Waste Treatment in the Process Industries © 2006 by Taylor & Francis Group, LLC Waste Treatment in the Process Industries edited by Lawrence K Wang Yung-Tse Hung Howard H Lo Constantine Yapijakis Boca Raton London New York A CRC title, part of the Taylor & Francis imprint, a member of the Taylor & Francis Group, the academic division of T&F Informa plc © 2006 by Taylor & Francis Group, LLC This material was previously published in the Handbook of Industrial and Hazardous Wastes Treatment, Second Edition © Taylor and Francis Group, LLC 2004 Published in 2006 by CRC Press Taylor & Francis Group 6000 Broken Sound Parkway NW, Suite 300 Boca Raton, FL 33487-2742 © 2006 by Taylor & Francis Group, LLC CRC Press is an imprint of Taylor & Francis Group No claim to original U.S Government works Printed in the United States of America on acid-free paper 10 International Standard Book Number-10: 0-8493-7233-X (Hardcover) International Standard Book Number-13: 978-0-8493-7233-9 (Hardcover) Library 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http://www.crcpress.com Preface Environmental managers, engineers, and scientists who have had experience with process industry waste management problems have noted the need for a book that is comprehensive in its scope, directly applicable to daily waste management problems of the industry, and widely acceptable by practicing environmental professionals and educators Many standard industrial waste treatment texts adequately cover a few major technologies for conventional in-plant environmental control strategies in the process industry, but no one book, or series of books, focuses on new developments in innovative and alternative technology, design criteria, effluent standards, managerial decision methodology, and regional and global environmental conservation This book emphasizes in-depth presentation of environmental pollution sources, waste characteristics, control technologies, management strategies, facility innovations, process alternatives, costs, case histories, effluent standards, and future trends for the process industry, and in-depth presentation of methodologies, technologies, alternatives, regional effects, and global effects of important pollution control practices that may be applied to the industry This book covers new subjects as much as possible Special efforts were made to invite experts to contribute chapters in their own areas of expertise Since the area of process industry waste treatment is very broad, no one can claim to be an expert in all areas; collective contributions are better than a single author’s presentation for a book of this nature This book is one of the derivative books of the Handbook of Industrial and Hazardous Wastes Treatment, and is to be used as a college textbook as well as a reference book for the process industry professional It features the major industrial process plants or installations that have significant effects on the environment Specifically this book includes the following process industry topics: industrial ecology, bioassay, biotechnology, in-plant management, pharmaceutical industry, oil fields, refineries, soap and detergent industry, textile mills, phosphate industry, pulp mills, paper mills, pesticide industry, rubber industry, and power industry Professors, students, and researchers in environmental, civil, chemical, sanitary, mechanical, and public health engineering and science will find valuable educational materials here The extensive bibliographies for each type of industrial process waste treatment or practice should be invaluable to environmental managers or researchers who need to trace, follow, duplicate, or improve on a specific process waste treatment practice The intention of this book is to provide technical and economical information on the development of the most feasible total environmental control program that can benefit both process industry and local municipalities Frequently, the most economically feasible methodology is combined industrial-municipal waste treatment We are indebted to Dr Mu Hao Sung Wang at the New York State Department of Environmental Conservation, Albany, New York, who co-edited the first edition of the v © 2006 by Taylor & Francis Group, LLC vi Preface Handbook of Industrial and Hazardous Wastes Treatment, and to Ms Kathleen Hung Li at NEC Business Network Solutions, Irving, Texas, who is the consulting editor for this new book Lawrence K Wang Yung-Tse Hung Howard H Lo Constantine Yapijakis © 2006 by Taylor & Francis Group, LLC Contents Preface Contributors