograms (pounds) of pollutant per day
which is the total of each pollutant discharged in a calendar
month divided by the number of days the production facility
operated that month.
2. Daily maximum, expressed in kilograms (pounds) per day.
Maximum daily limitations have not been statistically established for
all industrial categories. It is our intent that the discharge limitations
developed from the guidance and other considerations be a monthly
operating average and a daily maximum. Variations from this operating
average will be monitored and used as a basis for judgment of the
performance of the discharger and to establish statistical variability.
When statistically reliable data is_ available, a maximum variation will
be established on that basis. Until such is the case, a general limitation
for individual composite data shall be established that is no more than
3 times the average limitation (200% over) where water quality considerations
do not prevail. Discharges may be limited singly or as a group or a
combination of single discharges and groups or totally for the plant
depending on the engineering judgment of the reviewer. It may be necessary
to know the source of each discharge before making such a judgment. In
any case, the total allowance of pollutant limitations should not exceed
that calculated for the total plant production capability. Monitoring
programs and compliance schedules should be consistent with approach
chosen.
Production Figures to be Used in Permit Writing
A manufacturer should not be limited to less than full utilization of
actual installed production capability. However, do not allow the
purpose of effluent limitations to be circumvented by overstatements
of production capability. The manufacturer is responsible for
meeting the permit requirements without regard to seasonal variations
in treatment efficiency, production levels, or product mix.
Therefore, the "production" figure can be either product or raw material
as appropriate; shall be based on plant production capability whether
by engineering evaluation or production history; and shall be based
on the normal equipment operating schedule.
Where production units are separated, but utilize a common treatment
facility, production will be evaluated for the production complex
as a whole. One permit would be written for the production complex,
covering all discharges to receiving water individually or combined
as appropriate.
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Where "production" is based on product, the total produced (including
that shipped out of plant and/or placed in inventory) will be used.
Similarly, where raw material (not including process chemicals) usage
is the basis, the total processed will be used. In either case, assume
a reasonable product mix which most fully utilizes installed equipment.
For complex facilities, the capacity will be limited by the unit
process which controls production, e.g., if an intermediate process
can only supply 75 units to a downstream operation with a capability
of 100 units, then the overall capability is 75 units unless purchased
intermediate material is introduced. The determination, further, should
be based on a normal operating schedule, e.g., shifts per week. There
may be cases where increased production requirements are anticipated,
and will be met by a heavier operating schedule (running the equipment
more shifts per week). The heavier operating schedule may be used in
defining plant capacity, but should be supported by market projections,
production schedules, etc., that demonstrate the intent.
The production figure arrived at in this manner should not be an unreasonable
deviation from historical actual production.
In any event, the manufacturer can apply for re-issuance of his permit
based on increased production. As a rule-of-thumb, this should only
be necessary when the contemplated production increase would cause
overloading of treatment facilities, resulting in violation of the
effluent limitations in the permit.
Level A and Level B
Minimum levels of treatment (B Level) were originally proposed in
recognition of the economic hardship implicit in redirecting a
pollution abatement program already under construction. However,
setting specific minimum limitations for all industry raised the
possibility of an implied benefit to dischargers only recently
providing treatment. In addition, subsequent amplification of
"best practicable control technology currently available" requires
consideration of economic cost benefit relationships, as well as
engineering aspects, non-water quality oriented environmental impact
and others.
The primary mechanism of relief will be reflected in compliance schedules
terminating with acheivement of Level A guidance by July 1, 1977. The
most important consideration in using Level A and Level B is to remind
the discharger that Level A values are to be met as - minimum requirement
by July 1, 1977, by all dischargers.
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Permit Duration
Permits may be issued for periods up to five years. If a discharger
is expected to achieve A levels by July 1, 1977, and he commits to
a program to accomplish this, he will expect a permit of extended
duration, i.e., five years. Short term permits, e.g., less than
3-5 years, should be issued only in those situations where there
is a significant water quality problem that nay net be resolved or
where the technology for pollution abatement is not, in your opinion,
sufficient, or where the discharger is not sure of the success of
his planned program. In these instances the permit should be
written to terminate 9 months after the conclusion of the compliance
plan.
Settleable Solids
The presence of settleable solids in treated effluent can show biological
system misfunction and clarifier misoperation, assuming it is well
designed. The absence of settleable solids can therefore indicate con-
tinuing operational stability. Analysis for settleable solids may be
a useful monitoring tool to supplement and, to a certain extent, reduce
the frequency of BOD,- and suspended solids analyses, thus providing
greater operational control.
Staged Discharge
There may be instances where variability in receiving water flow
(either regulated or natural causes) precludes discharge of even very
highly treated wastewater due to stream quality considerations during
low flow periods. In such instances, treated wastewater may be stored
for discharge when receiving water considerations allow it. The discharge
permit may therefore contain supplemental conditions permitting discharge
in regulated amounts. In any case the total weight of individual
pollutants so scheduled shall not exceed an appropriate limitation
based on production capability.
Batch, Seasonal and Intermittent Operations
Batch, seasonal, and intermittent operations will be limited in the
same terms as are continuous operations, i.e., a monthly operating
average and a daily maximum, each expressed in pounds per day of
individual pollutants. It may also, however, be necessary to set a
limit on the rate of discharge in terms of pounds per hour in order
to prevent violation of receiving water quality standards due to slug
discharge.
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The rationale is based upon the essential logic in the discussion of
'production capability1 plus a general condition in each permit
requiring that the permittee operate the treatment facilities
efficiently at all times. No attempt should be made to specify the
days upon which a discharge is authorized.
Monitoring and Self Reporting
Separate guidance has been written for monitoring and self reporting.
Generally the approach is that the permittee notify the regulatory agency
in the event of violation of a daily maximum limitation (in which case,
if immediate telephone notification is required, a 24-hour telephone
number should be supplied), and that the permittee shall monitor and report
routinely at such a frequency as to assure management and the regulatory
agency that abatement programs are being implemented and the permit terms
and conditions observed. Any discharge characteristics that are limited
should be monitored, not necessarily all at the same frequency. Avoid
limiting the same characteristic by more than one limitation; for instance,
oxygen demand by BOD5, COD and TOD.
Compliance Schedules
Proposed or tentative compliance schedules should be expressed in months
elapsed from the effective date of the permit until the permit is issued
at which time specific dates should be typed into the schedules. Interim
limitations for 'immediate1 compliance (e.g., one month from effective
date) should be imposed as necessary and desirable in order to either abate
an "imminent hazard to public health or safety" or because it is feasible
to abate the discharge immediately. Compliance with other limitations
may require installation of waste treatment facilities, which would
require additional implementation and compliance schedules.
It should be noted that a pollution abatement program for a complex
industrial facility may involve installation of more than one treatment
facility. Our interest is in the end result, not on the design or program
planning, excepting insofar as total compliance is achieved in a timely
manner not to exceed July 1, 1977. Therefore, in a staged program,
interim limitations may be imposed based upon completion of facets of an
overall abatement program.
Treatment models described in the guidance are not intended to specify
procedures or processes, but to illustrate the means by which the limitations
may be met. Alternatives which will achieve the same end are acceptable.
Metric Units
All permits should be written in metric units (kilograms, meters, kiloliters)
with equivalent English units (pounds, feet, gallons) in parentheses
alongside.
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ALUMINUM
APPLICABILITY
These instructions apply to Standard Industrial Classification Codes
2819, 3334, 3352, and 3361. These include rolling and drawing of wire,
rod, bars, and structural shapes; and extrusion of tubes and shapes.
SUBCATEGORIES CONSIDERED
Operations in the aluminum industry are considered under the following
subcategories: refining of bauxite; primary smelting; ingot casting and
foundry operations; rolling of plate and sheet; rolling of foil; rolling
and drawing of rod, bar and structural shapes; and extrusion of aluminum
shapes and tubes.
OPERATIONS EXCLUDED
These guidelines cover only the listed operations. Metal Cleaning and
Coatings is included in the Metal Finishing guidance.
Secondary smelting guidance has not yet been developed. This operation
uses scrap aluminum as raw material and is significantly different from
the primary operation in regard to water usage.
Not covered in this guidance are the discharges of non-contact cooling
water and boiler water blowdown.
APPLICATION OF LIMITATIONS
The use of the interim guidance is limited solely to bauxite refining.
ABATEMENT MODELS
Bauxite Refining
The discharge from this operation is a mud slurry that comes from the
washing of the solids to recover caustic salts for reuse. The mud slurries
can be impounded in lagoons where the solids will settle out. The solids
should be allowed to accumulate in the bottom of the lagoon and the water
evaporated to prevent any discharge of solids. The permit should be
drafted with a suspended solids limit that would mean essentially no discharge.
Primary Smelting
This subcategory covers only scrubber water used to wash the gas from
the electrolytic cells. It includes pre-bake and Soderberg type operations.
It does not include other water uses such as non-contact cooling of rectifiers.
The B level can be attained by lime addition and clarification. The A
level treatment would include the addition of polyelectrolytes with
detention sufficient to attain the required limits. The A level assumes
recycle of this wash water.
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12 ALUMINUM
ABATEMENT MODELS (continued)
Ingot Casting and Foundry Operations
The discharge from this operation comes from water sprayed over
the molds and ingot surfaces. The minimum treatment is skimming
and clarification. The A level assumes recycle and treatment of
the concentrated blowdown by clarification and air flotation or
filtration.
Rolling of Plate and Sheet
This subcategory includes the first reduction of ingots to plate
and sheet by hot rolling and cold rolling mills. The minimum treatment
should be lime addition, emulsion breaking, skimming, and clarification.
The A level represents recycle and treatment with lime addition and
then air flotation and clarification.
Rolling of Foil
Cold reduction of sheet to foil normally requires a mineral base
oil and in some case an oil emulsion. The 1iT*i'cs assxv^e eyt«n«x
of plate and sheet rolling; if separate facilities are used, the
water usage may be significantly higher. The minimum treatment
should be emulsion breaking, skimming, and clarification. The
A level assumes recycle.
Rolling and Drawing of Rod, Bar, and Structural Shapes
A low-oil-content emulsion is used in this operation to lubricate
and cool the aluminum being rolled into rods, bars and structural
shapes. The model treatment system is emulsion breaking, skimming
and clarification, with recycle assumed for the A level. Not included
in the guidelines is water used for equipment cooling or in die
casting or forging operations where the water does not come in
contact with the metal.
Extrusion of Tubes Shapes
The water from this category comes from leakage and maintenance of
the water-hydraulic presses. The discharge could be continuous or
batch. The model treatment system is again emulsion breaking, skimming
and clarification, with recycle used for the A level.
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EFFLUENT LIMITATIONS
ALUMINUM
Process
Refining of Bauxite
Primary Smelting
Ingot Casting &
Foundry Operations
Rolling of Plate and
Sheet
Rolling of Foil
Rolling & Drawing
of Rod, Bar and
Structural Shapes
Extrusion of
Aluminum Shapes
Parameter
Pounds per 1,000 Pounds
Schedule A Schedule B
essentially no discharge
Fluoride 0.38
Total Suspended Solids 0.5
Oil and Grease 0.25
Total Suspended Solids 0.08
Oil 0.08
Total Suspended Solids 0.056
Oil 0.028
Phosphate as P 0.006
Total Suspended Solids 0.167
Oil 0.083
Total Suspended Solids 0.0834
Oil 0.0417
Total Suspended Solids 0.11
Oil 0.054
5.0
5.0
2.5
0.75
0.38
0.55
0.28
0.09
0.5
0.25
0.75
0.375
0.75
0.375
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15
BEET SUGAR
APPLICABILITY
These instructions apply to Standard Industrial Classification Code
2063.
OPERATIONS EXCLUDED
Separate guidance is being issued for cane sugar.
PRODUCTION BASIS
The daily processing capacity is expressed in tons per day of sugar
beets.
APPLICATION OF LIMITATIONS
Additional information since the preparation of this guidance
indicates that schedule A requirements may be less stringent
than BPCTCA. A closed condenser water cycle should be considered
in the preparation of any permit for the Beet Sugar Industry.
OTHER LIMITATIONS
The following may be significant parameters depending on production
methods and receiving water characteristics:
Ammonia Nitrogen
Temperature
Settleable Solids - Settleable solids shall not exceed 0.1 ml/1.
ABATEMENT MODELS
The process control and the treatment system visualized for
attainment of the recommended effluent limitations for the beet
sugar industry is as follows:
1) Separate impoundment of all lime mud waste and
flume mud waste.
2) Installation of a closed cycle or other treatment
for flume waters.
3) Complete removal and disposal of Settleable solids
from the closed flume water transport circuit.
4) Complete reuse of pulp press and transport waters.
5) Recovery and/or reuse of all Staffen filtrates.
6) Separate impoundment and/or reuse of strong general
plant wastes (e.g., acid and caustic boilouts,
line cleaning solutions, etc.)
7) Retention and disposal of flumed residual ash waste.
8) Maximum water reuse in all plant operations.
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BEET SUGAR
EFFLUENT LIMITATIONS
Criteria Lbs/Ton Beets Sliced
Five-Day BOD 0.50
Total Suspended Solids 0.50
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BEVERAGES
APPLICABILITY
These instructions apply to Standard Industrial Classification Codes
2084 and 2085.
SUBCATEGORIES CONSIDERED
Limitations are considered separately for distilled spirits (excluding
rum distilleries); wineries (table wines) in press season; wineries
(table wines) in process season; and wineries (distilled wines and
brandies).
OPERATIONS EXCLUDED
Rum distilleries are not covered by this guidance.
PRODUCTION BASIS
The maximum daily production (as determined at the time of application)
shall be the highest average level sustained for seven consecutive
operating days of normal production.
APPLICATION OF LIMITATIONS
The guidance should be limited to use for whiskey distilleries and
wineries.
Wineries making table wines have two phases of operation; (1) the
pressing of grapes into juice, and (2) the processing of juice into
wine. During the pressing season, the tonnage of grapes processed
is a significant production unit but during process season this unit
is not valid. Many wineries produce products blended with purchased
wine, thus, wine production is chosen as the significant production
unit during the non-pressing season.
The following may be significant parameters depending on production methods
and receiving water characteristics:
Color
Turbidity
Foam
Temperature
Nitrogen
Phosphorous
Settleable Solids - Settleable solids shall not exceed 0.1 ml/1 •
Consider receiving water quality and available technology if applying
effluent limits to these parameters.
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18
BEVERAGES
ABATEMENT MODELS
Distilled Spirits (Distilleries)
The following process considerations and treatment facilities can
be used to achieve the "best practicable pollution control technology
currently available":
1. Recycle of cooling water;
2. Maximum by-product recovery from stillage;
3. Improved evaporator entrainment for better separation
of organics contained in released water vapors in the
feed recovery operation;
4. Elimination of frequent and unnecessary spillage,
over-flows, dumps, and excess running water;
5. Biological oxidation by trickling filters and/or
activated sludge.
The Schedule A effluent limits are based on an effluent 6005 and
suspended solids concentration of 30 mg/1. The process wastewaters
from this industry are readily amenable to biological treatment. The
Schedule B effluent limits are based on 90% removal of the standard
raw waste loads and represent good present-day abatement practices.
Wineries
The following elements were used to develop the best "practicable
pollution control technology currently available" for "wineries":
1. Wine recovery from "lees" and dry handling of the
resulting waste solids;
2. Elimination of frequent and unnecessary spillage, over-flows,
dumps, and excess running water:
3. Elimination of cloth filters;
4. Use of low-volume, high-pressure methods of cleaning
process tanks;
5. Maximum possible recirculation and reuse of cooling,
wash-up, and process water;
6. Biological oxidation by activated sludge or equivalent
process;
7. Disinfection, if necessary.
The Schedule A effluent limits are based on BODs and suspended solids
levels of 30 and 40 mg/1 respectively. In one plant an activated
sludge treatment system is achieving effluent qualities consistent
with "A" levels. Two other wineries are presently constructing
treatment systems; one an activated sludge system, the other an RBC
unit. Each system is designed to produce effluent qualities consistent
with Schedule "A". The RBC unit design was verified by pilot plant
studies. All three of these wineries produce table wines, but the
-------
19
BEVERAGES
ABATEMENT MODELS (continued)
technology is transferable to wastewater from production of distilled
wines and brandies.
The flow data used was only that portion representing process and
wash-up wastewater and does not include utility wastewaters such as
cooling water or boiler blow-down.
-------
EFFLUENT LIMITATIONS - BEVERAGE INDUSTRY
LB/UNIT PRODUCTION
SCHEDULE A
INDUSTRY CLASS
DISTILLED SPIRITS^
(Distilleries)
WINERIES, Table Wines
Press Season
Process Season
WINERIES, Distilled
Wines and Brandies
UNIT PRODUCTION
1000 Bushels of
Grains Processed
Tons of Grapes
1000 Gallons of
Wine
Tons of Grapes
BODr
11.5
0.15
5.8
0.23
SUSPENDED
SOLIDS
11.5
0.20
7.8
0.23
SCHEDULE B
SUSPENDED
BODq SOLIDS
19
19
0.22 0.29
7.5 9.7
0.39 0.39
to
(a) Except rum distilleries
-------
23
CANE SUGAR REFINING
APPLICABILITY
These instructions apply to Standard Industrial Classification
Code 2062 (1967 SIC Manual) Cane Sugar Refining.
