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FET INDUSTRIAL WATEWATER OPERATOR TRAINING METAL FINISHING / METAL MOLDING AND CASTING

FET INDUSTRIAL WATEWATER OPERATOR TRAINING METAL FINISHING / METAL MOLDING AND CASTING. SESSION 1 – OCTOBER 4, 2006 Robert Peschel, P.E. (414) 643-4150 (Sigma) rpeschel@thesigmagroup.com. SESSION 1. Introduction of Course/Participants Course Outline Text: Treatment of Metal Wastestreams

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FET INDUSTRIAL WATEWATER OPERATOR TRAINING METAL FINISHING / METAL MOLDING AND CASTING

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  1. FET INDUSTRIAL WATEWATER OPERATOR TRAINING METAL FINISHING / METAL MOLDING AND CASTING SESSION 1 – OCTOBER 4, 2006 Robert Peschel, P.E. (414) 643-4150 (Sigma) rpeschel@thesigmagroup.com

  2. SESSION 1 • Introduction of Course/Participants • Course Outline • Text: Treatment of Metal Wastestreams • Need for Treatment (Chapter 1) • Regulatory Overview • Opportunities • Sources of Wastewater (Chapter 2) • Material Safety Data Sheets [MSDS] (Chapter 3) • Employee Right-To-Know (Chapter 4) • Arithmetic Problems (Appendix III) • Methods of Treatment (Chapter 5) • Batch and Continuous Processes (5.0) • Neutralization (5.1) • Common Metals Removal (5.2) • Complex Metals Removal (5.3) • Reduction Hex Chrome (5.4) • Cyanide Destruction (5.5)

  3. COURSE OUTLINE OCTOBER 4 Introduction/Overview RobertPeschel Regulatory Overview Basic Math Basics of Treatment Hexavalent Chrome Reduction Cyanide Destruction Metals Removal Example Calculations/Problems OCTOBER 11 Oily Waste Removal Scott Hartay Control of Solvents/Toxic Organics Sludge Treatment & Disposal Sampling Flow Measurements Steve Galewski Laboratory Support Example Calculations/Problems OCTOBER 18 Operation & Maintenance TBD Equipment & Instrumentation Example Calculations/Problems Recovery Technologies Kenneth Kaszubowski OCTOBER 25 Tour of Pretreatment System Course Review Rick Fulk

  4. NEED FOR TREATMENT • REGULATORY OVERVIEW • Clean Water Act • Objective and Goals • Policies • Structure • Important Sections • NPDES • Pretreatment • Stormwater

  5. OBJECTIVE OF CWA • To restore and maintain the chemical, physical, and biological integrity of the nation’s waters GOALS OF CWA • Achieve fishable and swimmable water by 1983 (interim) • Eliminate the discharge of pollutants into navigable waters by 1985

  6. NATIONAL POLICIES OF CWA • Prohibit discharge of toxics in toxic amounts • Provide federal assistance to construct POTWs • Develop and implement area-wide waste treatment management plants in each state (208 plans) • Conduct R&D necessary to develop zero discharge technology • Develop programs to control non-point sources of pollution • Encourage the minimization of paperwork and interagency decisions

  7. STRUCTURE OF ACT • Title 1 Research and Related Programs • Title 2 Grants for POTW Construction • Title 3 Standards and Enforcement • Title 4 Permits and Licenses • Title 5 General Provisions • Title 6 State Revolving Funds

  8. TITLE 1RESEARCH AND RELATED PROGRAMS • Objective, goals, and policies • Coordination between state and federal agencies • Develop research projects • Develop demonstration projects • Develop operator training programs • Develop specific programs (GLNPO)

  9. TITLE 2CONSTRUCTION GRANTS • Federal grant program • Authorizes funding • Defines eligible projects • Sets participation requirements • Establishes planning programs (208) • Establishes allotment formula

  10. TITLE 3STANDARDS AND ENFORCEMENT • Standards and standard setting procedures • Pollutants (priority) • Deadlines • Variances & waivers • Water quality criteria • Inventories of water quality • Monitoring & record keeping • Enforcement programs • Spills of hazardous substances

  11. TITLE 4PERMITS AND LICENSES • NPDES permit system • Discharger certification/public comment • Delegation to states • Anti-backsliding • Storm water discharges • Ocean discharges • Dredge & fill operations • Sludge disposal/management

  12. TITLE 5GENERAL PROVISISONS • Grants authority to EPA to carry out law • Provides key definitions • Creates advisory boards • Citizens suit provision • Employee protection for reporting violations • Supply of goods & services to federal government • Periodic needs surveys • American Indian tribes treated like states • State authority for NPDES/Pretreatment Programs

  13. EFFLUENT LIMITATIONS • Source category basis • Industrial categories • Technology based limits • Conventional and toxic pollutants • Local limits

  14. EFFLUENT LIMITATIONS • Direct discharges – NPDES • Indirect discharges – to POTW • Existing sources (3 years) • New sources (90 days) • BPT, BCT, BAT, BADCT • Concentration vs. mass

