Industrial Waste Treatment Handbook Industrial Waste Treatment Handbook Frank Woodard, Ph., President Copyright © 2001 by Butterworth–Heinemann A member of the Reed Elsevier group All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording, or otherwise, without the prior written permission of the publisher. Recognizing the importance of preserving what has been written, Butterworth–Heinemann prints its books on acid-free paper whenever possible. Butterworth–Heinemann supports the efforts of American Forests and the Global ReLeaf program in its campaign for the betterment of trees, forests, and our environment.
Library of Congress Cataloging-in-Publication Data Woodard, Frank, 1939 Industrial waste treatment handbook/Frank Woodard p. Includes bibliographical references and indexes. Factory and trade waste—Management—Handbooks, manuals, etc. Sewage—Purification—Handbooks, manuals, etc.
Industries—Environmental TD897.4—dc21 00-044448 British Library Cataloguing-in-Publication Data A catalogue record for this book is available from the British Library. The publisher offers special discounts on bulk orders of this book. For information, please contact: Manager of Special Sales Butterworth–Heinemann 225 Wildwood Avenue Woburn, MA 01801-2041 Tel: 781-904-2500 Fax: 781-904-2620 For information on all Butterworth–Heinemann publications available, contact our World Wide Web home page at: http://www.com 10 9 8 7 6 5 4 3 2 1 Printed in the United States of America Dedication To Dr. Buzzell, whose fascinating anecdotes lured me into this profession; Dr.
Sproul, by whose example I became accustomed to and enjoyed hard work and a scholarly approach to life; Dr. Etzel, by whose example I developed an insatiable desire to figure out better ways to achieve treatment of industrial wastes; and my (almost) lifelong best friend, Jean McNeary Woodard, who deserves much of the credit for the existence of this book. v 1 Management of Industrial Wastes: Solids, Liquids, and Gases .1 Management of Industrial Wastewater .3 Management of Solid Wastes from Industries .4 Management of Discharges to the Air .2 Characteristics of Industrial Wastewater .3 The Polar Properties of Water .4 Electrical and Thermodynamic Stability .5 Chemical Structure and Polarity of Water .7 Polar Solvents versus Nonpolar Solvents True Solutions .10 Mixtures Made Stable by Chelating Agents. 48 3 Laws and Regulations .2 History of Permitting and Reporting .4 Water Pollution Control Laws .5 Groundwater Pollution Control Laws .6 Air Pollution Control Laws.
60 4 Wastes from Industries .4 Electroplating of Tin .5 The Copper Forming Industry .6 Prepared Frozen Foods .7 Wastes From De-inking .8 Die Casting: Aluminum, Zinc, and Magnesium .9 Anodizing and Alodizing .10 Production and Processing of Coke .11 The Wine-Making Industry .12 The Synthetic Rubber Industry .13 The Soft Drink Bottling Industry .14 Production and Processing of Beef, Pork, and Other Sources of Red Meat .15 Rendering of By-Products from the Processing of Meat, Poultry, and Fish .16 The Manufacture of Lead Acid Batteries. 144 5 Industrial Stormwater Management .2 Federal Stormwater Regulations .3 Prevention of Groundwater Contamination .4 Stormwater Segregation, Collection, Retention, and Treatment .6 System Failure Protection .9 Stormwater as a Source of Process Water Makeup. 165 6 Wastes Characterization: The Wastes Characterization Study, Wastes Audit, and the Environmental Audit .1 Wastes Characterization Study .4 Characteristics of Industrial Wastewater .5 Characteristics of Discharges to the Air .7 Ambient Air Sampling .8 Characteristics of Solid Waste Streams from Industries. 208 Findings and Policy .3 The Waste Audit .4 Benefits of Pollution Prevention.
216 8 Methods for Treating Wastewaters from Industry .2 Principle and Nonprinciple Treatment Mechanisms .5 Chemical Methods of Wastewater Treatment .6 Biological Methods of Wastewater Treatment .7 Development of Design Equations for Biological Treatment of Industrial Wastes .8 Physical Methods of Wastewater Treatment. 394 9 Treatment and Disposal of Solid Wastes from Industry .1 Characterization of Solid Wastes .2 The Solid Waste Landfill .3 Solid Waste Incineration .4 The Process of Composting Industrial Wastes .5 Solidification and Stabilization of Industrial Solid Wastes. 433 10 Methods for Treating Air Discharges from Industry .1 Reduction at the Source. 461 Preface This book has been developed with the inten- of industry and size.
In all cases, the actual tion of providing an updated primary reference numbers and all pertinent information have for environmental managers working in indus- been reproduced as they occurred, with the try, environmental engineering consultants, intent of providing accurate illustrations of graduate students in environmental engineer- how environmental quality problems have been ing, and government agency employees solved by one of the leading consultants in the concerned with wastes from industries. It pre- field of industrial wastes management. sents an explanation of the fundamental This book is intended to fulfill the need for mechanisms by which pollutants become dis- an updated source of information on the char- solved or suspended in water or air, then builds acteristics of wastes from numerous types of on this knowledge to explain how different industries, how the different types of wastes are treatment processes work, how they can be most efficiently treated, the mechanisms optimized, and how one would go about effi- involved in treatment, and the design process ciently selecting candidate treatment processes. In many cases, “tricks” that enable lower Examples from the recent work history of cost treatment are presented.