OPERATIONS EXCLUDED
For guidance on facilities manufacturing raw sugar from cane,
see the separate document on SIC 2061.
APPLICATION OF LIMITATIONS
Guidance should be applied only to refineries whose maximum
capacity is 500 tons per day or greater.
Daily production shall be expressed in tons per day of raw cane
sugar, arid is the highest average production sustained over 20
days of full normal operation. (For a cane factory and refinery
at the same site, the permitted discharge per day shall be the
total of the permitted factory and refinery waste loads, but
only if both are operating concurrently).
Settleable solids shall not exceed 0.1 ml/1.
The following also may be significant parameters depending on
production methods and receiving water characteristics:
Color
Turbidity
Temperature
Nitrogen
Phosphorous
Ammonia
ABATEMENT MODELS
The waste management systems listed below represent the generalized
model used to develop the effluent limitations recommended for the
cane sugar refining industry as shown in Schedule A and under general
criteria. There are a great many variations possible (including
discharge to a municipal treatment system) which can be tailor-made
to processing plants in order to achieve the desired results.
The Schedule A levels were obtained by first separating the waste
effluent to reflect the two major waste streams, i.e., barometric
condenser effluent and process wastewater. It was considered that
the best practicable method of handling the dilute high volume
barometric condenser effluent is through application of process
control rather than an add-on treatment system. The characteristics
of the process wastewater, i.e., high carbohydrate content, make the
use of biological treatment the apparent best practicable treatment
method.
-------
24
CANE SUGAR REFINING
ABATEMENT MODELS (Continued)
1. The washwaters from the decolorizing and deashing columns
are combined with carbon transport drain waters, routine
floor and equipment washings, possible bad or spilled
process bataches, and the washdowns from the truck and/or
railroad car receiving/delivery stations (providing these
latter flows do not contain toxic elements), and these
combined wastewaters are directed to biological treatment
sites. Treatment may consist of activated sludge or equivalent
treatment means. Long-term impoundment/stabilization of these
wastewaters may be an acceptable alternative where sufficent
land is available.
2. Dry recovery and landfill disposal of filter cakes (muds).
Slurrying and impoundment of filter muds with eventual
disposal/reuse on nearby farms is a recognized alternative.
3. Elimination of indiscriminate wasting and discharge of
powered carbon (e.g., where used on a once-through basis
and as the major means of decolorizing sugars).
4. Minimum organic entrainment and carryover from the
evaporators and pans into the barometric condensers.
Maximum allowable waste loads are predicated upon
availability of adequate equipment to handle varying
process loads; good design of equipment and entrainment
arrestors, demisters and other control devices, and
conscientious operator attention to maintain evaporators,
pans, condensers, and the interconnecting circuits in
careful balance.
5. Scums from the phosphatation-frothing clarifier operations
are to be removed in subsequent vacuum or pressure
filter units, and to be treated in similar fashion to
the filter muds. Special handling of these scums is
required and their discharge to the receiving stream
is not acceptable.
6. Segregation, impoundment, and/or possible reuse of strong
cleaning/scouring waste and other similar plant and chemical
wastes.
7. Well designed and maintained impoundment ponds.
8. The elimination, special handling and/or treatment of
extraneous discharge, especially nondescript storm drains;
the runoff from refuse piles and storage areas: drainage
from the handling, disposal and/or resue of bagasse and
trash; and fly ash and air scrubbing effluents from air
-------
25
CANE SUGAR REFINING
ABATEMENT MODELS (continued)
pollution control devices are included in the subject
effluent guidelines.
EFFLUENT LIMITATIONS - NUMBERS
Parameter^ Ib/ton Raw Sugar Processed
Schedule A Schedule B
BOD5 0.65 1.0
Suspended Solids 0.2 1.0
-------
27
CANNED AND FROZEN FRUITS
AND VEGETABLES
APPLICABILITY
These instructions apply to Standard Industrial Classification
Codes 2C33, Canned Fruits and Vegetables; 2034, Dried and Dehydrated
Fruits and Vegetables; and 2037, Frozen Fruits and Vegetables (1967
SIC Manual).
SUBCATEGORIES CONSIDERED
Effluent limitations are set by commodity.
OPERATIONS EXCLUDED
The guidance covers only the listed commodities. SIC 2031, 2032,
2035, 2036 are not covered.
APPLICATION OF LIMITATIONS
The guidance may be used only for very large installations, i.e., those
producing over 500 cases per hour and operating over a period of six
continuous months or more. Commodity areas are limited to citrus, asparagus
and apples.
The maximum commodity input shall be the highest average level sustained
for seven consecutive operating days of normal production. For plants
processing a variety of food commodities, the permitted discharge shall
be determined for each commodity, as above, the sub-totals added together
to obtain a total permitted daily discharge.
This limit will be determined from the review of data supplied by the
company or of maximum daily processing rates of each commodity or
combination of commodities that could be processed on any single day.
Settleable Solids - Settleable solids shall not exceed 0.1 ml/1.
The following may be significant parameters depending on production methods
and receiving water characteristics:
Color
Turbidity
Temperature
ABATEMENT MODELS
The wastewater from this industry is generally characterized as containing
a high percentage of soluble organic material. For this reason biological
treatment is considered the best practicable method of treatment.
-------
28
CANNED AND FROZEN FRUITS
AND VEGETABLES
ABATEMENT MODELS (Continued)
The following waste management control system and process controls
were used as a model for developing the recommended effluent limitations
for this industry:
1. Use of in-plant controls to conserve water use and reduce
waste loads through:
(a) Maximum practicable recirculation and reuse of
cooling, condensate, fluming, cleaning, washing,
and filling waters.
(b) Dry handling and disposal of solids wastes from floors,
machines, and other work areas.
(c) Positive control for the prevention of unnecessary
overflows, spillages, and dumps.
(d) The elimination of excess running water.
2. Use of dry caustic peeling or equivalent procedures wherever
technically feasible.
3. Maximum by-product recovery.
4. Elimination of extraneous and uncontrolled drainage from
refuse storage areas.
5. Flow equalization.
6. Biological oxidation using aerated lagoons or activated
sludge.
7. Secondary clarification depending upon particular treatment
mode.
8. Disinfection, if necessary.
-------
EFFLUENT LIMITATIONS
Ib/ton of Raw Material Processed
Material
Processed
Apples
Apricots
Asparagus
Beans, Snap
Beets
Carrots
Cherries
Citrus
Corn
Peas
Peaches
Pears
Potato
Pumpkin & Squash
Sauerkraut
Spinach
Sweet Potato
Tomato
Schedule
BODq ,
1.4
2.7
3.0
1.6
1.2
1.2
0.9
0.6
0.8
1.9
2.0
1.2
1.0
0.5
0.3
2.2
0.9
0.9
A
Suspended
Solids
1.9
3.6
3.0
2.0
1.6
1.7
1.2
0.6
1.1
2.6
2.6
1.6
1.4
0.7
0.2
2.9
1.2
1.2
Schedule B
BODs
3.1
9.9
3.0
2.3
4.6
3.8
2.8
0.6
1.9
6.1
6.9
3.3
3.0
1.4
0.4
3.9
2.9
1.7
Suspended
Solids
2.1
6.7
3.0
2.0
3.1
2.5
1.8
0.6
1.2
4.1
4.6
2.2
2.0
0.9
0.3
3.1
1.9
1.2
to
\O
-------
31
CEMENT, LIME, GYPSUM AND
FLAT GLASS
APPLICABILITY
These instructions apply to Standard Industrial Classification
Codes 3211, 3241, 3271, 3273, 3274, 3275, and 3292.
SUBCATEGORIES CONSIDERED
Operations in this industry are considered under the following
subcategories: flat glass; flat glass products made of purchased
glass; cement, hydraulic; concrete block and brick; concrete
products other than block and brick; ready mix concrete; lime,,
gypsum products; and asbetos products.
APPLICATION OF LIMITATIONS
The interim guidance is acceptable for use for the cement industry
with the following limitations. The guidance specifies parameters
for suspended solids, COD and pH but does not cover heavy metals
and runoff from storage piles. All permits issued should specify
limitations for heavy metals and runoff from storage piles.
The flow base used in developing these limitations represents
process water only and does not include cooling water. Concrete
Products, and Ready Mix Concrete are generally classed as "job-shop
operations" wherein wide variations in production levels occur,
therefore, these industries are limited on concentration only.
ABATEMENT MODELS
The industries in these categories grind, heat, crush, and otherwise
process basically inert mineral substances to produce the final
end product. As a result, the major pollutants are suspended solids
consisting of mineral fragments. These can adequately be removed
by sedimentation, with the addition of coagulants as required.
Such treatment is widely practiced in industry, with the major
failures resulting from insufficient detention time and shortcircuiting
of flow. Acceptable criteria which are available for construction of
settling ponds should be utilized in the design and construction
of such ponds.
Dissolved inorganic ions, chiefly sulfate, leached from the raw
material or from air-pollution control devices, constitute the
second major class of pollutants. Significant reduction of
these inorganics can be realized by modifications in the process.
-------
32
CEMENT, LIME, GYPSUM AND
FLAT GLASS
ABATEMENT MODELS (continued)
Dissolved heavy metals may result from leaching of raw materials,
from plating operations, or from reagents added to the cooling
or process waters. Heavy metals are especially troublesome in
cement plants utilizing oyster or clam shells as raw materials.
The specified levels can be achieved by a combination of process
modifications and metal precipitation. Oil is used primarily
as a binder and/or emulsifier in the manufacture of both
asbestos and glass.
The following process controls will be useful in achieving these
effluent limitations:
A. Maximum practical recirculation and reuse of
cooling waters, condensates, cleaning, washing
and other process flows should be practiced.
Process water from lime and gypsum manufacturing
should be used for hydrator supply, scrubbing,
and consumptive used.
B. Water use, and time of contact of water with leachable
substances, should be reduced to a minimum. Frequent
and unnecessary spillage, overflows, excess running
water, and inefficient handling and washing methods
should be eliminated.
The treatment system model used in the development of these
limitations is as follows:
A. Equilization of Flow
B. Sedimentation (Coagulants where required)
C. Neutralization
D. Metal Precipitation (where required)
Asbestos products facilities should recycle mix and curing
water to maximum possible extent for both Level A and Level
B limitations.
Concrete products and Ready Mix Concrete facilities should
be encouraged to recycle their wash water to the maximum
extent.
-------
EFFLUENT LIMITATIONS - LEVEL A
Subcategory
Cement, Hydraulic
With Leaching
Dry Process
Wet Process
Without Leaching
Dry Process
Wet Process
Concrete Products
Ready Mix Concrete
Gypsum Products
Lime Manufacture
Load/Product Unit
lbs/1000 bbl
lbs/1000 bbl
Suspended
Solids
25
7
No Process Wastewater Discharge.
No Process Wastewater Discharge. Recycle
excess thickener water to grinding operation.
Concentration mg/1
Concentration mg/1
lbs/1000 Tons
lbs/1000 Tons
20
20
4
50
COD
25
7
Remarks
20
20
4
50
Recycle Grinding
waters.
Use scrubber
effluent for
hydrator.
o
>
•-3
CD
f
H
CD
in
i
-------
EFFLUENT LIMITATIONS - LEVEL A (Cont.)
Subcategory
Asbestos Products
Insulation
Asbestos Paper
Cement Pipe & Siding
Flat Glass Products
Float Glass
Plate, Rolled
Laminate and
Tempered Glass
Mirrored Glass
Load/Product Unit
lbs/1000 Tons
asbestos used
lbs/1000 Tons
lbs/1000 ft2
lbs/1000 ft2
Suspended
Solids
99
152
200
84
0.2
COD
99
152
200
84
0.2
Remarks
Total Phosphorous
0.25 lbs/1000 Tons
Total Phosphorous
4.2 lbs/1000 Tons
Hexane Exactractables
8.4 lbs/1000 Tons
Total Phosphorous
0.01 lbs/1000 ft2
w.
o
CD tr1
f H
tn -
en
-------
EFFLUENT LIMITATIONS - LEVEL B
Subcategory
Cement, Hydraulic
With Leaching
Dry Process
Wet Process
Without Leaching
Dry Process
Wet Process
Concrete Products
Ready Mix Concrete
Gypsum Products
Lime Manufacture
Asbestos Products
Load/Product Unit
lbs/1000 bbl
lbs/1000 bbl
Suspended
Solids
42
11
No Process Wastewater Discharge.
No Process Wastewater Discharge. Recycle
excess thickener water to grinding operation.
Concentration mg/1
Concentration mg/1
lbs/1000 Tons
lbs/1000 Tons
lbs/1000 Tons
asbestos used
Insulation
Asbestos Paper
Cement Pipe and Siding
198
304
400
COD
42
11
40
40
8
100
40
40
8
100
198
304
400
Remarks
Recycle Grinding Water
Use Scrubber effluent
for hydrator.
OJ
ui
n
td
hrj
tr1
O H
i
-------
EFFLUENT LIMITATIONS - LEVEL B (Cont.)
Subcategory
Flat Glass Products
Float Glass
Plate, Rolled,
Laminated and
Tempered Glass
Mirrored Glass
Load/Product Unit
lbs/1000 Tons
Suspended
Solids
10
COD
10
lbs/1000 ft2
lbs/1000 ft2
168
168:-
0.4
0.4
Remarks
Total Phosphorous
0.50 lbs/1000 Tons
Total Phosphorous
8.4 lbs/1000 Tons
Hexane Extractable
12.5 lbs/1000 Tons
Total Phosphorous
0.02 lbs/1000 ft2
o
*^
f
Q IT1
tn -
a
>d
01
§
-------
37
COAL
APPLICABILITY
These instructions apply to Standard Industrial Classification
Codes 11 and 12.
SUBCATEGORIES CONSIDERED
Operations in the coal mining industry are considered under the
following subcategories: coal preparation plants, underground
coal mining, and surface mining (strip mining).
OPERATIONS EXCLUDED
This guidance covers only the listed operations. Hardrock
mining, specifically, is excluded.
APPLICATION OF LIMITATIONS
Concentrations schedule (A) should be applied for mine drainage
and preparation plant discharges, with the exception of the
alkalinity criteria, which should be changed to acidity with
an upper limitation of 10 mg/1 in both cases. This guidance
should not be used as a basis for surface mining permits and
priority should be placed on significant dischargers.
Wastes from coal mining operations often are unrelated, or only
indirectly related, to production quantities. Therefore, effluent
limitations are expressed in terms of concentration rather than
units of production. Due to the wide variation of geological
and hydrological factors in the coal industry, a pound per day
limitation is impractical.
EFFLUENT LIMITATIONS
Underground Mine Drainage
1. There shall be no dilution of the effluent stream.
Surface Mining
1. The velocity of discharge shall be such that scouring of
stream bed shall not occur.
2a. All treatment facilities shall be of sufficient size to handle
the run-off resulting from a once-in-ten-years' storm. (Source-
Kentucky revised statutes relating to strip mining and reclamation,
1966, Chapter 350, Regulation 11.)
-------
38
COAL
EFFLUENT LIMITATIONS (Continued)
b. The effluent shall not contain suspended matter in excess of
30 mg/1, (A level) or 100 mg/1, (B level) with the exception of during
and four hours after a major precipitation event.
The operator is not at any time to discharge an effluent containing
suspended matter in excess of 1,000 mg/1 from any area of land ,
affected. A major precipitation event is the number in inches of
water greater than the duration of the storm in minutes divided by
100 plus 0.2. (Source - U.S.D.A. miscellaneous publication #204,
"Rainfall Intensity and Frequency Data, 1935.) (See Graph)
Since the operator must show the major precipitation event has
occurred, it will require an installation at the operating site
of a recording rain gauge. In addition, precipitation must be
included in the monitoring program.
Area of land affected is the area of land from which overburden is to
be or has been deposited, which shall include all land affected by
the construction of new roads or the improvement or use of existing
roads, other than public roads, to gain access and to haul coal.
c. Sudden release of large volumes of water from the treatment
facility as during a storm, must be prohibited to prevent scouring
of the treatment facility. Therefore, there should be established
a level at which the flow will be diverted from the treatment facility.
This level must be set for each individual operation taking into
consideration the following (i) average precipitation of area;
(ii) receiving stream water quality standards; and (iii) the volume
of water discharged during a once-in-ten-years' storm.
The applicability of any of the parameters listed must be at the
discretion of the Regional Administrator.