  15. STANDARDS BPT- Best Practicable Control Technology. Currently available. Subject to cost-benefit analysis. (middle ground between BCT and BAT) BCT-Best Conventional Control Technology Subject to cost effectiveness standard. Must be met within three years of effective guidelines or 3/89. BAT-Best Available Technology Economically Achievable. Deemed achievable unless plant closure would result. Must be installed within three years of guideline or 3/89. BADCT- for new sources (NSPS). Best Available Demonstrable Control Technology NSPS-New Source Performance Standards PSNS-Pretreatment Standards for New Sources PSES- Pretreatment Standards for Existing Sources

  16. POLLUTANTS • Conventional • BOD, TSS, pH • Non-conventional • Ammonia • Toxics • Priority pollutants (65) • Metals • Organics • pesticides

  17. NPDES PERMITS • Required for any discharge of “Pollutant” from any “Point Source” into any “Waters of the U.S.” • Key to enforcing CWA limits and standards • Delegation to States (e.g. WPDES) • Allows for public involvement in permitting process • Can be modified for reason • Anti-backsliding provisions

  18. PRETREATMENT REGULATIONS OBJECTIVES • Prevent pass-through of toxics to receiving water • Prevent interference with POTW operations • Prevent contamination of sludges • Protect health and safety of workers

  19. PRETREATMENT PROGRAM FRAMEWORK • EPA has prime responsibility • Delegations to states with approved programs • POTWs > 5 MGD must establish formal program and have first time responsibility • MMSD Chapter 11 • POTWs < MGD have state or EPA involvement

  20. PRETREATMENT STANDARDS • General prohibitive standards • Fire or explosion hazard • Corrosive, pH <5 • Flow obstruction • Slug loads • Heat • Toxic gasses or vapors • Categorical standards • Local POTW limits • Combined waste stream formula [409 CFR 403.6(e)] • Most stringent standard applies!

  21. PRETREATMENT STANDARDS • General prohibitive standards • Fire or explosion hazard • Corrosive, pH <5 • Flow obstruction • Slug loads • Heat • Toxic gasses or vapors • Categorical standards • Local POTW limits • Combined waste stream formula [409 CFR 403.6(e)] • Most stringent standard applies!

  22. MAJOR INDUSTRIAL WASTE PROGRAM (IWP) COMPONENTS • Sewer use ordinance • Permitting procedures • Compliance monitoring • Enforcement • Funding mechanism • Biennial review of effluent limitations

  23. STORM WATER REGULATIONS • Most point sources are not under control through NPDES permits • Waterway in heavily populated areas are still being degraded • Most states have identified storm water as leading cause of impairment • Various studies have confirmed problems • Illicit Connections till exist • Illegal dumping still occurs • Congressional mandates

  24. WHAT’S IN A PERMIT • Effective/expiration dates • Monitoring and reporting requirement • Location • Frequency • Parameter limits • Parameter monitoring • Notification • Reporting • Enforcement • Signatory requirements

  25. MMSD Chapter 11Prohibited Discharges • Explosive or fire hazard < 140 flash point • pH < 5 • Heat > 104 F • radioactive • Stormwater, cooling water, groundwater, unpolluted • Oil and Grease ( O&G) : 300 mg/l • Cadmium: 1.5 mg/l • Copper: 6.0 mg/l • Lead: 2.0 mg/l • Nickel: 4.0 mg/l • Silver: 5.8 mg/l • Zinc: 8.0 mg/l • Cyanide: 5.0 mg/l

  26. SOURCES OF WASTEWATER • Parts cleaning • Parts rinsing • Process baths • Floor wash • Process system cleaning/washing • Vibratory clean • Contact cooling • Performance testing • Leakage • Air Pollution Control • Blowdown • Backwash

  27. SOURCES OF WASTEWATER • 40 CFR 433 Metal Finishing • “Big Six” • Electroplating • Electroless plating • Anodizing • Coating: chromating, phosphating, metal coloring, passaviting. • Etching and chemical milling • Printed circuit board manufacturing

  28. SOURCES OF WASTEWATER • 40 CFR 464: Metal Molding and Casting • Subcategories for aluminum, zinc, ferrous • Processes • Quenching • Cleaning • Manufacturing system leakage • Heat treating • Contact cooling • Mass based discharge limits

  29. SOURCES OF WASTEWATER ISSUES OF CONCERN • Segregating waste streams, i.e., cyanide, hex chrome • Bypass treatment • Batch dump • Equalization • Production schedule • Special conditions

  30. SOURCES OF WATERWATER MANAGEMENT TOOLS: • Process schematic • Flows and loads • Dump schedule • Quality driven / production issues • Pretreatment at source • Maintenance Improvements

  31. Material Safety Data Sheets (MSDS) • Explanation of form • Table 1 in text • Section I • Section II – Hazardous Ingredients / Identify Information • Hazardous components • TLV • PEL • Section III – Physical / Chemical Characteristics • Boiling point • Vapor pressure • Vapor density • Specific gravity • Melting point • Evaporation rate • Solubility in water • Appearance and odor

