Industrial Waste Treatment Handbook

486 Pages·2001·5.78 MB·English

by  Frank Woodard

Industrial Waste Treatment Handbook

Industrial Waste Treatment Handbook
Frank Woodard, Ph.D., P.E.,
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. cm.
Includes bibliographical references and indexes.
ISBN 0-7506-7317-6
1.Factory and trade waste—Management—Handbooks, manuals, etc. 2. Sewage—Purification—Handbooks, manuals,
etc. 3. Industries—Environmental
TD897.W67 2000]
628.4—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: [phone]
Fax: [phone]
For information on all Butterworth–Heinemann publications available, contact our World Wide Web home page at:
http://www.bh.com
10 9 8 7 6 5 4 3 2 1
Printed in the United States of America
Dedication
To Dr. James C. Buzzell, whose fascinating
anecdotes lured me into this profession; Dr. Otis
J. Sproul, by whose example I became accustomed to
and enjoyed hard work and a scholarly approach
to life; Dr. James E. 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
1.1 Management of Industrial Wastewater................................................................................ 1
1.2 O&M Costs........................................................................................................................... 10
1.3 Management of Solid Wastes from Industries..................................................................... 18
1.4 Management of Discharges to the Air.................................................................................. 20
1.5 Bibliography......................................................................................................................... 28
2 Fundamentals .................................................................................................... 29
2.1 Introduction.......................................................................................................................... 29
2.2 Characteristics of Industrial Wastewater.............................................................................. 29
2.3 The Polar Properties of Water ............................................................................................. 30
2.4 Electrical and Thermodynamic Stability............................................................................... 33
2.5 Chemical Structure and Polarity of Water............................................................................ 36
2.6 Hydrogen Bonding............................................................................................................... 37
2.7 Polar Solvents versus Nonpolar Solvents (cid:132) True Solutions .................................................. 38
2.8 Emulsification....................................................................................................................... 40
2.9 Colloidal Suspensions.......................................................................................................... 43
2.10 Mixtures Made Stable by Chelating Agents....................................................................... 44
2.11 Summary............................................................................................................................ 44
2.12 Examples........................................................................................................................... 45
2.13 Bibliography....................................................................................................................... 48
3 Laws and Regulations....................................................................................... 49
3.1 Introduction.......................................................................................................................... 49
3.2 History of Permitting and Reporting..................................................................................... 49
3.3 Requirements....................................................................................................................... 49
3.4 Water Pollution Control Laws............................................................................................... 50
3.5 Groundwater Pollution Control Laws ................................................................................... 52
3.6 Air Pollution Control Laws.................................................................................................... 55
3.7 Bibliography......................................................................................................................... 60
4 Wastes from Industries..................................................................................... 61
4.1 Chemical Descaling............................................................................................................. 61
4.2 Degreasing........................................................................................................................... 62
4.3 Rinsing................................................................................................................................. 64
4.4 Electroplating of Tin............................................................................................................. 65
4.5 The Copper Forming Industry.............................................................................................. 74
4.6 Prepared Frozen Foods....................................................................................................... 77
4.7 Wastes From De-inking....................................................................................................... 86
4.8 Die Casting: Aluminum, Zinc, and Magnesium.................................................................... 93
4.9 Anodizing and Alodizing....................................................................................................... 99
4.10 Production and Processing of Coke................................................................................... 103
4.11 The Wine-Making Industry................................................................................................. 107
4.12 The Synthetic Rubber Industry.......................................................................................... 110
4.13 The Soft Drink Bottling Industry......................................................................................... 119
4.14 Production and Processing of Beef, Pork, and Other Sources of Red Meat..................... 124
4.15 Rendering of By-Products from the Processing of Meat, Poultry, and Fish....................... 130
4.16 The Manufacture of Lead Acid Batteries............................................................................ 138
4.17 Bibliography....................................................................................................................... 144
5 Industrial Stormwater Management................................................................. 149
5.1 General................................................................................................................................ 149
5.2 Federal Stormwater Regulations......................................................................................... 149
5.3 Prevention of Groundwater Contamination.......................................................................... 151
5.4 Stormwater Segregation, Collection, Retention, and Treatment.......................................... 152
5.5 Design Storm....................................................................................................................... 152
5.6 System Failure Protection.................................................................................................... 153