ABATEMENT MODELS
The effluent limitations for the coal mining industry are based
on utilization of the geochemical approach which encompasses
oxidation potentials, reaction rates, and solubility constants,
as well as pH control.
A. Preparation Plant Wastes
Semi-colloidal particles of coal, shale, and clay in suspension
form one of the principal pollutants—suspended solids. Reduction
in the amount of suspended solids reaching the stream can be
-------
39 COAL
ABATEMENT MODELS (continued)
achieved by installation of settling and impounding facilities.
Other methods of control include froth flotation, flocculation,
filtration, and mechanically operated sedimentation and clarification
basins. Organic coagulants such as polyacrylamide, used alone
or in combination with inorganic coagulants may demonstrate good
settling qualities.
In addition to the problem of suspended solids, the effluent from
coal washing-may contain iron and sulfur compounds in suspension.
In high enough concentration, these would cause considerable loading
on the stream and will require chemical treatment before discharge.
The effluent limitations for preparation plant wastes reflect the
eventual goal of complete recycling.
B. Underground Mine Drainage
The term "underground mine drainage" as used herein applies
not only to discharges which have a low pH value but also to
discharges with a neutral value but which are high in metallic salts
which can be a problem in an alkaline environment.
Drainage from coal mines may be acid and may contain sulfuric
acid, ferrous and ferric iron, aluminum, and manganese in significant
concentrations. Carbon dioxide, and calcium, magnesium, and
sodium salts, all of which contribute to a very high degree of
hardness may also be present. Preventive measures might include
reduction of the amount of infiltration into the mine, controlled
dewatering to reduce contact with acid-forming materials, removal
of acid forming materials, sealing or flooding of inactive
mines, and replacement of waste rock. Treatment methods which
might be used to meet the effluent requirements include
neutralization, and removal of iron and manganese.
C. Surface Mining
To meet the effluent limitations for surface mining, operators
will have to employ one or all of the following methods:
1. Keep as much water as possible out of
the operating site;
2. Provide proper drainage and removal to ;
treatment facility;
3. Separate contaminated and non-contaminated
water; and
4. Insure that all water receives proper
pH control as well as removal of suspended
solids and metallic materials.
-------
40
COAL
ABATEMENT MODELS (continued)
At present, a number of operations are employing lagooning
systems. Evaporation results in a reduction in the suspended
solids as well as the ferric hydroxide and the ferric sulfate.
Precipitation eventually results through the oxidation process.
One source of acid mine water is the reuse pile or "gob pile"
which contains sulfurous refuse from the preparation and
cleaning process. Control of the gob piles could eliminate
a source of acid drainage. The simplest system for control
is to cover these piles with a non-acid producing material
such as two feet of dirt. At a later time, to insure stability,
some form of vegetation should be planted. Sealing or benching of
the cut area so that there are no opportunities for oxidation
of pyritic material will eliminate a major part of the problem.
Neutralization
Neutralization to pH of 6.0 to 9.0 can be accomplished by the
use of lime,limestone, oxidation, or varied combinations of
the three depending on the characteristics of the waste.
The use of a two-step neutralization process, that is, the use
of limestone to bring the pH to 5, with the addition of lime
to complete the neutralization, could result in a considerable
savings both in the cost of chemicals and in sludge handling.
-------
EFFLUENT LIMITATIONS
Preparation Plants
A B
Suspended Solids 30 mg/1 40 mg/1
pH
Total Iron
Alkalinity
6.0-9.0 6.0-9.0
4.0 mg/1 7.0 mg/1
Greater than acidity
*1
Underground
Mine Drainage
A B
30.0 mg/1 40 mg/1
6.0-9.0 6-0-9.0
4.0 mg/1 7.0 mg/1
greater than acidity
*2
Surface Mining
A B
30.0 mg/1 100 mg/1
6.0-9.0
4.0 mg/1
6.0-9.0
7.0 mg/1
greater than acidity
*3
o
p
-------
GOAL
-------
45
DAIRY
APPLICABILITY
These instructions apply to Standard Industrial Classification
Codes 202 and 5043.
SUBCATEGORIES CONSIDERED
Operations in the dairy industry are considered under the following
subcategories-. receiving stations, fluid milk processing, butter,
natural cheese, ice cream, condensed milk, dry milk, whey condensing,
whey drying, and cottage cheese.
PRODUCTION BASIS
The maximum daily receipts in 1,000 pounds milk equivalent,
shall be the highest average level sustained for seven
consecutive operating days of normal production, determined
at the time of application. (Milk equivalent may be determined
from Attachment 1.).
APPLICATION OF LIMITATIONS
If permits are issued in the dairy industry, they should be
issued only to very large operations.
Except for cottage cheese manufacturing, there is little statistical
difference between unit wastewater flows from single product plants
and multi-product plants. The unit loads for each product are additive
and proportional to the milk equivalent used in each operation.
However, the level for receiving stations applies only to receiving
stations and is not additive to product plants.
The following may be significant parameters depending on production
and receiving water characteristics:
Color
Turbidity
Foam
Ammonia
Nitrogen
Phosphorous
Settleable Solids - Settleable solids shall not exceed 0.1 mg/1.
ABATEMENT MODELS
The following generalized production process controls and treatment
systems were used as a model in developing the effluent limitations
for the dairy products industry:
-------
46
DAIRY
ABATEMENT MODELS (continued)
1. good degree of management effort in controlling
available product and raw material losses;
2. recovery of whey and by-products;
3. biological oxidation using trickling filter or
various modifications of activated sludge;
4. secondary clarification;
5. disinfection, if necessary.
The system described above is a generalized model which is applicable
to the entire industry. At the present time there are very few
alternatives to this model. Of major importance in the above model
is the control of the production process.
-------
EFFLUENT LIMITATIONS
(lbs/1000 Ibs milk or milk equivalent)
Schedule A Schedule B
Subcategory
Receiving Stations
Fluid Milk Processing
Butter
Natural Cheese
Ice Cream*
Condensed Milk
Dry Milk
Whey Condensing
Whey Drying
Cottage Cheese
NOTE: *Novelty items
BOD5
0.032
0.03
0.03
0.03
0.03
0.03
0.03
0.03
0.03
0.13
(e.g. , stick
Suspended
Solids
0.032
0.03
0.03
0.03
0.03
0.03
0.03
0.03
0.03
0.13
confections, popsicles)
0.053
0.13
0.13
0.20
0.45
0.11
0.11
0.15
0.20
0.95
shall be
Suspended
Solids
0.053
0.13
0.13
0.20 ^
0.45
0.11
0.11
0.15
0.20
0.95
D
considered on a £j
K
-------
48
DAIRY
ATTACHMENT I
DETERMINATION OF MILK EQUIVALENT
Milk equivalent is the quantity (in pounds) of milk used to produce one
pound of product. Milk is considered to include skim milk, whole milk,
and other milk with a butterfat content of less than 3.5 percent.
If the facility receives higher than 3.5 percent butterfat milk or
cream as a raw product, an adjustment according to the butterfat ratio
should be made. In the case of cream this ratio would be 48/3.5;
1000 Ibs of cream would therefore be equivalent to 13,700 pounds of
milk.
If the raw product received is whey, the milk equivalent should be
considered as the BOD ratio of whey to whole milk (i.e. 0.4); therefore,
1000 Ibs of whey is equivalent to 400 Ibs of milk. If the pounds
of final product are available but no raw material data are known,
the following data can be used to convert the final product to its
milk equivalent.
Product Ib. Milk Equivalent/lb Product
Butter 21.3
Natural Cheese 9.9
Cottage Cheese 6.3
Ice Cream 2.7
Condensed Milk 2.4
Dry Whole Milk 7.4
Dry Skim Milk 11.0
-------
49
FERTILIZER
APPLICABILITY
These instructions apply to Standard Industrial Classification
2871.
SUBCATEGORIES CONSIDERED
The following categories are considered:
Sulfur Burning, Sulfuric Acid Plants
Phosphoric Acid
Normal Superphosphate
Triple Superphosphate
Mono-Ammonium Phosphate
Di-Ammonium Phosphate
N-P-K Fertilizers
Ammonia Production-Centrifugal and Reciprocal Compressors
Ammonium Sulfate
Urea
Nitric Acid
Ammonium Nitrate
OPERATIONS EXCLUDED
Other SIC codes are addressed only to a limited extent. Ammonia,
ammonium nitrate, ammonium sulfate, and all of the acids (sulfuric
phosphoric, and nitric) are also listed under SIC 2819. Urea is
listed under SIC 2818. Phosphoric rock mining and potash mining
(SIC 1474) are not covered in this guidance.
APPLICATION OF LIMITATIONS
The interim guidance should be used only for primary producers and
should not be used for formulators. Capacity of facilities
permitted should equal or exceed:
NH3 100,000 tons/yr
prilled NH4 NO3 100,000 tons/yr
synthetic (NH4) 2SO4 100,000 tons/yr
(NH4)2HP04 100,OOOtons/yr
prilled NH42HPO 50,000 tons/yr
EFFLUENT LIMITATIONS
Fertilizer Industry process waste contain fluoride, phosphorus,
suspended solids, oil (primarily from compressor and pumping
operations), and nitrogen from ammonia and nitrates. Utility
blowdown wastes include alkalinity, suspended solids, phosphorus,
zinc, chromium, and free chlorine. Parameters like iron, vanadium,
nickel, and cobalt are
-------
50
FERTILIZER
EFFLUENT LIMITATIONS (continued)
introduced in water treatment chemicals, catalysts, and from equipment
corrosion products (stainless steel and stablizers), Phosphate rock
and raw sulfur sometimes contain significant quantities of selenium,
arsenic, cadmium and natural uranium. If it is believed that any of
these parameters are present, they should be limited.
ABATEMENT MODELS
Phosphate Fertilizer Industry
Phosphorus, Fluoride, and Suspended Solids - Conventional treatment
for waste from the phosphate fertilizer industry is to route the waste
flows to an impoundment area, (gypsum pond) and then through a two-
stage double liming process. The first stage neutralizes the highly
acidic water to a 3-4 pH level and precipitates out some of the fluoride
and phosphorus in the wastewater. The second stage further neutralizes
the stream to a 6-7 pH level.
Some heavy metals precipitate out from this process, but further
treatment may be necessary to reach established effluent levels.
This treatment system will meet Schedule A levels. If lower levels
are required in cases where water quality is being impaired,
additional treatment consists of mineral addition to secondary and
tertiary treatment systems which combine flotation, sedimentation,
sand and dual media filtration, and aeration.
Heavy Metals - If the heavy metals content in the effluent from the
double liming process does not meet established Schedule A levels, then
additional treatment will be necessary. The location of the precipitation-
sedimentation system used to remove the heavy metals will depend on the
waste stream being treated and the design situation. It is probably
more practical to integrate this system with the double liming process
or to have it follow directly behind it.
The procedure is basically the adjustment of pH, usually with lime,
to achieve an alkaline condition, followed by precipitation of the
hydroxide. Coagulating aids are often required to achieve the levels
of precipitation necessary. Variations and individual treatments may
be necessary for several of the metal ions. These variations include
reduction or oxidation to different oxidation states, removal of
interfering constitutents prior to precipitation, and adjustment of
the pH to different levels (pH of 7 to 10).
Arsenic - The stream can be treated by adjusting the pH to around
10, adding coagulating aids, and allowing settling, followed by
filtration if necessary.
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51
FERTILIZER
ABATEMENT MODELS (continued)
Nitrogen Fertilizer Industry
Ammonia Nitrogen - Treatment methods include microbial nitrification,
biological devitrification, air stripping, and steam stripping.
Stream stripping appears to be the most dependable. In stream
stripping, a single tower equipped with trays or packing is used.
The waste stream enters the top of the stripper and the stripping
medium, in this case steam, is introduced at the bottom of the
column below the trays or packing. The ascending steam removes
the free ammonia from the waste stream. The operation usually occurs
in a temperature range of 230-270°F and 5-30 psig. If a dry
overhead gas product is desired, a condenser may be used to
remove water from the gas ; the condensed water is refluxed back
to the tower-feed. The ammonia solution should be kept at a pH of
9.5 or higher.
If it becomes economically desirable to recover the ammonia or if
an air pollution problem exists for a certain site location, then
the overhead from the stripping tower can be recovered through
the application of reflux, compression, and purification.
Nitrate Nitrogen - Good housekeeping and inplant controls are
required in order to meet Schedule A limits. Off gas from the
neutralizer can be vented directly to the atmosphere. In situations
where this will not be allowed, the off gas must be condensed
and the condensate treated to remove NH 3 and NH4NO3 , and recycled back
to the neutralizer, or concentrated and used directly as product.
For plants where the effluent does not meet Schedule A levels, and
recycling and inplant modifications have been applied, additional
waste treatment will be required. One treatment system which is
successfully being used involves ion exchange. The essential steps
in the ion exchange process are: collecting of waste in large settling
ponds, filtering through anthracite coal filters to remove particulate
matter , contacting wastewater with strong acid cation exchange
resin that removes the ammonium cation contaminant, contacting the
"decationated" water with a weak base resin in the hydroxide form
with 7% ammonium hydroxide, and corribining backwash from each separate
unit and neutralizing excess acid with ammonia.
A dual effect evaporator system may also be used for treating waste
liquors containing ammonium nitrate. (These wastes include condensed
neutralizer off gas, leaks, spills,etc). The liquor is concentrated
to 60-80% depending on the point of usage in the plant. The only
waste discharge is steam from the evaporators and it does not
constitute an air pollution problem. Significant steam economy
is achieved from the dual effect evaporator design.
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52
FERTILIZER
ABATEMENT MODELS (continued)
Organic Nitrogen - The major source of organic nitrogen in waste
effluent is the production of urea. Urea production can be broken
down into three categories of plants: once-through, partial recycle
and total recycle.
In ohis case, recycle does not refer to the waste effluent, but the
rev?/cling of unreacted ammonia and carbon dioxide (ammonium carbamate
is also broken down into ammonia and carbon dioxide and recycled).
With once-through and partial recycle systems, there is no process
effluent other than leaks and spills. On the other hand, total
recycle plants have a considerable amount of effluent containing
significant amounts of urea and ammonia.
In the effluent limits table (Table I) two A and B levels are given
for NH3-N and Organic N under the urea industrial category. The lower
levels apply to once-through and partial recycle plants while the higher
level is to be applied to total recycle facilities. A waste removal
system is on the market using urea hydrolysis and steam stripping. The
system is designed to give an effluent of 15 pounds ammonia nitrogen and
85 pounds organic nitrogen per lOOOtons of urea production (total recycle
plants). To allow for fluctuations in the system and to establish an
average limit which can be met consistently, a level of 100 Ibs. of
ammonia nitrogen and 100 Ibs. of Organic Nitrogen per 1000 tons of urea
production has been set. Since ammonia is produced in the hydrolysis of
urea, it would probably be more practical to apply steam stripping to
the total waste stream after hydrolysis of the urea.
Heavy Metals - The precipitation-sedimentation systems described under
phosphate fertilizer above apply here also. The location may depend
on a number of things including the waste stream being treated and the
design situation.
Oil and Grease - Where oil and grease in the waste effluent are a
problem, a properly operated API-designed oil separator or the use
of air flotation and skimming can reduce the oil in the effluent to
meet the Schedule A levels.
SPECIAL WASTE ALLOWANCE CONSIDERATIONS
In the production of ammonia, ammonium nitrate, and urea, there are
situations (absorption of ammonia in cooling water) and processes
(prilling, solid materials handling) which require the consideration
of additional waste allowances for certain parameters. For discussion
of this see the memorandum to the Regional Permit Program Directors,
dated February 16, 1973, subjected "Waste Allowances Above the Effluent
Limitation Guidance Schedule A Levels for the Nitrogen Fertilizer
Industry."
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TABLE 1
EFFLUENT LIMITATIONS i/
FERTILIZER INDUSTRY
Subcategory
Sulfuric Acid
Sulfur Burning
Phosphoric Acid
Normal and Triple Superphosphate
Mono-and Di-Ammonium Phosphate
N-P-K
Characteristics
Iron
Suspended Solids
Vanadium
Selenium
Arsenic
Iron
Suspended Solids
Phosphorus
Fluorine
Heavy Metals (U-Nat,Va)
Cadmium
Iron
Suspended Solids
Phosphorous
Fluorine
Heavy Metals (U-Nat,Va)
Cadmium
Effluent Limits
lbs/1000 Ton Product
A
1.0
25.0
1.0
0.5
0.25
25.0
625.0
125.0
125.0
25.0
5.0
8.3
208.0
41.5
41.5
8.3
1.7
B
1.0
25.0
1.0
1.0
-
25.0
625.0
250.0
250.0
. 25.0
25.0
8.3
208.0
83.0
83.0
8.3
8.3
H
tr1
H
IS!
M
I/ For ammonia, ammonium nitrate, and urea see section entitled "Special Waste Allowance
Considerations" on previous page.