These “tricks” Woodard & Curran, as well as other environ- have been developed through many years of mental engineering and science consultants, experience and have not been generally avail- are presented to illustrate both the approach able except by word of mouth. used in solving various environmental quality The chapter on laws and regulations is pre- problems and the step-by-step design of facili- sented as a summary as of the date stated in the ties to implement the solutions. Where permis- chapter itself and/or the addendum that is sion was granted, the industry involved in each issued periodically by the publisher. For infor- of these examples is identified by name.
Other- mation on the most recent addendum, please wise, no name was given to the industry, and call the publisher or Woodard & Curran’s the industry has been identified only as to type office in Portland, Maine, at (207) 774-2112. ix Acknowledgments This work was produced over a period of more Robinson; Dr. Etzel; James than five years; during that time, a very large D. Townsend; Katahdin number of individuals, corporations, and various Analytical Services; Keith A.
Weisenberger; business organizations contributed significant Kurt R. Marston; Michael Harlos; Michael material. I have tried to cite each contributor, J. Proux-Lough; Paul and I apologize mightily if I have missed one or Bishop; Randy E.
King; Ray- more. Thus, I extend heartfelt gratitude and mond G. Severance; Steven acknowledgement to: N. Whipple; Steven Smock; Susan G.
Steinman; Aeration Technologies, Terry Rinehart; and Thora Knakkergaard, all of Inc. Gary Gilbert; Albert M. Presgraves; whom contributed text or verbal information Andy Miller; Claire P. Betze; Connie Bogard; from which I freely drew, either word-for-word Connie Gipson; Dennis Merrill; Dr.
Steven or by way of paraphrase. Pellechia; George thanks to Adam Steinman, Esq., who provided Abide; George W. text and verbal information regarding laws, Hugh J. Alastair Lough; Janet regulations and environmental audits.
x 1 Management of Industrial Wastes: Solids, Liquids, and Gases The approach used to develop systems to treat surface waters by way of leachate entering the and dispose of industrial wastes is distinctly groundwater and traveling with it through the different from the approach used for municipal ground, then entering a surface water body wastes. There is a lot of similarity in the char- with groundwater recharge. Volatile organics in acteristics of wastes from one municipality, or that recharge water can contaminate the air. Air one region, to another.
Because of this, the best pollutants can fall out to become surface water approach to designing a treatment system for or groundwater pollutants, and water pollutants municipal wastes is to analyze the performance can infiltrate into the ground or volatilize into characteristics of many existing municipal sys- the air. tems and deduce an optimal set of design Waste treatment processes can also transfer parameters for the system under consideration. substances from one of the three waste catego- Emphasis is placed on the analysis of other sys- ries to one or both of the others. Air pollutants tems, rather than on the waste stream under can be removed from an air discharge by means consideration.
In the case of industrial waste, of a water solution scrubber. The waste scrub- however, few industrial plants have a high ber solution must then be managed to enable it degree of similarity between products pro- to be discarded within compliance with appli- duced and wastes generated. Therefore, cable water regulations. Airborne particulates emphasis is placed on analysis of the wastes can be removed from an air discharge using a under consideration, rather than on what is tak- bag house, thus creating a solid waste to be ing place at other industrial locations.
This is managed. On still a third level, waste treatment not to say that there is little value in analyzing or disposal systems themselves can directly the performance of treatment systems at other, impact on the quality of air, water, or ground. more or less similar, industrial locations. Quite Activated sludge aeration tanks are very effec- the opposite is true.
It is simply a matter of tive in causing volatilization of substances emphasis. Failed landfills can be potent Wastes from industries are customarily clas- polluters of both groundwater and surface sified as liquid wastes, solid wastes, or air pol- water. lutants, and often the three are managed by The total spectrum of industrial wastes, then, different people or departments. The three sep- must be managed as substances resulting from arate categories are regulated by separate and a system of interrelated activities.
Materials distinct bodies of laws and regulations, and his- balances must be tracked, and overall cost torically, public and governmental emphasis effectiveness must be kept in focus. has moved from one category to another from one time period to another. The fact is, how- ever, that the three categories of wastes are Management of Industrial Wastewater closely interrelated, both as they impact on the With respect to industrial wastewater, Figure environment and as they are generated and 1-1 illustrates the approach for developing a managed by individual industrial facilities. well-operating, cost-effective treatment system.
Solid wastes disposed of in the ground can The first step is to gain familiarity with influence the quality of groundwater and the manufacturing processes themselves. This 1 2 Industrial Waste Treatment Handbook usually starts with a tour of the facility, and then progresses through a review of the litera- ture and interviews with knowledgeable people. The objective is to gain an understand- ing of how wastewater is produced, for two reasons. The first is to enable an informed and therefore effective wastes reduction, or minimi- zation (pollution prevention) program; the second is to enable proper choice of candidate treatment technologies.
Analysis of Manufacturing Processes One of the first steps in the analysis of manu- facturing processes is to develop a block diagram that shows how each manufacturing process contributes wastewater to the treatment facility, as is illustrated in Figure 1-2. In Figure 1-2, a block represents each step in the manu- facturing process. The supply of water to each point of use is represented on the left side of the block diagram. Wastewater that flows away from each point of wastewater generation is shown on the right side.
Figure 1-2 is representative of the processes involved in producing finished woven fabric from an intermediate product of the textile industry. The “raw material” for this process is first subjected to a process called “desizing,” during which the substances used to size the woven greige goods, or raw fabric, are removed. The process uses sulfuric acid; there- fore, the liquid waste from this process would be expected to have a low pH as well as contain whatever substances were used as sizing.