5.7 Stormwater Retention.......................................................................................................... 153
5.8 Stormwater Treatment......................................................................................................... 153
5.9 Stormwater as a Source of Process Water Makeup............................................................ 154
5.10 Bibliography....................................................................................................................... 165
6 Wastes Characterization: The Wastes Characterization Study, Wastes
Audit, and the Environmental Audit.................................................................... 166
6.1 Wastes Characterization Study............................................................................................ 166
6.2 Wastes Audit........................................................................................................................ 169
6.3 Environmental Audit............................................................................................................. 172
6.4 Characteristics of Industrial Wastewater.............................................................................. 179
6.5 Characteristics of Discharges to the Air............................................................................... 192
6.6 Sample Analysis .................................................................................................................. 198
6.7 Ambient Air Sampling .......................................................................................................... 198
6.8 Characteristics of Solid Waste Streams from Industries...................................................... 201
6.9 Bibliography......................................................................................................................... 205
7 Pollution Prevention.......................................................................................... 208
Findings and Policy.................................................................................................................... 208
7.1 General Approach................................................................................................................ 209
7.2 Source Reduction................................................................................................................ 212
7.3 The Waste Audit .................................................................................................................. 215
7.4 Benefits of Pollution Prevention........................................................................................... 216
7.5 Bibliography......................................................................................................................... 216
8 Methods for Treating Wastewaters from Industry.......................................... 219
8.1 General................................................................................................................................ 219
8.2 Principle and Nonprinciple Treatment Mechanisms............................................................. 220
8.3 Waste Equalization.............................................................................................................. 223
8.4 pH Control............................................................................................................................ 227
8.5 Chemical Methods of Wastewater Treatment...................................................................... 230
8.6 Biological Methods of Wastewater Treatment ..................................................................... 255
8.7 Development of Design Equations for Biological Treatment of Industrial Wastes............... 256
8.8 Physical Methods of Wastewater Treatment....................................................................... 322
8.9 Bibliography......................................................................................................................... 394
9 Treatment and Disposal of Solid Wastes from Industry................................ 397
9.1 Characterization of Solid Wastes......................................................................................... 398
9.2 The Solid Waste Landfill...................................................................................................... 400
9.3 Solid Waste Incineration...................................................................................................... 409
9.4 The Process of Composting Industrial Wastes.................................................................... 421
9.5 Solidification and Stabilization of Industrial Solid Wastes.................................................... 427
9.6 Bibliography......................................................................................................................... 433
10 Methods for Treating Air Discharges from Industry .................................... 437
10.1 Reduction at the Source.................................................................................................... 437
10.2 Containment....................................................................................................................... 437
10.3 Treatment........................................................................................................................... 438
10.4 Bibliography....................................................................................................................... 456
Index ...................................................................................................................... 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. itself. 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 [phone].
ix
Acknowledgments
This work was produced over a period of more Robinson; Dr. James E. Etzel; James
than five years; during that time, a very large D. Ekedahl; Karen L. 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. Curato; Patricia A. Proux-Lough; Paul
and I apologize mightily if I have missed one or Bishop; Randy E. Tome; Eric P. King; Ray-
more. Thus, I extend heartfelt gratitude and mond G. Pepin; Robert W. Severance; Steven
acknowledgement to: N. Whipple; Steven Smock; Susan G. Stevens;
Adam H. Steinman; Aeration Technologies, Terry Rinehart; and Thora Knakkergaard, all of
Inc.; R. 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. I extend special
E. Woodard; Geoffrey D. Pellechia; George thanks to Adam Steinman, Esq., who provided
Abide; George W. Bloom; Henri J. Vincent; Dr. text and verbal information regarding laws,
Hugh J. Campbell; 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
from wastewater. Failed landfills can be potent
emphasis.
polluters of both groundwater and surface
Wastes from industries are customarily clas-
water.
sified as liquid wastes, solid wastes, or air pol-
The total spectrum of industrial wastes, then,
lutants, and often the three are managed by
must be managed as substances resulting from
different people or departments. The three sep-
a system of interrelated activities. Materials
arate categories are regulated by separate and
balances must be tracked, and overall cost
distinct bodies of laws and regulations, and his-
effectiveness must be kept in focus.
torically, public and governmental emphasis
has moved from one category to another from
one time period to another. The fact is, how-
Management of Industrial Wastewater
ever, that the three categories of wastes are
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