-------
EFFLUENT LIMITATIONS (Cent.)
FERTILIZER INDUSTRY
Subcategory
Ammonia Production Centrifugal
and Reciprocal Compressors
Ammonium Sulfate
Characteristics
Iron
Nickel
Ammonia Nitrogen
Suspended Solids
Oil
Iron
Nickel
Ammonia Nitrogen
Suspended Solids
Urea Iron
Nickel
Organic Nitrogen 3/
Ammonia Nitrogen .?_/
Oil
Suspended Solids
Cobalt
Effluent Limits
lbs/1000 Ton Product
A
5.3
2.6
52.0
130.0
52.0
2.0
1.0
19.8
50.0
3.2
1.6
32.0-100
32.0-100
32.0
80.0
1.6
B
5.3
5.3
104.0
130.0
130.0
2.0
2.0
39.8
50.0
3.2
3.2
64.0-100
64.0-100
80.0
80.0
3.2
VJl
S
H
IT1
H
(SI
M
2/
The 32 and 64 lbs/1000 Tons Product limits are to be applied to once-through and partial
recycle urea plants and the 100 lbs/1000 Tons product limit to total recycle plants.
-------
S ubc a tego ry
Nitric Acid
Ammonium Nitrate
EFFLUENT LIMITATIONS (Cont.)
FERTILIZER INDUSTRY
Characteristics
Iron
Ammonia Nitrogen
Nitrate Nitrogen
Suspended Solids
Nickel
Cobalt
Oil
Iron
Nickel
Ammonia Nitrogen
Suspended Solids
Nitrate Nitrogen
Oil
Effluent Limits
lbs/1000 Ton Product
A
2.9
28.0
28.0
72.0
1.4
1.4
28.0
2.5
1.3
25.0
62.5
25.0
25.0
B
2.9
56.0
56.0
72.0
2.9
2.9
72.0
2.5
2.5
50.0
62.5
50.0
62.5
Ul
Ul
H
W
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57
INORGANIC CHEMICALS
APPLICABILITY
These instructions apply only to Standard Industrial Classification
Codes 2812, 2816, and 2819.
SUBCATEGORIES CONSIDERED
The following subcategories are considered:
aluminum chloride, aluminum sulfate, chlorine - sodium hydroxide,
hydrochloric acid, hydrofluoric acid, hydrogen peroxide, lime, nitric
acid, elemental phosphorus, and sulfuric acid.
OPERATIONS EXCLUDED
Inorganic compounds such as anhydrous ammonia, superphosphates, and
urea are included in the guidance for the fertilizer industry (SIC
2871) .
APPLICATION OF LIMITATIONS
The use of the interim guidance is limited to single product plants
for the ten categories covered in the interim guidance.
The effluent guidelines are based on process wastewater, i.e., that
coming in contact with process materials. This does not include non-
contact cooling water, cooling tower blowdown or boiler blowdown.
The mercury effluent limitation of 0.1 pounds per day for the entire
chlor-alkali operation is to be measured at the outlet from the mercury
treatment unit. Should there be another process at the location that
has an effluent containing mercury, that stream must be treated in the
mercury treatment unit and thus be included in the 0.1 pound per
day. Mercury residuals (i.e., mercury picked up between the
treatment unit outlet and the discharge to the stream) are frequently
a problem. Where residuals are a demonstratable problem, identify
the quantity of mercury involved and develop a program with schedules
for correction.
ABATEMENT MODELS
The industries in these categories manufacture products from raw
materials that are inorganic in nature, thereby resulting in wastewater
containing a low biochemical oxygen demand, inert solids, large
amounts of dissolved solids, and effluents with a wide range of
pH values. The major pollutant common to nearly all of the industry
is inorganic suspended solids, a parameter that can be controlled
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58
INORGANIC CHEMICALS
ABATEMENT MODELS (continued)
with sedimentation basins designed for minimal short circuiting
and sufficient detention time.
Total dissolved solids, chiefly chlorides and sulfates, constitute
the second major class of pollutants for the inorganic industry.
However, it should be noted that guidelines are not presently
placed on dissolved solids, chlorides and sulfates. When the discharge
of any of these parameters may be in violation of Federal or State
or local water quality standards, limits will be established.
When such is the case a substantial amount of dissolved solids
reduction can be effected through in-plant controls some of which
are:
1. Chlorine-caustic
(a) non-contact vapor condensers.
(b) use of indirect chlorine coolers in the
chlorine compression process
(c) collection and reuse of drying acid.
(d) recycling of sodium chloride from the
evaporators concentrating caustic soda
(e) use of indirect vapor condensers in
the brine dechlorination process
(f) recycle of brine filter back washwater
(g) collection and reuse of effluent from waste
chlorine gas disposal system
(h) maximum removal of brine solution from slurries
resulting in precipitation of impurities from
raw brine solutions
(i) containment and recycling of spills and leaks
back to the process.
2. Nitric Acid
(a) replacement of barometric quench condensers with
non-contact condensers
(b) the use of single and double mechanical pump
seals
(c) curbing the process area with recycling of spills.
3. Hydrochloric Acid
(a) curbing and floor sumps to collect and recycle
strong acid spills and leaks.
(b) maximizing the efficiency of the cooler and absorber to
minimize the chloride wasteload from the scrubber.
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59
INORGANIC CHEMICALS
ABATEMENT MODELS (continued)
4. Hydrogen Peroxide (organic method)-separation of organic
solvents from the aqueous media with decanters or API
separators for recycle or recovery.
5. Hydrofluoric Acid-maximize for efficiency of the acid
absorbers to minimize the fluoride wasteload from ejecter
scrubber systems.
6. Sulfuric Acid - curbing and floor sumps to collect and
recycle spills and leaks.
Treatment models representing "Best Practicable Treatment"
described for each of the product industries are described to
illustrate means by which "A" levels may be achieved.
Aluminum Chloride - sedimentation and coagulation.
Aluminum Sulfate - sedimentation and recycling of clarified
effluent.
Chlorine-caustic - sedimentation, chemical precipitation-coagu-
lation-sedimentation, filtration, carbon
adsorption, neutralization, water recycling,
and water conservation practices.
Hydrochloric Acid - segregation of cooling water, collection of
spills and leaks for recycle or land disposal.
Hydrofluoric Acid - lime precipitation, coagulation flocculation,
sedimentation, and neutralization.
Hydrogen peroxide - (organic method) - Biological oxidation of
organic solvents, sedimentation.
Lime - dry collection of dust.
Nitric Acid - segregation of cooling water, collection of spills
and leaks for recycle or land disposal.
Phosphorus - sedimentation and recycle.
Sulfuric Acid - segregation of cooling water, collection of spills
and leaks for recycle or land disposal.
B levels can be achieved by the following methods:
Aluminum Chloride - reduction of suspended solids in scrubber
wastewaters which do not use alkaline
solutions. Aluminum hydroxide readily flocculates
and settles out
Aluminum Sulfate - lime neutralization followed by sedimentation
and recycle of a portion of the effluent.
Chlorine-Caustic - separation of process water from cooling water,
and water recycle will be required for both A and
B levels. Soda ash or caustic treatment may be
required for lead, but it generally separates out
in settling ponds. Installation of metal anodes
will eliminate lead.
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60
INORGANIC CHEMICALS
ABATEMENT MODELS (continued)
Hydrochloric Acid -
Hydrofluoric Acid -
Hydrogen Peroxide -
Lime -
Nitric Acid
Phosphorus -
Sulfuric Acid -
(chlorine burning process) - caustic neutralization
of acid leaks and wastewater from the scrubber.
Hydrochloric acid processes are quite commonly
located at the same site as caustic chlorine
plants. In this case the acid wastewaters can
be used to neutralize alkaline wastewaters.
treatment with lime to a pH of 10-11. This
neutralizes the sulfuric acid, reduces the
fluoride content to 5 ppm and suspended solids
to 25 ppm. Acidification of the effluent
reduces pH to 9 or less.
disposal of the biodegradable solvent waste, either
by discharge to a municipal biological treatment
system or a solvent collection and recycling system.
discharge of wet scrubber waste to a settling
pond with effluent containing 20 ppm suspended
solids.
neutralization of leakage with caustic.
phosphorus burial, lime and settling pond
treatment for soluble phosphates and fluorides
and dry collection of solid phosphates. A
small part of the flow to the settling pond
is discharged. The remainder is recycled.
lime and sattling pond treatment of the leaks
to 25 ppm suspended solids.
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61
LEVEL A
INORGANIC CHEMICALS, ALKALI AND CHLORINE INDUSTRY
EFFLUENT GUIDELINES
LB PER TON OF PRODUCT
PRODUCT
FLOW BASIS*! TOTAL SUSPENDED
GAL/TON j SOLIDS
OTHER BY
NOTE
ALUMINUM CHLORIDE
ALUMINUM SULFATE
CAUSTIC CHLORINE:**
Diaphragm Cell
Mercury Cell
Downs Cell
HYDROCHLORIC ACID
(Chlorine burning)
HYDROFLUORIC ACID
HYDROGEN PEROXIDE
(Organic process)
LIME/CALCINATION
NITRIC ACID
PHOSPHORUS
SULFUR!C ACID
(Sulfur burning
contact plants)
0.015
120
No waterborne process effluent
8,000
5,000
7,300
1.0
0.6
0.9
No waterborne process effluent
4,672
8,600
0.6
1.1
No waterborne process effluent
No waterborne process effluent
No waterborne process effluent
No waterborne process effluent
1
2
pH range is 6-9 for all products
NOTES: 1. 0.04 #/ton lead
2. 0.1 #/day mercury for the entire operation without regard to capacity***
3. 0.2 #/ton fluorides
4. 0.06 ft/ton TOC
*The flow basis numbers are to show how numbers were derived and are not intended
as flow limitations.
**Units are per ton of chlorine production
***The EPA goal of no mercury discharge may reduce this number as it becomes practical.
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62
LEVEL B
INORGANIC CHEMICALS ALKALI & CHLORINE INDUSTRY
EFFLUENT GUIDELINES
PRODUCT
ALUMINUM CHLORIDE
ALUMINUM SULFATE
CAUSTIC CHLORINE**
Diaphragm Cell
Mercury Cell
Downs Cell
HYDROCHLORIC ACID
(Chlorine burning)
HYDROFLUORIC ACID
HYDROGEN PEROXIDE
(Organic process)
LIME/CALCINATION
NITRIC ACID
PHOSPHORUS
SULFURIC ACID
(Sulfur burning
contact process)
FLOW BASIS*
GAL/TON
120
400
30,000
20,000
7,300
1,000
36,000
8,600
200
86
8,000
1.200
, LB PER TON OF
TOTAL SUSPENDED
SOLIDS
0.025
0.08
6.3
4.3
1.5
-
7.5
1.8
0.03
0.01
1.7
0.25
PRODUCT
OTHER BY
NOTE
-
1
2
-
3
4
-
5
pH range is 6-9 for all products
NOTES: 1. 0.2 #/ton, lead
2. 0.1 #/day of mercury for the entire operation without regard to capacity
3. 1.5 #/ton, fluorides
4. 0.03 #/ton, COD
5. 0.2 ft/ton, phosphates; 0.2 #/ton, fluorides; 0.001 #/ton, elemental
phosphorus
*The flow basis numbers are to show how numbers were derived and are not intended
as flow limitations.
**Units are per ton of chlorine production.
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63
MEAT PRODUCTS
APPLICABILITY
These instructions apply only to Standard Industrial Classification
codes 2011, 2013 and 2015.
SUBCATEGORIES CONSIDERED
Operations in the meat products industry are considered under the
following subcategories:
Meat packing, slaughterhouse, packinghouse, and processing plant
only;
Poultry Processing: broilers (eviscerating), broilers (eviscerating
cut-up), fowl and duck, and turkeys.
OPERATIONS EXCLUDED
Off-site rendering plants are not included in this guidance.
PRODUCTION BASIS
The maximum daily production capacity, as determined at the time
of application, shall be the highest average level sustained for
seven consecutive operating days of normal production.
APPLICATION OF LIMITATIONS
Guidance should be applied only to the following categories :
Segment Maximum Capacity
Beef Slaughter (only) greater than 800,000 Ibs Iwk/day
Mixed Slaughter greater than 100,000 Ibs Iwk/day
Packing Houses greater than 100,000 Ibs Iwk/day
Meat Processing greater than 10,000 Ibs of product
per day
Poultry Processing greater than 40,000 Ibs Iwk/day
Allowable waste loads for a packinghouse may require adjustment when
normal day-to-day processing is less or greater than would usually
be related to the live weight kill. The following equations can
be used to make this adjustment for Schedule A values. They relate
BODj and suspended solids effluent limitations to live weight kill
and edible products where one of the above situations exists.
It should be stressed that manufactured edible products refers to
such products as sausage, bacon, hot dogs, etc.
Settleable Solids - Settleable solids shall not exceed 0.1 ml/1.
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64
MEAT PRODUCTS
APPLICATION OF LIMITATIONS (continued)
1. When a packinghouse is processing an unusually large amount of meet
compared with the live weight kill (Iwk):
BODp = 0.26 (1000 Ib. Iwk/day) + 0.0625 [(1000 Ib. mfg. edible product/day
- 0.25* (1000 Ib. Iwk/day)]
BOD = Permitted Ib. BOD5
SSp =0.35 (1000 Ib. Iwk/day) + 0.083 [(1000 Ib. mfg, edible product/day
-0.25* (1000 Ib. Iwk/day)]
SSp = Permitted Ib. Suspended Solids
An example of the above is as follows:
Slaughter - 2000 thousand pounds Iwk/day
Processing - 1000 thousand pounds manufactured edible product/day
BODp- 0.26 (2000)+ 0.0625 [(1000) - 0.25 (2000)]
= 520 + 31.3 = 551.3 Ib. BOD5
SSp= 0.35 (2000)+ 0.083 [(1000) - 0.25 (2000)]
700 + 41.5 = 741.5 Ib. Suspended Solids
2. Plant processing a relatively small amount of meat.
BODp = 0.26 (1000 Ib Iwk/day) - 0.0625 [0.25*(1000 Ib Iwk/day)-
(1000 Ib. mfg. edible product/day)]
SSp = 0.35 (1000 Ib. Iwk/day)- 0.083 [ 0.25*(1000 Ib. Iwk/day)-
(1000 Ib. mfg. edible product/day)]
An example of the above is as follows:
Slaughter - 2000 thousand pounds Iwk/day
Processing - 200 thousand pounds manufacture edible product/day
BODp = 0.26 (2000) - 0.0625 [0.25(2000) - (200)]
520 - 18.75 = 501.3 Ib. BODS
SSp= 0.35 (2000) - 0.083 [0.25(2000) - (200)]
700 - 25 = 675 Ib. Suspended Solids
*Represents the fraction of Iwk normally processed into edible
product.
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65
MEAT PRODUCTS
APPLICATION OF LIMITATIONS (continued)
The following may be significant parameters depending on production
methods and receiving water characteristics:
Ammonia - The quantity present in treated effluent from systems
using anaerobic lagoons is a potential problem. In
discussion with industrial representatives this fact
should be made clear so they can develop their abatement
programs accordingly.
Phosphate
Dissolved Solids
Color
Turbidity
Toxicity
When deemed necessary, effluent limits applied to these parameters
shall consider receiving water quality and available technology.
ABATEMENT MODELS
Meat Packing
The following process considerations and treatment facilities can be
used to achieve the 'best practicable pollution control technology
currently available.'
1. Efficient blood collection
2. Dry handling of paunch
3. Dry clean-up prior to wash down
4. High pressure spray system for wash down
5. Screening and grit removal
6. Dissolved air flotation
7. Anaerobic lagoons followed by aerated lagoons or activated
sludge systems.
8. Disinfection
Schedule A guidance is based on effluent BOD^ and suspended solids
concentrations of 30 and 40 mg/1 respectively. Processing plant
concentrations are slightly lower. Wastewaters from this industry
are readily amenable to biological treatment to these specified
quality levels.
The Schedule B guidance represents good present-day abatement
practices.
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66
MEAT PRODUCTS
ABATEMENT MODELS (continued)
Poultry Processing
The following elements can be used to achieve the "best practicable
pollution control technology currently available1 for the poultry
industry.
1. Efficient blood collection
2. Dry clean-up prior to wash down
3. High pressure water spray systems for wash down
4. Reuse of chiller water in such areas as the feather
flume
5. Grease removal
6. Biological oxidation by activated sludge or aerated
lagoon systems.
7. Disinfection
The Schedule A effluent guidance is used based on BOD,. and suspended
solids concentrations of 20 mg/1 and 30 mg/1 respectively. This
wastewater is readily amenable to biological treatment to the
quality levels indicated. The Schedule B guidance represents good present-day
abatement practices.
-------
EFFLiUENT LIMITATIONS - MEAT PRODUCTS INDUSTRY
LB/1000 UNITS
SUBCATEGORY
MEAT PACKING
UNIT
Slaughterhouse Ib. lwk
Packinghouse Ib. lwk
Processing Plant
Only Ib. Prod.