Implementation of Industrial Ecology for Industrial Hazardous Waste Management Lawrence K Wang and Donald B Aulenbach v ix Bioassay of Industrial and Waste Pollutants Svetlana Yu Selivanovskaya, Venera Z Latypova, Nadezda Yu Stepanova, and Yung-Tse Hung 15 In-Plant Management and Disposal of Industrial Hazardous Substances Lawrence K Wang 63 Application of Biotechnology for Industrial Waste Treatment Joo-Hwa Tay, Stephen Tiong-Lee Tay, Volodymyr Ivanov, and Yung-Tse Hung 133 Treatment of Pharmaceutical Wastes Sudhir Kumar Gupta, Sunil Kumar Gupta, and Yung-Tse Hung 167 Treatment of Oilfield and Refinery Wastes Joseph M Wong and Yung-Tse Hung 235 Treatment of Soap and Detergent Industry Wastes Constantine Yapijakis and Lawrence K Wang 307 Treatment of Textile Wastes Thomas Bechtold, Eduard Burtscher, and Yung-Tse Hung 363 Treatment of Phosphate Industry Wastes Constantine Yapijakis and Lawrence K Wang 399 10 Treatment of Pulp and Paper Mill Wastes Suresh Sumathi and Yung-Tse Hung 453 11 Treatment of Pesticide Industry Wastes Joseph M Wong 499 vii © 2006 by Taylor & Francis Group, LLC viii Contents 12 Treatment of Rubber Industry Wastes Jerry R Taricska, Lawrence K Wang, Yung-Tse Hung, Joo-Hwa Tay, and Kathleen Hung Li 545 13 Treatment of Power Industry Wastes Lawrence K Wang 581 © 2006 by Taylor & Francis Group, LLC Contributors Rensselaer Polytechnic Institute, Troy, New York, U.S.A Donald B Aulenbach Leopold Franzens University, Innsbruck, Austria Thomas Bechtold Leopold Franzens University, Innsbruck, Austria Eduard Burtscher Indian Institute of Technology, Bombay, India Sudhir Kumar Gupta Indian Institute of Technology, Bombay, India Sunil Kumar Gupta Cleveland State University, Cleveland, Ohio, U.S.A Yung-Tse Hung Nanyang Technological University, Singapore Volodymyr Ivanov Kazan State University, Kazan, Russia Venera Z Latypova NEC Business Network Solutions, Irving, Texas, U.S.A Kathleen Hung Li Howard H Lo Cleveland State University, Cleveland, Ohio, U.S.A Svetlana Yu Selivanovskaya Nadezda Yu Stepanova Suresh Sumathi Kazan Technical University, Kazan, Russia Indian Institute of Technology, Bombay, India Hole Montes, Inc., Naples, Florida, U.S.A Jerry R Taricska Joo-Hwa Tay Kazan State University, Kazan, Russia Nanyang Technological University, Singapore Stephen Tiong-Lee Tay Nanyang Technological University, Singapore Lawrence K Wang Lenox Institute of Water Technology and Krofta Engineering Corporation, Lenox, Massachusetts and Zorex Corporation, Newtonville, New York, U.S.A Joseph M Wong Black & Veatch, Concord, California, U.S.A Constantine Yapijakis The Cooper Union, New York, New York, U.S.A ix © 2006 by Taylor & Francis Group, LLC Implementation of Industrial Ecology for Industrial Hazardous Waste Management Lawrence K Wang Lenox Institute of Water Technology and Krofta Engineering Corporation, Lenox, Massachusetts and Zorex Corporation, Newtonville, New York, U.S.A Donald B Aulenbach Rensselaer Polytechnic Institute, Troy, New York, U.S.A 1.1 INTRODUCTION Industrial ecology (IE) is critically reviewed, discussed, analyzed, and summarized in this chapter Topics covered include: IE definitions, goals, roles, objectives, approach, applications, implementation framework, implementation levels, industrial ecologists’ qualifications, and ways and means for analysis and design The benefits of IE are shown as they relate to sustainable agriculture, industry, and environment, zero emission and zero discharge, hazardous wastes, cleaner production, waste minimization, pollution prevention, design for environment, material substitution, dematerialization, decarbonation, greenhouse gas, process substitution, environmental restoration, and site remediation [1 – 46] Case histories using the IE concept have been gathered by the United Nations Industrial Development Organization (UNIDO), Vienna, Austria [39 –41] This chapter presents these case histories to illustrate cleaner production, zero discharge, waste minimization, material substitution, process substitution, and decarbonization 1.2 DEFINITIONS OF INDUSTRIAL ECOLOGY Industry, according to the Oxford English Dictionary, is “intelligent or clever working” as well as the particular branches of productive labor Ecology is the branch of biology that deals with the mutual relations between organisms and their environment Ecology implies more the webs of natural forces and organisms, their competition and cooperation, and how they live off one another [2 – 4] The recent introduction of the term “industrial ecology” stems from its use by Frosch