  32. MSDS • Section V – Reactivity Data • Stability, incompatibility, hazardous decomposition, hazardous polymerization • Section VI – Health Hazard Data • Routes of Entry, acute and chronic, carcinogenicity, signs and symptoms of exposure, medical conditions generally aggravated, emergency and first aid • Section VII – Precautions for safe handling or storage, other • Section VIII – Control Measures • Respiratory, ventilation, protective gloves, eye protection, other PPE, work/hygiene practices

  33. MSDSUSEFUL INFORMATION • Knowledge and understand risk • Emergencies • Environmental reporting • Diagnosing a situation

  34. EMPLOYEE RIGHT-TO-KNOW • OSHA Haz Com Standard – 29 CFR 1910.1200 • Need • Notification • Training • Access to records • Exposure and medical records • Limitations • Refusal to work • Liability • Notice

  35. ARITHMETIC PROBELMS • Appendix III • Steps in problem solving • Conversion factors • Volume • Percent removal or efficiency • Loading • Example problems

  36. STEPS IN PROBLEM SOLVING Step 1What does the problem tell you? A. Read the problem twice, underlining the key words and data B. Draw a picture of the situation C. Label the picture with the given information Step 2What does the problem ask? A. Determine from the problem and picture the unknown you are trying to find. B. Select the formula which solves for the unknown Step 3Determine the solution (Work the problem) A. Write down selected formula B. Plug in information from problem and picture C. Check units of conversions D. Compute the solution E. Check your results

  37. CONVERSION FACTORS: A relationship by which you can express a quantity in different units. • Length: 1 foot = 12 inches • Area (A): 1 sq. yd.= 9 sq.ft. • Volume (V): 1 cu. ft. = 7.48 gal • Weight: 1 gal= 8.34 lbs of water • Velocity: 1 ft/sec • Flow (Q): = A x V gpm or mgd or ml per second =1 cu.ft/sec= 7.48 gal/sec=449 gal/min • Metric (liters, grams) vs. English ( gallons, pounds)

  38. VOLUME Volume = (Area x Depth) or (Area X Height) • Rectangular Solids • Volume = L x W x H Tank 4’ x 2’ x 2’ = 16 cu ft. 16 cu. ft. x 7.48 gal/cu. ft. = 120 gal • Cylinders • Volume = A x H Tank 30 ft. dia., 10 ft high πx r2 x H 3.14 x 15 x 15 x 10= 7065 cu. ft. = 52,846 gal

  39. PROBLEM What is the detention time in a clarifier that has a diameter of 40 feet, a depth of fluid of 12 feet, and a flow rate of 1.3 MGD?

  40. PERCENT (%) REMOVAL OR EFFICIENCY • Definition: The portion of pollutants removed in a process (unit) expressed as a percentage of what goes into the process (unit). % Removal = (In – Out/ In) X 100 Removed = In – Out • Importance Calculations of treatment unit of plant efficiency used.

  41. SAMPLE PROBLEM • A tank has an influent suspended solids (SS) concentration of 100 mg/L and an effluent SS concentration of 60 mg/L. What is the percent (%) reduction in suspended solids in the tank?

  42. SAMPLE PROBLEM BREAKDOWN • % removal = In-Out/In X 100 • % removal = 100-60/100 X 100 • % removal= 40%

  43. LOADING: Definition Loading is the amount of pollutant that a treatment unit or plant receives. It is normally expressed as pounds per day (lb/day). Load (lb/day)= Concentration (mg/L or PPM) x Flow (MGD) x 8.34 The loading formula is the only formula that the terms multiplied together don’t cancel. But as long as the concentration is mg/L is multiplied by the flow in MDG and is then multiplied by 8.34, the answer will be lbs/day. Mg/L is milligrams per liter PPM is parts per million MGD is million gallons per day Importance • Loading is a basic design consideration for a treatment system. It determines the basic size and type of treatment. • Computation of amount (pounds) of chlorine needed per day or amount (cubic feet) of air needed in an aeration tank. • Assessment of payment on user charges.

  44. SAMPLE PROBLEM • A treatment plant receives a raw wastewater flow of 100,000 gallons per day with an average influent Zinc concentration of 300 milligrams per liter (mg/L). What is the Zinc loading upon the facility? • Loading in pounds per day? • Given: concentration= 300 mg/l, flow= 0.1 mgd • Loading= concentration x MGD x 8.34 • Loading= 300 mg/l x 0.1 MGD x 8.34 = 250 lbs/day

  45. SAMPLE PROBLEM • An operator uses 1300 pounds of Alum per day in a wastewater flow of 12 MGD. What is the Alum concentration in mg/liter? • Given: pounds of Alum used = 1300 lbs per day wastewater flow = 12 mgd (million gallons per day) • Find: Alum concentration in mg/l (milligrams per liter)

  46. Solution • Use the “pounds” formula: pounds/day = Q x C x 8.34 where Q = wastewater flow in units mgd C = concentration in units mg/l 8.34 = conversion factor 8.34 lbs/gallon in dilute steam systems, where the specific gravity is close to 1.0 • Substitute in: 1300 lbs/day = 12 mgd x C (mg/L) x 8.34 • Rearrange to solve for C: 1300 lbs/day ---------------------- = C (mg/L) = 13 mg/L alum (12 mgd)(8.34)

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