POULTRY
PROCESSING^/
Broilers Ib. lwk
(eviscerting)
Broilers Ib. lwk
(eviscerating
cut-up)
Fowl s Duck!/ Ib. lwk
Turkeys Ib. lwk
SCHEDULE A
BOD_5
0.17
0.26
0.26
SUSPENDED
SOLIDS
0.23
0.35
0.26
0.41
0.46
0.4
0.4
0.62
0.69
0.62
0.62
BODc-
-^
0.30
0.61
0.32
0.59
0.73
0.78
0.57
SCHEDULE B
I/ Live weight killed.
2/ Figures do not include rendering.
3/ For plants doing cooking, boning, and dicing, limits may be increased up to 15%.
SUSPENDED
SOLIDS
0.47
0.87
0.42
1.01
1.18
1.09
0.68
V
§
o
c
o
i-3
(n
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69
METAL FINISHING
APPLICABILITY
These instructions apply to Standard Industrial Classification Codes
3471 and 3479.
APPLICATION OF LIMITATIONS
The interim guidance should be used only for the large establishment
having discharges greater than 20,000 gpd for the categories covered
in the guidance.
The metals involved in the effluents discharged by this industry are
in ionic form, in solution, or as part of a compound in suspended
form. Limits for each parameter are given on the basis of pounds
per thousand gallons. Small companies, (9 employees or fewer) may
have relatively low total weight loadings of toxic discharges. How-
ever, the concentration of these discharges may be far above the
levels prescribed herein. Such companies, because of their size,
may not be able to meet Schedule A or even Schedule B discharge
levels. Nevertheless, if exceptions were made to allow for their
discharge to be permitted and guided solely by total weight basis,
then the following problems would be immediately apparent:
a. The effect on receiving waters of a highly concentrated
discharge of toxic materials in the vicinity of the
discharge pipe.
b. The cumulative effect of concentrated toxic discharge
from numerous small shops, which tend to be congregated
in the same general locality.
The following are estimates*a' of water usage by job shops in terms
of volume of business and number of employees:
Water Use (gpd) Annual Sales (_$ 1,OOP's) Employees
(A) <20,000 16-145 1-9
(B) 20,000-60,000 170-485 10-30
(C) 61,000-300,000 510-1100 31-60
(D) 300,000 1100 60
The use of dilution to achieve discharge limits will not be allowed.
^a'1967 Census of Manufacturers, U.S. Department of Commerce,
Bureau of Census Publication MC 67(2) 34D.
-------
70
METAL FINSHING
ABATEMENT MODELS
The basic treatment model assumed herein is that of unit process
stream precipitation. Some possible variations are described below.
For essentially all of the parameters, best practicable control
technology currently available involves precipitation which includes
coagulation, sedimentation, flotation, and finally, filtration. A
modified version generally regarded as more effective is known as
the "Integrated Process." Evaporative recovery and ion exchange
offer other effective approaches. In some cases, chemical oxidation
(for cyanides) and chemical reduction (for chromium) are needed as
part of the treatment process. Such heavy metals as copper, zinc,
iron, manganese, nickel, chromium +3, and conceivably cobalt, can
be readily and inexpensively precipitated as the hydroxides by
lime treatment. Cadmium is most effectively precipitated as the
sulfide; soda ash is most effective for lead.
Most of the hydroxides are precipitated at pH 9. Zinc hydroxide,
being amphoteric, manifests its minimum solubility in the pH range
of 8-9. Aluminum hydroxide, being amphoteric, manifests its minimum
solubility over the pH range of 5-6. Depending on the kinds of
heavy metal ions present in the effluent, it is possible to remove
them either concurrently or in stages by precipitation techniques.
The necessity for pH control and desirability of segregation of
streams would be governed by the particular combination of heavy
metal ions involved.
In essence, the discharge limits would apply equally as well to
effluents containing one or more metals; however, in treating
effluents containing a mixture of metals, compliance with the
effluent guidance must be evaluated on a case-by-case basis.
It may be possible for groups of small companies in the same
locality to technically and economically meet concentration effluent
guidelines by placing their pollution abatement resources into
centrally located treatment facilities. Some of the costs involved
could be recovered by return of useful materials such as precious
metals in proportion to individual input. (Cooperative arrange-
ments of this type should be given serious consideration.)
COD should be considered because various types of organic compounds
are likely to be used as components of metal finishing process baths.
In addition, oil and grease are removed from working parts during
pickling operations. Owing to the relatively low proportion of
organics, this parameter may have limited significance in the Metal
Finishing Industry. It is recommented that discharge limits be
-------
71
METAL FINISHING
considered individually on a case-by-case basis. In addition, such
parameters as ammonia (N) and phosphate (P) should be considered
similarly on an individual case-by-case basis for similar reasons.
The various metals listed in the effluent limits are the most
frequently encountered in the Industry.
-------
EFFLUENT LIMITATIONS
EFFLUENT
PARAMETER
COD (c)
TSS
CYANIDE Dest. by C12
FLUORIDE
ALUMINUM
BARIUM
CADMIUM
CHROMIUM CR+6
CRfc
COPPER
IRON
LEAD
MANGANESE
NICKEL
SILVER
ZINC
pH (Ave. Daily Discharge)
SCHEDULE A
Concentration lbs/1000 gal
mg/1 (a) (b)
10
0.03
18
0.2
1.0
0.1
0.05
0.25
0.2
0.5
0.05
1.0
1.0
0.05
0.5
0.0834
0.00025
0.150
0.00167
0.00834
0.000834
0.000417
0.00209
0.00167
0.00417
0.000417
0.00834
0.00834
0.000417
0.00417
SCHEDULE B
Concentration lbs/1000 gal
mg/1 (a)
50
0.1
18
0.5
2.0
0.2
0.1
0.5
0.5
1.0
0.1
2.0
2.0
0.05
0.05
0.417
0.000834
0.150
0.00417
0.0167
0.00167
0.000834
0.00417
0.00417
0.00834
0.000834
0.0167
0.0167
0.000417
0.000417
Ul
6-9
6-9
(a) Metal concentrations are based on analysis of filtered clear solutions.
(b) The maximum permissible concentration for a particular metal in the total suspended solids
shall be 1 mg/1, (0.00834 lbs/1000 gal).
(c) Limited significance in this industry, should be considered on a case-by-case basis.
in
X
Z
cn
-------
75
MINING AND MILLING
APPLICABILITY
These instructions apply to Standard Industrial Classification
Codes 1011, iron ores; 1021, copper ores; 1031, lead and zinc
ores; 1042, lode gold; 1043, placer gold; 1044, silver ores;
1051, bauxite and other aluminum ores; 1062, manganese ores;
1064, tungsten ores; 1069, ferroalloy ores, except vanadium,
not elsewhere classified; 1092, mercury ores; 1093, titanium ores;
1094, uranium, radium and vanadium ores; and 1099, metallic minerals
(ores) not elsewhere classified.
OPERATIONS EXCLUDED
All subcategories not considered are excluded.
APPLICATION OF LIMITATIONS
This guidance should only be applied in very selected cir-
cumstances in the hard rock milling industry.
The effluent limitations are expressed only in concentrations. Due
to the wide variations in ore types processed in this industry a
pound-per-day limitation has been found to be impractical. If
significant changes in production rates or changes in ore type
processed are encountered this should be reported to the Regional
Admini strator.
A review of such changes will be necessary to determine the appropriateness
of the limits used for preparation of the permit.
EFFLUENT LIMITATIONS
SCHEDULE A
CRITERIA RECOMMENDED LIMITS
Suspended Solids 20mg/l
Cyanide (Total) When cyanide compounds are used
in the milling process, effluent
from the waste abatement system
shall not exceed 0.02 mg/1.
Sulfate The Regional Administrator or his
designated representative shall
establish an effluent limitation
if beneficial downstream water
uses are affected.
Radioactivity Discharge concentration shall not
exceed 1/10 of Bureau of Standards
-------
76
MINING AND MILLING
EFFLUENT LIMITATION (continued)
CRITERIA RECOMMENDED LIMITS
Handbook 69 values, or such Standards
as may be developed. RA-226 concentrations
shall be as close to background as possible
but in no case to exceed the addition of
1.0 picocurie per liter.
Iron (Dissolved) 0.5 mg/1
Manganese 0.1 mg/1
EFFLUENT LIMITATIONS
SCHEDULE B
CRITERIA RECOMMENDED LIMITS
Suspended Solids 30 mg/1
Cyanide (Total) When cyanide compounds are used in the
milling process, effluent from the waste
abatement system shall not exceed 0.03 mg/1.
Sulfate The Regional Administrator or his designated
representative shall establish an effluent
limitation if benefical downstreams water
uses are affected.
Radioactivity Discharge concentrations shall not exceed
1/5 of Bureau of Standards Handbook 69 values,
or such standards may be developed. Ra- 226
concentrations shall be as close to background
as possible but in no case to exceed the addition
of 3.0 picocurie per liter.
Iron (Dissolved) 7.0 mg/1
Manganese 1.0 mg/1
ABATEMENT MODELS
Mine Discharge
Mine discharge is commonly characterized by high acidity, and high metal and
sulfate concentrations, resulting from the oxidation of sulfate minerals to
form sulfuric acid and metal ions. Major reduction in the pollution caused by
mine discharge can be achieved by procedures such as reducing the flow of the
water to the mines, reducing the exposure of sulfide minerals to the atmosphere,
-------
-ff
MINING AND MILLING
ABATEMENT MODELS (continued)
or by flooding abandoned mine working to reduce the rate of sulfide oxidation.
Treatment of coal mine discharge usually takes the form of lime or limestone
neutralization of free acidity, followed by sedimentation to remove the
various metal hydroxides. Common treatment techniques are neutralization
and sedimentation, with further metals removal by precipitation of the
remaining metals as metal sulfide. This may, for example, be achieved by
adding barium sulfide, resulting in the formation of a sludge which has
excellent settling characteristics. The sludge can be smelted to recover
the various metals. The reagent requirements are minor , as '
most of the metal ions are removed during the neutralization process.
Milling Discharge
Waste from milling consists of a water stream, frequently containing
dissolved toxicants, acting as a carrier for ground mineral fragments.
These latter usually include metal sulfides, subject to oxidation if
exposed to atmospheric conditions. Other materials of concern include
reagents, such as cyanide, added to the milling circuit. The mill waste
generally is alkaline.
Common treatment techniques utilized by the milling industry consist of
discharging the slurry into a tailings pond, with sufficient detention
to reduce the suspended-sediment concentration to approximately 20 mg/1.
The clarified water is then either decanted to receiving streams or, in
an increasing number of cases, recycled as mill process water. The latter
procedure is preferred for environmental considerations. The treatment
considered in the development of the attached limits, for dishcarge to
streams, consists of primary sedimentation in a tailings pond, as is
currently practiced throughout the milling industry. Following sedimentation,
it is anticipated that the waste will be neutralized and treated for
metals removal, as in the case of mine discharge, by sulfide precipitation.
Cyanide is frequently used in milling, both to dissolve gold and to
prevent flotation of pyrite. Several other, less toxic, reagents are
known to function equally as well as cyanide as a pyrite suppressant,
and are recommended. Cyanide often decomposes during detention in a
tailings pond. If the tailings pond decant contains high concentrations
of cyanide, it is anticipated that the cyanide concentration will be
reduced by the use of the alkali chlorination procedure.
Combined Discharge
Many operations produce both mine discharge and mill waste. Sontf improvement
in water quality can be achieved by introducing the mine discharge into the
tailings pipe line. This results in partial neutralization of the acid mine
discharge and alkaline mill waste.
-------
78 MINING AND WILLING
ABATEMENT .MODELS (continued)
Metals are removed through surface adsorption on the ground silica
fragments. Where both wastes are present/ it is anticipated that the
two streams will be mixed, and treated as a single waste.
-------
79
MOTOR VEHICLES
APPLICABILITY
These instructions were developed to apply to SIC Codes 3711,
3712, 3714, and 3461, (1967 edition).
SUBCATEGORIES CONSIDERED
Operations in the motor vehicles industry are considered under
the following subcategories: casting; engine machining and
assembly; stamping; body assembly; frame manufacture; electroplating
of metal; and final assembly.
OPERATIONS EXCLUDED
This guidance only covers the listed operations. Other operations
not listed such as aluminum casting, conversion coating, and the
manufacture of springs, radiators, heaters, and transmissions
are not included but must be taken into consideration.
APPLICATION OF LIMITATIONS
The interim guidance is based on fragmented data and the
information base is very limited. Hence, it must be used
very selectively.
ABATEMENT MODELS
Good in-plant control must be practiced to maintain waste flow and
loads to the treatment facilities at the lowest possible levels to
attain highest wastewater treatment efficiency.
Typical process controls that may be needed to meet permit
conditions are as follows:
1. Separation of contaminated low volume waste waters
from other plant waters such as cooling waters,
2. Separation of soluble oils utilized in machining
or hydraulic systems from other plant waste
waters,
3. Recirculation of emulsified oil systems,
4. Electrostatic painting would materially reduce the
pollution load from typical body assembly or
final assembly plants,
5. Non-phenol paint strippers should be employed
wherever possible,
6. Reduction of drag-in to the rinsing circuit by
-------
80
MOTOR VEHICLES
ABATEMENT MODELS (continued)
such means as increasing draining time, the
installation of drip board or drip tanks, air
jetting, tumbling, or vibrating the pieces,
7. Curtailment in waste usage by such expedients
as countercurrent rinsing, the use of sprays,
better control of water flow, proper racking
and proper maintenance of racks, tanks, etc.
8. Segregation of nontoxic wastewaters from the
normal toxic waste streams,
9. Prevention of leaks, overflows, and spills, and
10. Provisions for impounding these if they should
occur by standby tanks, sumps, etc.
-------
81
MOTOR VEHICLE
EFFLUENT LIMITATIONS - MOTOR VEHICLE INDUSTRY
SUBCATEGORY
EFFLUENT
CHARACTERISTICS
SCHEDULE A
Ibs/unit*
SCHEDULE B
Ibs/unit*
Casting1
Total Suspended Solids
Phenol
Total Iron
Oil and Grease
Engine Machining and Ajssembly
Stamping
Body Assembly
Total Suspended Solids
Oil and Grease
Zinc
Total Chromium
Copper
Phenol
Phosphate (P)
Total Suspended Solids
Oil and Grease
BOD5
Zinc
Total Chromium
Phosphate (P)
Total Suspended Solids
Oil and Grease
BOD5
Phosphate (P)
Total Chromium
.0834
.0008
.0025
.04
.0125
.00625
.0006
.00006
.00004
.000125
.00125
.0142
.007
.0142
.0007
.00007
.00142
.05
.025
.05
.005
.00025
.29
.008
.025
.08
.07
.02
.002
.001
.0006
.002
.01
.06129
.0175
.0437
.00175
.0009
.0088
.26
.073
.18
.04
.004
Represents the use of dry air pollution control devices. These values may
be multiplied by a factor not to exceed 10 where wet air pollution control
equipment must be employed.
-------
82
MOTOR VEHICLE
EFFLUENT LIMITATIONS - MOTOR VEHICLE INDUSTRY (Cont.)
SUBCATEGORY
EFFLUENT
CHARACTERISTICS
SCHEDULE A
Ibs/unit*
SCHEDULE B
Ibs/unit*
Frame Manufacture
Total Suspended Solids
Oil and Grease
Phenol
Phosphate
BODC
Electroplating of metal
Final Assembly
Copper
Nickel
Cyanide
Total Chromium
Total Iron
Oil and Grease
Zinc
Total Suspended Solids
Total Suspended Solids
Oil and Grease
BOD5
Total Chromium
Phosphate (P)
*The units of production are:
.008
.004
.00008
.0008
.008
.003
.04
.0025
.005
.03
.50
.05
1.0
.008
.004
.008
.00004
.0008
Casting
Engine Machining and Assembly
Stamping
Body Assembly
Frame Manufacture
Plating
Final Assembly
.035
.01
.001
.005
.025
.075
.250
.0063
.125
.75
2.5
.25
8.76
.056
.0167
.04
.00083
.0083
Ton Metal Cast
Engine
Thousand Sq. Ft.
Body
Frame
Thousand Sq. Ft.
Body
Metal Stamped
Plated
The above limits are based upon the following process water usage:
A B
Casting (gal/ton metal cast) 1000 1000
Engine Machining and Assembly (gal/engine) 150 240
Stamping (gal/1,000 sq. ft.) 170 210
Body Assembly (gal/body) 600 875
Frame Manufacture (gal/frame) 100 125
Electroplating (gal/sq. ft ) 12 30
Final Assembly (gal/body) 100 200
-------
PETROLEUM DEFINING
APPLICABILITY
These instructions apply to Standard Industrial Classification
Code 2911.
SUBCATEGORIES CONSIDERED
Operations in the petroleum refining industry are divided into
five classifications which recognize varying degrees of processing
complexity. They are: (A) Crude topping; (B) Topping and
cracking/reforming; (C) Topping and cracking and petrochemicals;
(D) "B" category and lube oil processing; (E) "D" category
and petrochemicals.
OPERATIONS EXCLUDED
"Petrochemicals" excludes all first generation conventional
refinery-associated production such as BTX, alkenes, alkynes,
and other miscellaneous items such as hydrogen, sulfur, coke or
carbon black and ammonia. To qualify as a class "C" or "E"
refinery, intermediate chemical manufacture must be shown,
including such typical products as cumene, phthalic anhydride,
alcohols, ketones, triiner (nonene) , and styrene.
Lube oil processing excludes formulating blended oils and
additives. It requires production of blending stocks via
such operations as dewaxing, lube hydrotreating, and clay
treatment.
APPLICATION OF LIMITATIONS
If it is necessary to issue permits during the interim before
effluent limitations guidelines are proposed, we recommend that
concentration schedule (A) be applied to all refineries practicing
recycle. Refineries using saline or brackish water for process
should be considered on an individual basis. This guidance
applies only to those refineries with greater than 10,000 bbl/day
production capacity, except in Class J where it includes all
refineries.
Substantial deviations from the definition under each of the refinery
classification categories should be accommodated by adjusting the
waste load assignments for a particular plant.
The effluent limitations shown for A & B levels are expressed
in pounds per thousand barrels (lb/1000 bbl) of crude or other
feedstocks processed.
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84
PETROLEUM REFINING
APPLICATION OF LIMITATIONS (continued)
Significant differences in water use practices, and hence effluent
volume, exist between refineries. The underlying reasons include
age of the plant, process employed, and water availability, to
mention a few.
The greatest single difference is that of one-time water use
and discharge versus direct or indirect air cooling and recycle.
Once-through cooling water where direct process contact (i.e.
barometric) 'is not involved, is excluded from consideration
in determining effluent limitations. Relative to 'best practicable'
treatment, one-time water use in direct process contact represents
a necessary consideration in determining effluent limitations,
relative to a similar refinery which, by virtue of age or technology,
etc., practices water recycle. Additional information is presented
in order to assist in making these engineering judgements.
Table I shows effluent limitations applicable to the major categories
of refineries, as described. Table II shows effluent limitations
applicable to tho'se refineries within the major categories practicing
water reuse via direct or indirect air cooling and recycle.
Refineries in which direct contact (barometric) cooling water is
cooled via cooling towers and recycled are to be categorized as
practicing water reuse (Table II). All blowdown from such towers
must be included (via treatment) in effluent accounted against
the limitation.
Once-through cooling water that does not come in direct contact
with petroleum materials (shell and tube heat exchangers) discharging
into segregated sewers is to be excluded from effluent accounted
against the limitation of the refinery categorized as practicing
water reuse (Table II) on the basis of process and other contaminated
wastewaters. Treatment of such cooling water for such quantities of
process material as may ordinarily or commonly be leaked into the
cooling water is not deemed 'practicable1 for the following
reasons:
1. The large volumes of water relative to the pollutant
leakage result in concentrations so low as to produce
dubious analytical results.
2. Unless a specific violation of water quality standards
results, such low concentrations would not ordinarily
be expected to have a significant adverse impact on
the receiving water.
3. In the absence of a significant adverse impact on
the receiving water, the benefit of treating such
large quantities of water does not justify the cost,
i.e., such treatment is not 'practicable1.
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85
PETROLEUM REFINING
APPLICATION OF LIMITATIONS (continued)
Other considerations to be taken into account in the application
of this guidance are discussed under "special considerations."
ABATEMENT MODELS
The treatment required for industrial wastes should include "good
industrial practice" and tight process control must at least equal
the level of treatment required for municipal sewage.
The treatment results should be translated into allowable discharge
loads in terms of "pounds per day" for each of the contaminants,
taking into account the capacity and processing complexity employed
in a refinery.
Treatment models representing "best practicable treatment" illustrate
the means by which "A" level requirements may be met. The unit
operations may vary in hydraulic order and relative size and importance
according to the needs of a specific refinery.
In developing these limitations, two possible treatment system
models were used, one physical/chemical, the other biological.
Biological treatment methods are generally satisfactory in
removing the major contaminants from the wastewater. Before
biological treatment, some pre-treatment steps such as removal
of high concentrations of hydrogen sulfide, ammonia, and
oil may be required. Biological systems are sensitive to shock
loads which can be overcome with good plant operation and/cr
equalization ponds.
Physical/chemical systems normally involve the use of sand filters
and activated carbon. The advantages of these systems are that
shock loads do not greatly affect their performance, they are
flexible and can easily be added to, and they occupy about 1/7
the land that a biological system needs.
Ammonia nitrogen can be removed by stripping or by selective ion
exchange. The cost of an activated carbon system is approximately
the same as that of a biological system. Two major refineries
have physical/chemical systems in development or under construction.
General applicability to refinery effluent remains to be demonstrated.
Physical/Chemical
1. API Oil Separators
2. Chemical Coagulation and Clarification
3. pH Control
4. Sand or dual media Filters
-------
86 PETROLEUM REFINING
ABATEMENT MODELS (continued)
5. Chromate removal system
6. Ammonia stripper or ion exchange
7. Carbon adsorbers
8. Carbon reactivation system
Biological
1. API Oil Separators
2. Equalization
3. Sour Water Stripping
4. Dissolved Air Flotation
5. Biological Oxidation, using aerated lagoons
or activated sludge
6. Secondary Clarification
7. Chromate Removal System
8. Sand or dual media Filters
SPECIAL CONSIDERATIONS
Socio/economic impact is an important consideration when
reviewing water pollution abatement programs and compliance
schedules for a given refinery. In applying this effluent
guidance, it must be recognized that the costs of achieving
incremental improvements in effluent quality and therefore,
economic impact, will vary widely among individual refineries.
Factors which could influence the relative cost of various
waste treatment alternatives include:
Availability of land: If it has access to a large land area,
a refinery can install long-residence time lagoons and/or
activated sludge treatment facilities to achieve satisfactory
removals. A land-short refinery may be unable to do so.
Types of crude oils and products: The composition of the-
crude oil and the types of raw materials and process materials
affect the raw waste load production, as does the final product
mix.
Once-through cooling water: Factors that can affect cost-effectiveness
include location, existing tubular heat exchange capacity, water
temperature, availability of suitable makeup water, and the like.
Refinery complexity: The refinery classification system may
tend to overstate or understate the raw waste load potential
of certain unusual processing configurations.
Refinery Age and Layout: Problems, particularly in older refineries,
may be encountered with segregation of process, cooling, boiler house,
storm, sanitary, and other waters to meet proposed effluent limitations.
-------
Q -7
PETROLEUM REFINING
SPECIAL CONSIDERATIONS
Climate and geographical location; Low ambient temperature
inhibits biological treatment, and high annual rainfall complicates
water handling.
Available resources needed to accomplish such programs: If an
approved pollution abatement program should entail major modifications
to in-plant process units which, would result in extended shutdown
time and loss of production for either the process -unit affected or
the refinery, the reviewer should adjust the compliance schedule so that
shutdowns will coincide with normal and reasonable refinery turnaround
and inspection schedules. Examples include major changes to on-line
process piping and heat exchangers.
-------
EFFLUENT LIMITATIONS
TABLE I
(Pounds of Pollutant per 1000 bbI/Stream Day)
Refinery NH3 (1)
Class (N) TOC BODr COD Cr+6 Crfc O&G Phenol Sulfide TSS
A 1.6 4.
B 3.3 8.
C 4.1 11.
D 5.0 16.
E 7.5 27.
0 2.5
0 5.0
6 7.3
0 10.0
0 16.8
(1) TOC is shown as a possible
for estimating BOD, using
15.3
30.6
44.6
61.0
102.9
0.0008
0.0017
0.0021
0.0025
0.0038
0.041
0.083
0.104
0.125
0.187
organic monitoring parameter
an agreed correlation factor
1.66
3.34
4.18
5.00
7.50
0.017 0.028 3.3
0.033 0.057 6.6
0.042 0.071 8.3
0.050 0.085 10.0
0.075 0.128 15.0
Either TOC or TOD may be used
for the refinery.
PETEOLEUJ
so
w
Ti
00
00
-------
tABLE II
Effluent Limitatio- -; (BPCTCA)
Recycle-Air Cooling Subcategory
(Pounds Per 1,000 b/sd Capacity)
Refinery NH3 TOC BOD5 COD Cr+6 Crfc O&G Phenol Sulfide TSS
Class (N)
A
B
C
D
E
1.0
2.2
1.9
3-9
2.9
2.4
5.2
5.3
12.5
10.5
1.5
3.3
3.4
7.8
6.6
9.2
19.9
20.5
47.6
40.0
0.0005
0.0011
0.0009
0.0019
0.0014
00
0.025 0.99 0.010 0.017 2.0 '*
0.054 2.17 0.021 0.037 4.3
0.048 1.92 0.019 0.033 3.8
0.098 3.90 0.039 0.066 7.8
0.073 2.93 0.029 0.049 5.9
I
a
s
H
z
H
a
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91
PLASTIC MATERIAL AND SYNTHETICS
APPLICABILITY
These instructions apply to Standard Industrial Classification
Codes 2821, 2823, and to some extent to 2851 and 2891 (Epoxy
Resins).
SUBCATEGORIES CONSIDERED
The following subcategories are considered:
Polyvinyl acetate resins, polypropylene resins, urethane resins,
polyethylene-low density, cellulose acetate fibers and resins,
cellulose triacetate fibers, polyacetal resins, nylon resins
and fibers, phenolic resins, polyvinyl alcohol resins, ABS and
SAN resins, acrylic resins and fibers, polyester resins and fibers,
cellophane, rayon fibers, urea plastics, melamine plastics, epoxy
resins, polyethylene-high density, and polyvinyl chloride resins.
OPERATIONS EXCLUDED
All subcategories not considered are excluded.
APPLICATION OF LIMITATIONS
The guidance in this industry should be used only for those dischargers
that can be handled on a building block approach in the categories
covered with the guidance document.
Waste from several different plants (nylon, polyethlyene, polystyrene,
etc.) may all go to the same waste treatment system. Assume an
"additive" approach for applying the effluent limitations. A
weighted average based on production levels for each of the plants
is to be used in applying each of the effluent limits.
This type of an approach will have to be used for all of the
limited constituents as_ well as BOD and COD.
The BOD and COD Schedule-A limits represent a 4-5/1 COD/BOD
ratio for the treated effluent. In certain cases this ratio
may be higher (Acrylic Resins and fibers, PVC Resins, Phenolic
Resins, PVA Resins and Epoxy Resins). If the biological system
which is used can meet the Schedule A BOD limit, but cannot
meet the Schedule A limit for COD, then some flexibility may
have to be used. Depending on what constituents of the remaining
COD are left after the waste treatment, a decision will have to be made
as to the need for further treatment.
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92
PLASTIC MATERIAL AND SYNTHETICS
OTHER LIMITATIONS
Process wastes, from the Plastic Materials and Synthetics Industry
contain BODS, COD, suspended solids, oil, monomers, and/or raw
materials, and chemicals used in initiators (sulfates) , solvents,
(xylene, acetone toluene, etc), modifiers (dodecyl mercaptans),
inhibitors (hydroquinone), plasticizers (phosphate), and polymerizing
catalyst (boron fluoride). Utility blowdown wastes include suspended
solids, phosphorus, zinc, chromium, and free chlorine. Parameters
such as iron, vanadium, nickel, cobalt, titanium, aluminum, chromium,
lithium, molybdenum, and cyanide are introduced in water treatment
chemicals, catalysts, and from equipment corrosion products (stainless
steel and stabilizers). If it is believed that any of these parameters
are present, they should be limited.
Suspended solids for the glass reinforced polyvinyl acetate or
polyester resin, or any other glass reinforcing industry, should
be kept as low as possible because of the adverse effect the glass
particles have on fish and other aquatic animals (TSS should be
10 mg/1).
ABATEMENT MODELS
Removal of BQD^ COD, and suspended solids
- The basic model wastewater treatment system includes chemical
coagulation and settling followed by a biological treatment
system (usually completely mixed activated sludge). Because of
variations in the waste stream of the industrial categories,
certain pretreatroents may have to be made prior to biological
treatment. The system will basically be the same as that
described below.
The primary treatment method (flocculator-clarifier system)
consists of chemical coagulation and settling. A coagulant
which gives good results is the salt of the ferric ion.
A good coagulant aid is a slightly cationic to non-ionic
polyelectrolyte. Settling is then used for solids removal.
At this point, toxicity tests are run to see if any of the
constituents in the waste are toxic to micro-organisms to
be used in the secondary treatment system.
The secondary treatment system which provide good waste removal is the
completely mixed activated sludge process.
This process has proved to be highly efficient and more capable
of wxthstanding shock loadings. Phosphoric acid and ammonia
provxde the supplemental nutrients; equalization also has to be
provided to achieve maximum removal efficiency, in using
nutrients for biological systems, nitrogen,and phosphorus
-------
93
PLASTIC MATERIALS AND SYNTHETICS
ABATEMENT MODELS (continued)
levels of the effluent should be kept to 10 and 5 ppm respectively.
Some flexibility may have to be used in this regard.
For very high influent concentrations, multiple biological systems
may be needed.
By preceding the activated sludge system with a trickling filter
or following it with a stabilization pond or polishing lagoon,
necessary removals for BOD, COD and suspended solids can be achieved.
Heavy Metals
The location of the precipitation-sedimentation system used to
remove heavy metals will depend on the waste stream being treated
and on the design situation. Some of the possibilities would include
integration with the primary system, placement of the system preceding
the biological system (if toxicity tests show the need for
removal at this point), or following the activated sludge system
or other biological treatment method used. Generally, the
closer the removal system is to the source (process) the more
effective the removal.
The models for removing heavy metals are basically the same
in each case and include adjustment of pH, usually with lime,
to achieve the alkaline condition, followed by precipitation of
the hydroxide. Coalgulating aids are often required to achieve
the levels of precipitation necessary. Variations and individual
treatments may be necessary for several of the metal ions. These
variations should include reduction or oxidation to different oxidation
states, removal of interferring constituents prior to precipitation,
and adjustment of the pH at different levels.
Oil and Grease
The biological system described for removing BOD will effectively
remove oil from effluents down to a range of 5-10 ppm. Coagulation-
precipitation methods using coagulating aids can also effectively
remove emulsified oil to the range of 5-10 ppm.
Phenols
Activated sludge systems, as described above, effectively remove
phenols from waste streams. Systems using activated sludge with
nutrients, preceded by trickling filters, have achieved 99.9+%
removal of phenol. Levels of 0.01 ppm have been reached; this is
more than adequate to reach the Schedule A levels.
-------
94
PLASTIC MATERIAL AND SYNTHETICS
ABATEMENT MODELS (continued)
Other Parameters
Cyanide
Where free cyanide may be a problem, as in the production of acrylonitrile
(hydrogen cyanide is used), reduction of cyanides in effluent streams
is by destruction by chlorination. This system consists of oxidation
of the cyanide to cyanate with chlorine or sodium hypochlorite at
pH of 10 or higher. The cyanate can be oxidized to carbon dioxide and
nitrogen through additional chlorination or by acid hydrolysis.
Organic Nitrogen
This parameter could be a problem in the effluent streams for acrylic
fiber and resin, nylon, and urea or melamine plastic plants. Organic
nitrogen in the form of urea can be treated by hydrolizing the urea
to ammonia with biological or chemical treatment. If necessary, the
ammonia can then be removed by steam stripping.
Other Treatment Process
Other methods are being used for certain wastewater streams which have
exceptionally high influent concentrations of BOD and COD or that have waste
waste" constituents which may interfere with biological treatment.
One such method is fluidized-bed incineration. In applying this
method to waste from the paint (including phenolic and epoxy resins)
and plastics (polyvinyl chloride and polystyrene) industries, the COD
concentrations in the scrubber effluent(the only liquid waste) ranged
from 8 to 24 mg/1.
This effluent can be recycled to the scrubber continuously and
incinerated concurrently with the other waste.
-------
EFFLUENT LIMITATIONS
PLASTICS AND SYNTHETICS INDUSTRY
SUBCATEGORY
Polyvinyl Acetate Resins
Polypropylene Resins
CHARACTERISTICS
BOD5
COD
Suspended Solids
BOD 5
COD
Suspended Solids
Vanadium
Titanium
Aluminum
Polypropylene Fiber - No Waste Water
Urethane Resins - No Waste Water
Polyethelene - Low Density
(ICI Process-02 Catalyst)
Polystyrene Resins
Cellulose Triacetate Fibers
BOD5
COD
Suspended Solids
BOD 5
COD
Suspended Solids
Iron
Aluminum
Nickel
Total Chromium
BOD5
COD
Suspended Solids
lbs/1000 Ibs Product
Level A Level B
0.38 1.0
1.88 3.12
0.38 1.0
0.62
3.00
0.62
0.021
0.042
0.021
0.21
1.06
0.26
0.19
0.87
0.24
0.01
0.01
0.005
0.001
0.90
3.12
0.90
1
4
2
1
2
1
0.60
1.0
1.0
0.005
3.0
5.0
3.0
<£>
Ul
H
M
O
SO
I—I
£
ff>
o
CO
a
M
H
M
O
co
-------
EFFLUENT LIMITATIONS
SUBCATEGORY
Polyacetal Resins
Nylon Resins
Nylon Fiber
Phenolic Resins
Polyvinyl Alcohol Resins
ABS, SAN Resins
PLASTICS AND SYNTHETICS INDUSTRY
CHARACTERISTICS
BOD 5
COD
Suspended Solids
BOD 5
COD
Suspended Solids
Phenols
BOD 5
COD
Suspended Solids
BOD 5
COD
Suspended Solids
Phenols
BOD 5
COD
Suspended Solids
BOD 5
COD
Suspended Solids
Total Chromium
Iron
Aluminum
Nickel
Cyanide
lbs/1000 Ibs Product
Level A Level B
1.38 1.38
6.90 6.90
1.38 1.38
1.30
6.50
1.30
0.008
0.83
4.2
1.10
0.38
1.90
0.38
0.0024
4.0
8.0
3.0
1.0
4.2
2.0
2.0
10.0
0.5
0.38
1.90
0.38
0.46
2.36
0.46
0.0016
0.016
0.016
0.008
0.0008
0.38
1.90
0.38
1.5
3.0
1.5
fc
£
en
o
CO
-------
EFFLUENT LIMITATIONS
PLASTICS AND SYNTHETICS INDUSTRY
SUBCATEGORY
Acrylic Resins and Fibers
CHARACTERISTICS
BOD 5
COD
Suspended Solids
Cyanide
Heavy Metals (Metal Salt
bath for fiber)
lbs/1000 Ibs Product-
Level A Level B
0.78
5.22
0.78
0.0015
0.01
4.0
6.0
1.0
Polyester Resins and Fibers
(Alkyd Resins)
Cellophane
Rayon Fibers
Urea Plastics
BOD 5
COD
Suspended Solids
Heavy Metals (Catalyst)
BOD5
COD
Suspended Solids
BOD 5
COD
Suspended Solids
Zinc
BOD 5
COD
Suspended Solids
Organic Nitrogen!/
Nickel - Stab.
Cobalt - Stab.
0.62
3.00
0.62
0.031
10.1
50.0
10.1
4.5
22.5
4.5
1.0
4.9
0.7
20
50
50
15
40
24
VO
•J
0.15
0.055
0.27
0.055
0.0144
0.0009
0.0018
0.055
0.27
0.055
0.0144
0.0009
0.0018
H
H
M
£
v>
D
C/l
H
a
n
I/ As Urea
-------
SUBCATEGORY
Melamine Plastics
Epoxy Resins
EFFLUENT LIMITATIONS
PLASTICS AND SYNTHETICS INDUSTRY
CHARACTERISTICS
BOD 5
COD
Suspended Solids
Organic NitrogenV
BOD 5
COD
Suspended Solids
I/ As Urea
lbs/1000 Ibs Product
Level A
0.040
0.20
0.04
0.01
0.11
0.54
0.09
Level B
0.040
0.20
0.04
0.01
0.11
0.54
0.09
fe
H
1-4
O
10
00
DC
M
-------
EFFLUENT LIMITATIONS
SUBCATEGORY
Polyethylene, High Density
(Ziegler (z), Phillips (P),
or Indiana (I) Process)
Cellulose Acetate Resins
Cellulose Acetate Fibers
PLASTICS AND SYNTHETICS
CHARACTERISTICS
BOD 5
COD
Suspended Solids
Total Chromium
Vanadium (Z)
Titanium (Z)
Aluminum (Z,P)
Molybdenum (I)
BOD 5
COD
Suspended Solids
BOD 5
COD
Suspended Solids
INDUSTRY
Level
Solution
Process
0.59
2.90
0.67
0.003
0.03
0.06
0.03
0.03
Level
With
Acetic
Acid
Recovery
4.4
14.1
4.3
Level
With
Acetone
Recovery
4.6
15.6
4.6
lbs/1000 Ibs Product
A
Poly form
Process
0.044
0.22
0.05
0.0002
0.002
0.004
0.002
0.002
A
Without
Acetic
Acid
Recovery
0.78
2.58
0.78
A
Without
Acetone
Recovery
0.50
2.70
0.50
Level
Solution
Process
1.0
2.90
1.0
0.015
Level
With
Acetic
Acid
Recovery
6.0
14.1
6.0
Level
With
Acetone
Recovery
4.6
15.6
4.6
B
Polyform
Process
1.0
2.0
1.0
0.001
B
Without
Acetic
Acid
Recovery
6.0
10.0
6.0
B
Without
Acetone
Recovery
4
5
4
10
U3
r
CO
H
1 — 1
o
S
H
tfl
to
IE-
CO
>-^
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CO
2!
M
H
M
CO
-------
EFFLUENT LIMITATIONS
PLASTICS AND SYNTHETICS INDUSTRY
SUBCATEGORY
CHARACTERISTICS
lbs/1000 Ibs Product
Level A
Level B
Polyvinyl Chloride Resins
COD
Suspended Solids
Suspension &
Solvent
Process
0.45
2.25
0.45
Emulsion
Process
0.16
0.82
0.16
Suspension &
Solvent
Process
2.0
4.0
1.0
Emulsion
Process
2.0
4.0
1.0
o
o
fe
H
M
O
H
W
00
C/5
«:
2
H
ac
-------
101
PULP AND PAPER
APPLICABILITY
These instructions apply to Standard Industrial Classification
Codes 2611, 2621, and 2631.
5JUBCATEGORIES CONSIDERED
Operations in the pulp and paper industry are considered under
the following subcategories: Kraft pulping and manufacture
of coarse paper and liner board, newsprint, bleached and unbleached
grades, bleached grades; Sulfite pulping and the manufacture of
paper and dissolving pulp; Neutral sulfite semi-chemical, groundwood
pulping and manufacturing of unbleached and bleached grades; Deinking
mills; Waste Paperboard (no deinking); and Paper manufacture from
purchased pulp (coarse, fine, book, and tissue).
PRODUCTION BASIS
The maximum daily production, in air-dry tons, (as determined
at the time of application) shall be the highest average level
sustained for seven consecutive operating days of normal
production.
APPLICATION OF LIMITATIONS
The guidance with the mandatory requirement of suspended solids
limitation may be used. The guidance should not be applied to
the following categories:
Segment Maximum Capacity
Acid Sulfite (paper grade) less than 200 T/D
Waste Paperboard less than 100 T/D
Tissue from Purchased Pulp less than 50 T/D
Fine Paper from Purchased Pulp less than 200 T/D
NSSC A13
Integrated Kraft with NSSC All
Speciality Mills should be handled on a selective basis.
EFFLUENT LIMITATIONS
Settleable Solids - Settleable solids shall not exceed O.
The following may be significant parameters depending on production
methods and receiving water characteristics:
Color
Turbidity
Foam
Phenol
Ammonia
Sulfite Waste Liquor
-------
102
PULP AND PAPER
ABATEMENT MODELS
The following production process controls and treatment systems
are a model for attaining the recommended effluent limitations
in Schedule A:
1. Heat and/or chemical recovery from pulping liquors,
efficient save-alls within the paper making process,
and a high degree of water reuse,
2. primary clarification,
3. biological oxidation using aerated lagoons or
activated sludge,
4. secondary clarification,
5. disinfection, if necessary.
The system described above is a generalized model which is
applicable to the entire industry.
The treatment model for tissue mills, using purchased pulp, is
based on an expected effluent quality from efficient physical or
physical-chemical treatment. The majority of the BOD in this
wastewater is associated with fibrous materials and thus is
amenable to this type of treatment. The application of biological
oxidation to this wastewater would not significantly lower the
effluent BOD. The wastewater is also nutrient deficient and,
therefore, subsequent nutrient additions to support a biological
system would result in an additional loading on the receiving
water.
The effluent limits given in Schedule B are based on existing
facilities and are the levels which the industry should be
achieving today.
-------
103
PULP AND PAPER
EFFLUENT LIMITATIONS
PRODUCTION LB. OF SUSPENDED SOLIDS PER TON OF PRODUCT
PROCESS Schedule A Schedule B
I. KRAFT PULPING AND
MANUFACTURE OF:
Coarse Paper and Liner Board 5 5
Newsprint 6 6
Bleached & Unbleached Grades 10 10
Bleached Grades 10 10
II. SULFITE PULPING AND THE
MANUFACTURE OF:
Paper 20 20
Dissolving Pulp 20 20
III. NEUTRAL SULFITE SEMI-CHEMICAL 8 15
IV. GROUNDWOOD
Unbleached 5 9
Bleached 9 10
V. DEINKING MILL 12 15
VI. PAPERBOARD ( No Deinking) 3 5
VII. PAPER MANUFACTURE
(From Purchased Pulp)
Coarse 3 5
Fine ( < 8% filled) 7 8
Book ( > 8% filled) 4 15
Tissue & 6
NOTES: (1) Groups I, II, III, and IV apply to integrated mills (combined pulping
and papermaking operations).
(2) Groups V and VI refer to wastepaper processing plants.
-------
104 PULP AND PAPER
EFFLUENT LIMITATIONS
PRODUCTION LB. OF BOD^ PER TON OF PRODUCT
PROCESS Schedule A Schedule B
I. KRAFT PULPING AND THE
MANUFACTURE OF:
Coarse Paper and Liner 5 6
Newsprint 5 8
Bleached & Unbleached Grades 9 10
Bleached Grades 11 12
II. SULFITE PULPING AND THE
MANUFACTURE OF:
Paper 35 40
Dissolving Pulp 60 80
III. NEUTRAL SULFITE SEMI-CHEMICAL 14 25
IV. GROUNDWOOD
Unbleached 2,5 5
Bleached 4.5 6
V. DEINKING MILL 10 25
VI. PAPERBOARD (No Deinking) 3 5
PAPER MANUFACTURE
(From Purchased Pulp)
Coarse 2 5
Fine ( < 8% filled) 6 6
Book ( > 8% filled) 3 6
Tissue 8 8
NOTES: (1) Groups I, II, III, and IV apply to integrated mills (combined
pulping and papermaking operations).
(2) Groups V and VI refer to wastepaper processing plants.
-------
105
RAW CANE SUGAR
APPLICABILITY
These instructions apply to Standard Industrial Classification Code
2062, RAW CANE SUGAR, i.e-, those facilities which manufacture
raw sugar, molasses, and cane syrup from sugar cane.
OPERATIONS EXCLUDED
For guidance on facilities refining raw sugar see the separate
document on Cane Sugar Refining (SIC 2062).
PRODUCTION BASIS
Daily production shall be expressed in tons per day of gross cane,
and is the highest average production sustained over 20 days of
normal operation. (For a cane factory and refinery at the same
site, the permitted discharge per day shall be the total of the
permitted factory and refinery waste loads, but only if both are
operating concurrently).
APPLICATION OF LIMITATIONS
The guidance should be utilized selectively since the data is
based on continental operations.
The following may be significant parameters depending on
production methods and receiving water characteristics:
Color
Turbidity
Temperature
Nitrogen
Phosphorous
Ammonia
Settleable Solids - Settleable solids shall not exceed 0.1 mVl-
ABATEMENT MODELS
The following waste management system represents the model used
to develop the effluent limitations recommended for the raw cane
sugar industry as shown in Schedule A:
1. Cane wash water recycling with removal of wash solids,
and/or long-term impoundment/aeration/stablization
of cane wash waters during and beyond the grinding campaign;
2. Segregation, impoundments and/or possible reuse of
general plant and chemical wastewater;
-------
106
RAW CANE SUGAR
ABATEMENT MODELS (continued)
3. "Dry" recovery and disposal of filter muds;
4. Recycling of condenser waters (including cooling
as necessary) for use in cane wash, condensers
and other needs;
5. Prevention of organic entrainment carry-over from
the evaporators and pans by providing adequate equipment
and operational control;
6. Elimination and/or special handling of extraneous
discharge, especially nondescript drains, from refuse
storage piles, factory yards, washing of trucks,
railroad cars, tanks, etc;
7. Separate handling, disposal and/or reuse of bagasse and
trash;
8. Treatment of scrubber effluents from air pollution
control devices for removal of pollutants.
The waste characteristics of cane sugar factories lend themselves
to physical and biological treatment. A thorough analysis of the
process operations and waste water flows and characteristics
coupled with proper design inplant modifications, water reuse
and wastewater treatment facilities, will achieve the recommended
effluent levels.
EFFLUENT LIMITATIONS
Parameter Ib/ton Gross Cane ^'Processed
Schedule A Schedule B
BOD5 0.5 1.0
Suspended Solids 0.5 1.0
NOTES:
(1) Gross cane is defined as field cane incoming to the factory,
-------
107
STEEL
APPLICABILITY
These instructions apply to Standard Industrial Classification
Code 3312. The effluent limits were developed separately by
subcategory and may be applied irrespective to other subcategories.
SUBCATEGORIES CONSIDERED
Subcategories are coke manufacture/ iron manufacture, steel
manufacture, hot forming, pickling, cold rolling sheet and
strip (recirculation) / cold rolling sheet and strip (direct
application) , tin plate and chromium-coated steel, and other
coatings.
APPLICATION OF LIMITATIONS
The interim guidance should be used only for carbon steel integrated
facilities.
The effluent limitations are process weight limits and were developed
on the basis of the actual process water needed in each of the listed
operations. The treatment levels (A arid B) are values to be applied
to each operation after treatment and prior to mixing with other
process wastewater or cooling water. The calculations for each operation
can be made separately and the values accumulated for all operations
to evaluate the adequacy of treatment facilities and/or control
technology.
The basis for the development of the effluent limits is treatment
models described in the support document; "Basis For The Development
of Effluent Guidelines For The Carbon Steel Industry".
-------
108
STEEL
TREATMENT MODELS
SUBCATEGORY
SCHEDULE A
SCHEDULE B
Coke Manufacturing
Iron Manufacturing
Steel Manufacturing
Pickling
Cold Rolling
(Recirculating Oil)
Cold Rolling
Direct Application
Tinplate and Chromium
Plating
Other Coatings
Dephenolizer
Solvent Extraction
Biological
Recycle and Slowdown
Treatment
Recycle and Slowdown
Treatment
Neutralization
Precipitation
Chemical Treatment
Flocculation
Clarification
Acid Regeneration
Emulsion Breaking
Recirculation
Skimming
Air Flotation
Magnetic Separation
Biological
Settling
Emulsion Breaking
Air Flotation
Chemical Treatment
Skimming
(Cr) Ion Exchange
Air Flotation
Chemical Treatment
Flocculation
Settling Basin
Segregation and Separate
Treatment
Dephenolizer
Solvent Extraction
No green coke
"Fines Free" limestone
"Fines Free"limestone
Neutralization
Emulsion Breaking
Recirculation of Oil
Settling
Air Flotation
Skimming
Settling
Air Flotation
Skimming
Terminal
Treatment
-------
109
EFFLUENT LIMITATIONS
STEEL
SUBCATEGORY
Coke Manufacturing
Iron Manufacturing
Steel Manufacturing
Hot Forming
Pickling
Cold Rolling
Sheet & Strip
(Recirculating Oil)
EFFLUENT
CHARACTERISTICS
Ammonia (N)
Cyanide
Phenol
Suspended Solids
Ammonia (N)
Cyanide
Phenol
Suspended Solids
Suspended Solids
Oil & Grease
Suspended Solids (1)
Iron, Dissolved (1)
Chloride (2)
Sulfate (2)
Suspended Solids
Iron, total
Iron, Dissolved
Oil & Grease
TREATMENT
LEVEL A
Ibs/ton
.2
.005
.0002
.09
.1
.006
.005
.02
.1
.1
.025
.002
3
7
.04
.02
.002
.016
TREATMENT
LEVEL B
Ibs/ton
.3
.01
.1
.9
.2
.02
.01
.06
1.8
.9
.075
.006
16
50
.5
.25
.012
.2
(1) »A« level is based on flow of 200 gal/ton-variations in process may require a flow
up to 600 gal/ton but not to exceed an "A" suspended solids number of
0.075 #/ton or a dissolved iron number of 0.006 ft/ton.
(2) Batch pickling is not included in this guidance.
-------
STEEL
EFFLUENT LIMITATIONS
SUBCATEGORY
Cold Rolling
Sheet & Strip
(Direct Application)
Tin Plate and
Chromium Coated Steel
(Cleaning, pickling,
plating & chemical
rinse)
Coatings other than
Tin & Chromium
(Dip or Electrolytic)
TREATMENT
EFFLUENT LEVEL A
CHARACTERISTICS Ibs/ton
Suspended Solids
Oil & Grease
Suspended Solids
Chromium, total dissolved
I r on , di s so Ived
Oil & Grease
Tin
Cyanide, Free
Iron, dissolved
Chromium, total dissolved
Zinc, total dissolved
Cyanide , Free
Suspended Solids
Oil & Grease
.2
.06
.2
.009
.015
.125
.09
.01
.02
.0008
.02
.003
.25
.17
TREATMENT
LEVEL B
Ibs/ton
.3
.1
.8
.015
.02
.25
.15
.03
.2
.008
.2
.03
2.5
2.4
Values are expressed in pounds per ton of product associated with the process:
Coke Manufacturing - Ibs/ton dry coal
Iron Manufacturing - Ibs/ton hot metal
Steel Manufacturing - Ibs/ton liquid steel
Hot Forming - Ibs/ton hot formed
Cold Finishing - Ibs/ton processed
-------
Ill
TEXTILES
APPLICABILITY
These instructions apply to Standard Industrial Classification Code
22, except 229.
For the purpose of this guidance the Textile Industry is defined as
including the processing, finishing and manufacturing of cotton, wool,
blends, and various synthetic textile goods.
SUBCATEGORIES CONSIDERED
Eight subcategories are considered:. Wool scour and finish mills
(integrated); Wool finish mills; Greige goods mills-woven and
knitted goods; Finishing mills - woven products of cotton synthetics
and blends; Finishing mills - knitted products of cotton, synthetics,
and blends; Integrated woven goods mills (includes manufacture of
greige goods); Integrated carpet mills; and yarn dyeing plants - all
yarns.
OPERATIONS EXCLUDED
This guidance covers only the listed operations. Specifically excluded
are SIC Code 229, "Miscellaneous Textile Goods," and also the basic
manufacture of synthetic fibers, which are covered under guidance for
the plastic/synthetics industry.
APPLICATIONS OF LIMITATIONS
The interim guidance will be updated to include COD values. Guidance
for Categories I and II ( wool scouring and finishing, respectively)
should not be used pending additional performance data and economic
impact analysis.
Pending analysis of recently complied study data, daily allowance
pollutant loads will be calculated, using concentration values in
tables A & B, and water use values established in accordance with
the following procedure:
1. Compare water use data submitted by applicant with those shown
herein for the particular process.
2. Meet with applicant and reach agreement as to the water use
value appropriate for "loading" determination which incorporates
good water conservation practices.
-------
112
TEXTILES
APPLICATION OF LIMITATIONS (continued)
3. If appropriate, secure a response from applicant as to why
EPA water use values, which do incorporate water conservation
practices, should not be used in determining allowable loads.
As part of the study referred to above, limitations for COD will be
confirmed; therefore, this guideline does not include values for this
parameter. The pH of final effluents shall be within the range 6.0
to 9.0, with no free hydroxyl alkalinity present. Oil and Grease
should be limited, where applicable, at an effluent limitation based
on 10 mg/1.
ABATEMENT MODELS
These unit operations may vary in hydraulic order and relative size
and importance according to the needs of a specific textile mill.
Nutrient addition may be necessary to maintain biological activity.
Carbon treating facilities should be guarded against suspended solids
and lint because of the possibility of plugging the carbon bed. Guard
filters and/or backwashing provisions may be necessary.
Wool Processing: - Wastewater is characterized by brown color, high
grease content and high alkalinity (pH 10) . Treatment/control model
is:
Solvent extraction of grease and suint
Screening
Dissolved air flotation
pH adjustment
Equalization
Chemical coagulation
Settling
Aerated lagoon
Cotton-Synthetics Integrated Mill; - Wastewater characteristics are high
BOD, COD, and alkalinity, and possibly high color. Treatment/control model
is:
Caustic recovery and reuse
Equalizing pond
pH adjustment
Bar and fine screens
Chemical coagulation and sedimentation
Carbon absorption
Biological oxidation
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113
TEXTILES
ABATEMENT MODELS (continued)
Carpet Integrated Mill; - Waste water characteristics may include high
color, COD, temperature, latex emulsion and solvent content. Treatment/
control model is:
Equalization
Fine screening
Chemical coagulation and sedimentation
Carbon adsorption
Biological Oxidation
Because of the high temperatures associated with carpet processes, heat
recovery from waste waters is recommended. Again, the treatment operations
may vary in hydraulic order and importance depending on the needs of the
specific carpet mill.
In-Plant Control
It is considered quite important that measures be taken to limit or
control the discharge of dyestuff and waste caustic. For this reason,
caustic recovery and reuse, where applicable, has been included in
the treatment model. In addition, separate disposal or reuse of
excess printing paste is recommended.
Supplementary process controls, the majority of which, for a single
plant, represent feasible implementation measures, include the following:
Improved control over wet process operations ( e.g., redox
measurement) to permit reduced excess chemical usage in
sizing, desizing, bleaching, dyeing, finishing, etc.
Improved water usage controls, to reduce water needs in
processing, and to reduce water wastage via spills, leaks,
and continuously running hoses.
Improved housekeeping, use of retaining sills, splash
boards, special waste collection containers, etc.
For the waste resulting from printing operations, excess pastes
should be separated from the print room wastewaters and the pastes
collected manually or automatically into barrels or other suitable
containers. These pastes should not be allowed to enter floor
drains in the print rooms or the screen cleaning/repair rooms.
The viscous printing pastes clog drain lines, sewers, and treatment
works appurtenances, and further settle out on the sides of aerated
basins and in other areas where least desired. Print pastes may
exhibit considerable toxicity but conversely, certain pastes have
extremely high BOD's from 200,000 mg/1 to more than 400,000 mg/1.
The collected mass should be incinerated with strict caution in
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114
TEXTILES
ABATEMENT MODELS (continued)
preventing air pollution; or should be partially refined of varsol and other
hydrocarbons or possibly recovered.
For wool processing, recovery of wool grease and suint are essential in
achieving effluent limits. Recovery of wool greases by solvent systems
and conversion into lanolin was practiced when the lanolin market was
favorable'. Calcium chloride cracking or acid cracking are possible
alternatives. Solvent systems with recovery of the solvents can reduce
scour waste loads by 96-97.
Substantial waste reduction can be effected by recovery of caustic
solution by means of dialysis, filtration, and multiple-stage evaporation.
Countercurrent washing and rinsing following scouring and mercerizing are
feasible. A number of textile mills are currently practicing evaporation
and reuse of mercerizing solutions with various forms of contercurrent
washing. When a cotton finishing plant does not recover mercerizing
wastes, significant problems may arise due to high hydroxyl alkalinity
in the plant wastes; combined plant wastes will exhibit pH levels of
11.0-13.0 which could seriously affect ensuing biological treatment,
and such wastes will likely require neutralization before final discharge.
With recovery of mercerizing solution, caustic purchases may be reduced
more than 50 percent resulting in significant cost savings to a textile
mill.
Treatment Comments and Alternatives:
Disposal of spent cooling waters, evaporator condensates, air conditioning
waters, and cooling tower blowdcwn constitute additional pollution problems
in textile mills. Air conditioning systems which use scrubbers for incoming
air will contain lint, oils, and extraneous contaminants. Cooling tower
blowdown and spent cooling waters will probably contain chromates, phosphates,
or other rust inhibitors, and probably fungicides and biocides, e.g.,
chlorophenates, thiocyanates, and bromopropionates. Most of these materials
are extremely toxic to the aquatic environment and their discharge may
be critical. Chromates can be eliminated by the use of sulfate salts in
chemical treatment, by calcium bisulfite, or other means. Evaporators
within textile mills warrant very close attention to ensure minimum
entrainment of solids in the condensates; caustic soda evaporators represent
a high potential waste source.
Extensive equalization/balancing facilities will be required for smoothing
out the abrupt changes and highly-variable characteristics of the raw
wastewaters generated by textile mills prior to entering the treatment works.
Physical-chemical treatment units are generally less vulnerable to random
fluctuations than biological treatment^units, but, nevertheless, flow
equalization will serve to promote most efficient treatment. Storage/
equalization/automatic control of final discharges to the receiving stream
may likewise be found necessary to satisfactorily comply with effluent
limits. A separate collection system for "strong" wastewaters, including
dyes, detergents/ and finishing agents is desirable to prevent shock
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115
TEXTILES
ABATEMENT MODELS (continued)
loading of colorants and toxics to treatment systems. It would also
lend itself to special handling and treatment of "strong" wastewaters
in the future.
Fine mesh screening of plant wastewaters to remove lint and extraneous
fibers can be incorporated into some textile mills. Natural and synthetic
fibers, if not removed from wastewaters, may comprise up to 10 percent
of the weight of biological sludges. Lint and fibers cause troublesome
treatment problems and may be released to the receiving stream. Efficient
removal of lint and fibers by means of 40-80 mesh screens ( or equivalent)
serves to significantly reduce suspended and total solids, and BOD and
COD loads in the generated wastewaters, and will substantially lessen the
color bodies passed on through succeeding treatment facilities. Screening
is considered necessary for protecting trickling filtration, carbon adsorption,
reverse osmosis and other forms of waste treatment. Solids are disposed of via
sanitary landfill, incinerated, or possibly converted into useful by-products.
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EFFLUENT LIMITATIONS
(Pounds of Pollutant Per 1000 Pounds of Product)
Level A
Mill
Type*
I
II
III
IV
V
VI
VII
VIII
Product
Fin. Wool
Fin . Wool
Greige Goods
Fin. Cloth
Fin. Cloth
Fin. Cloth
Pri . Backed
Carpet
Yarn
Gals/lb
35
25
5
16
11
20
22
18
BODc;
8
6
1.5
6
4
7
6
2.5
TSS
8
6
2
6
5
7
6
2.5
Crt
.07
.05
.01
.03
.02
.04
.05
.04
Cr+6
.0015
.0010
.0002
.0007
.0005
.0008
.0009
.0008
Phenol ics
.07
.05
.01
.03
.02
.04
.05
.04
Sulfide
.15
.10
.02
.06
h™1
M
.04 -i
.08
.09
.08
*As defined under "Subcategories considered".
NOTE: Fecal coliform are not to exceed 1000 organisms per 100 ml in the
various effluents when sanitary sewage is present in the system.
H
M
X
H
OT
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Effluent Limitations
(Milligrams of Pollutant Per Liter of Water Discharged)
Level A
Mill
Type*
I
II
III
IV
V
VI
VII
VIII
Product
Fin. Wool
Fin . Wool
Greige Goods
Fin. Cloth
Fin. Cloth
Fin. Cloth
Pri. Backed
Carpet
Yarn
Gals/lb
35
25
5
16
11
20
22
18
BOD 5
27
29
36
45
44
42
33
17
TSS
27
29
48
45
54
42
33
17
Crfc
.25
.25
.25
.25
.25
.25
.25
.25
Cr*
.005
.005
.005
.005
.005
.005
.005
.005
Phenolic s
.25
.25
.25
.25
.25
.25
.25
.25
Sulfide
.5
.5
.5
.5
.5
.5
.5
.5
it
^
h
t
CO
*As defined under "subcategories considered".
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EFFLUENT LIMITATIONS
(Pounds of Pollutants Per 1000 Pounds of Product)
Level B
Mill
Type*
I
II
III
IV
V
VI
VII
VIII
Product
Fin.
Fin .
Wool
Wool
Greige Goods
Fin.
Fin.
Fin.
Pri.
Cloth
Cloth
Cloth
Backed
Carpet
Yarn
Gals/lb
35
25
5
16
11
20
22
18
BOD
20
15
3
8
5
8
8
4
TSS
10
8
3
8
6
9
8
4
Crfc
.07
.05
.01
.03
.02
.04
.Ob
.04
Cr+6
.0015
.0010
.0002
.0007
.0005
.0008
.0009
.0008
Phenolics
.07
.05
.01
.03
.02
.04
.05
.04
Sulfide
.15
.10
.02
.06
.04
.08
.09
.08
H
X
H
| |
f
M
* As defined under "Subcategories considered".
NOTE: Fecal coliform are not to exceed 1000 organisms per 100 ml in the various effluents when
sanitary sewage is present in the systems.
-------
EFFLUENT LIMITATIONS
(Milligrams of Pollutant Per Liter of Water Discharged)
Level B
Mill
Type*
I
II
III
IV
V
VI
VII
VIII
Product
Fin . Wool
Fin. Wool
Greige Goods
Fin. Cloth
Fin . Cloth
Fin. Cloth
Pri. Backed
Carpet
Yarn
Gals/lb
35
25
5
16
11
20
22
18
BOD,,
68
72
72
60
54
47
43
27
TSS
34
38
72
60
65
53
43
27
Cr*
.25
.25
.25
.25
.25
.25
.25
.25
Cr+6
.005
.005
.005
.005
.005
.005
.005
.005
Phenolics
.25
.25
.25
.25
.25
.25
.25
.25
Sulfide
.5
.5
.5
5 K"^
.5
.5
.5
.5
*As defined under "Subcategories Considered"
£
w
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121
INSULATION FIBERGLASS
APPLICABILITY
These instructions apply to Standard Industrial Classification
Code 3296.
SUBCATEGORIES CONSIDERED
This guidance applies only to insulation fiberglass,
(mineral wool).
OPERATIONS EXCLUDED
Effluents from the textile (SIC 3329) and reinforced fiberglass
industries are excluded from discussion in this guideline.
APPLICATION OF LIMITATIONS
The guidance applies to process wastewater only.
EFFLUENT LIMITATIONS
By July 1, 1977, all fiber glass insulation manufacturing plants
should have total recycling of all waste streams.
No waterborne waste discharge shall be permitted from the
manufacturing process. The only exception to this closed
cycle requirement shall be discharge to a municipal sewage
treatment plant with acceptable secondary or higher treatment
and the capability to handle the process load.
Sludge from closed cycle treatment systems shall be disposed of
in such a manner as to prevent entry into navigable waters or
their tributaries.
ABATEMENT MODELS
In a typical closed system the chain-cleaning (phenolic) wastes,
cooling water blowdown, cullet water wastes (if raw glass is also
manufactured), overspray water, and miscellaneous machinery and
floor-cleaning wastes are all put through the same system. The
system may consist of several or all of the following: bulk fiber
screening, primary filtration, equalization, flocculation, diatomite
filtration and sludge removal. Diatomite filtration may be replaced
by flocculation and settling (clarification) in some cases. The
processed water is recirculated as wash water overspaay and binder
mix water. Makeup water is added to account for evaporative losses
in the overspray and binder. The dissolved solids accumulation is
mainly exited via the product in the binder. Sludge from the
treatment process is landfilled.
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122
INSULATION FIBERGLASS
ABATEMENT MODELS (.continued)
Special treatment problems may result from operations which use
a changing variety of binder compounds, and from operations which
apply oils to the mat. However, these are not unsolvable problems.
The elimination of the "chain" cleaning phenolic process waste
can be achieved by reuse of the "chain" cleaning water to provide
the water source for process needs. With the adoption of 1000
psi, low volume, spray cleaning to replace the mandrel cleaning
operation, the elimination of the need for caustic for "chain"
cleaning is expected. One of the most significant problems from
the combined treatment of all waste is the foaming caused by the
introduction of caustic into the wastewater treatment system for
the mandrel cleaning operation.
The other waste discharges which must be treated included domestic
wastes, boiler and cooling tower blowdown, softener backwash, and
storm water run off. With the exception of storm water, these
wastes can be routed to municipal treatment systems. If a tie-in
to the municipal system cannot be made, a closed system treating
all these wastes can be installed. The typical closed system would
probably include screening, primay filtration, coagulation,
flocculation, sedimentation, diatromite "filtration, and sludcre"removal.
In addition, good in-plant control must be practiced to minimize
water usage and to maintain the lowest possible waste levels to achieve
the highest efficiency and lessen problems in water recirculation.
Process control which may be needed to meet the "no discharge"
requirement is as follows:
1. Minimization of volume of chain-cleaning water by utilization of
high pressure in lieu of volume. This 1000 psi spray will also
replace the mandrel cleaning operation thereby eliminating
caustic waste water.
2. Careful adjustment of minimization of the variety of binder
resins and lubricants to reduce the potential for upsets in
the treatment system.
3. Use of recirculated water in resin mix to the extent necessary
to control buildup of dissolved solids in the treatment system.
Blowdown should go into the product. The dissolved solids, however,
should not accumulate in the system, because they remain with
the product on evaporation of excess water in curing ovens.
4. Use of lubricants and sizing compatible with treatment systems.
5. Good housekeeping practices to minimize the need for washdo\m
of machinery and floors and the minimization of water usage for
such purposes.
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