and Gallopoulos [10] in a paper on environmentally favorable strategies for manufacturing Industrial ecology (IE) is now a branch of systems science for sustainability, or a framework for designing and operating industrial systems as sustainable and interdependent with natural © 2006 by Taylor & Francis Group, LLC Wang and Aulenbach systems It seeks to balance industrial production and economic performance with an emerging understanding of local and global ecological constraints [10,13,20] A system is a set of elements inter-relating in a structured way The elements are perceived as a whole with a common purpose A system’s behavior cannot be predicted simply by analysis of its individual elements The properties of a system emerge from the interaction of its elements and are distinct from their properties as separate pieces The behavior of the system results from the interaction of the elements and between the system and its environment (system ỵ environment ẳ a larger system) The definition of the elements and the setting of the system boundaries are “subjective” actions In this context, industrial systems apply not only to private sector manufacturing and service, but also to government operations, including provision of infrastructure A full definition of industrial systems will include service, agricultural, manufacturing, military and civil operations, as well as infrastructure such as landfills, recycling facilities, energy utility plants, water transmission facilities, water treatment plants, sewer systems, wastewater treatment facilities, incinerators, nuclear waste storage facilities, and transportation systems An industrial ecologist is an expert who takes a systems view, seeking to integrate and balance the environmental, business, and economic development interests of the industrial systems, and who will treat “sustainability” as a complex, whole systems challenge The industrial ecologist will work to create comprehensive solutions, often simply integrating separate proven components into holistic design concepts for possible implementation by the clients A typical industrial ecology team includes IE partners, associates, and strategic allies qualified in the areas of industrial ecology, eco-industrial parks, economic development, real estate development, finance, urban planning, architecture, engineering, ecology, sustainable agriculture, sustainable industry systems, organizational design, and so on The core capability of the IE team is the ability to integrate the contributions of these diverse fields into whole systems solutions for business, government agencies, communities, and nations 1.3 GOAL, ROLE, AND OBJECTIVES An industrial ecologist’s tasks are to interpret and adapt an understanding of the natural system and apply it to the design of man-made systems, in order to achieve a pattern of industrialization that is not only more efficient, but also intrinsically adjusted to the tolerances and characteristics of the natural system In this way, it will have a built-in insurance against further environmental surprises, because their essential causes will have been designed out [29] A practical goal of industrial ecology is to lighten the environmental impact per person and per dollar of economic activity, and the role of the industrial ecologist is to find leverage, or opportunities for considerable improvement using practical effort Industrial ecology can search for leverage wherever it may lie in the chain, from extraction and primary production through final consumption, that is, from cradle to rebirth In this regard, a performing industrial ecologist may become a preserver when achieving endless reincarnations of materials [3] An overarching goal of IE is the establishment of an industrial system that recycles virtually all of the materials It uses and releases a minimal amount of waste to the environment The industrial systems’ developmental path follows an orderly progression from Type I, to Type II, and finally to Type III industrial systems, as follows: Type I industrial systems represent an initial stage requiring a high throughput of energy and materials to function, and exhibit little or no resource recovery It is a once flow-through system with rudimentary end-of-pipe pollution controls © 2006 by Taylor & Francis Group, LLC 4 4 4 4 4 4 4 4 4 0 0 1 1 1 2 1 0 ,10 4.4 – 6.8 ,5 4.6 ,10 ,10 ,10 ,10 50 ,10 0.13 – ,10 0.87 – 23 0.17 – 3.8 0.23 0.07 2.6 12 4 4 4 4 4 4 4 4 4 1 2 1 2 2 0 0 1 30– 290 ,10 ,10 0.12– ,10 ,10– ,60 ,10– ,10 910 ,10 ,10– ,10 ,10– ,10 ,10– ,10 160 2.6 ,35 ,10 ,10 ,10 ,10 Treatment of Power Industry Wastes Benzene 1,1,1-Trichloroethane 1,1,2,2-Tetrachloroethane Chloroform 1,1-Dichloroethylene Ethyl benzene Methylene chloride Bis(2-thylhexyl)phthalate Butyl benzyl phthalate Di-n-butyl phthalate Diethyl phthalate Tetrachloroethylene Toluene Trichloroethylene Dichlorobromomethane Chlorodibromomethane 1,1,2-Trichloroethane Bromoform 1,3-Dichloropropene Phenol ,10 ,10 10 Source: USEPA 607 © 2006 by Taylor & Francis Group, LLC 608 Wang transfer-retarding deposits, which consist mainly of iron oxides resulting from corrosion This removal of iron is evident in all total boiler cleaning operations through its presence in boiler cleaning wastes Cleaning mixtures used include alkaline chelating rinses, proprietary chelating rinses, organic solvents, acid cleaning mixtures, and alkaline mixtures with oxidizing agents for copper removal Wastes from these cleaning operations will contain iron, copper, zinc, nickel, chromium, hardness, and phosphates In addition to these constituents, wastes from alkaline cleaning mixtures will contain ammonium ions, oxidizing agents, and high alkalinity; wastes from acid cleaning mixtures will contain fluorides, high acidity, and organic compounds; wastes from alkaline chelating rinses will contain high alkalinity and organic compounds; and wastes from most proprietary processes will be alkaline and will contain organic and ammonium compounds Other waste constituents present in spent chemical cleaning solutions include wide ranges of pH, high dissolved solids concentrations, and significant oxygen demands (BOD and/ or COD) The pH of spent solutions ranges from 2.5 to 11.0 depending on whether acidic or alkaline cleaning agents are employed Table presents a summary of toxic and classical pollutants detected in three common cleansing solutions: ammoniacal sodium bromate, hydrochloric acid without copper complexer, and hydrochloric acid with copper complexer Boiler Fireside Wastewater When boiler firesides are washed, the waste effluents produced contain an assortment of dissolved and suspended solids Acid wastes are common for boilers fired with high-sulfur fuels Sulfur oxides absorb onto fireside deposits, causing low pH and a high sulfate content in the waste effluent Air Preheater Wastewater Fossil fuels with significant sulfur content will produce sulfur oxides that absorb on air preheater deposits Water washing of these deposits produces an acidic effluent Alkaline reagents are often added to washwater to neutralize acidity, prevent corrosion of metallic surfaces, and maintain an alkaline pH Alkaline reagents might include soda ash (Na2CO3), caustic soda (NaOH), phosphates, and/or detergent Preheater washwater contains suspended and dissolved solids, which include sulfates, hardness, and heavy metals including copper, iron, nickel, and chromium 13.3.6 Ash Pile, Chemical Handling, and Construction Area Runoff Runoff wastewater characteristics change all the time No reliable data have been gathered The readers are referred to the literature for similar technical information [4,5] 13.3.7 Coal Pile Runoff No reliable data have been gathered for the wastewater characteristics of coal pile runoff Example (Section 13.6.3) presents the technical information on the characteristics of a combined wastewater (consisting of coal pile runoff, regeneration wastewater, and fly ash), and its treated effluent © 2006 by Taylor & Francis Group, LLC Ammoniated EDTA Solutions Pollutant Number of samples Classical pollutants (mg/L) TDS TSS COD Oil and grease pH, pH Units Phosphorous Bromide Chloride Fluoride Aluminum Calcium Barium Sodium Potassium Tin Iron Manganese Magnesium Range of detections 60,000 – 74,000 24 41 8.8– 10 260 31 21 – 45 2 Median of detections 9.2 Mean of detections Number of samples Number of detections Range of detections Median of detections Mean of detections 67,000 3 2 2 2 3 2 3 3 2 2 2 2 2 340– 1,400 – 77 24– 120 ,5 – ,5 10– 10 10– 30 ,5 – 52 60 1.5 – 6.1 ,0.2 – ,0.2 0.4 – ,0.1 – ,0.1 3.7 – 59 70– 220 ,1 – ,1 0.15 – 4.9 0.01 – 0.04 0.67 – 2.9 1,000 71 920 52 72 ,5 10 20 28 9.3 33 370 2,200– 8,300 50 – 73 11 – 21 6,900 6,300 61 16 15 1.8 0.03 3.0 ,0.2 1.7 ,0.1 26 140 ,1 2.2 0.03 1.8 (continues ) 609 © 2006 by Taylor & Francis Group, LLC Number of detections Ammonia Sodium Bromide Solutions Treatment of Power Industry Wastes Table Summary of Priority Pollutants in the Steam Electric Industry Metal Cleaning Wastes 610 Table Continued Ammoniated EDTA Solutions Pollutant Number of samples Toxic pollutants (mg/L) Toxic metals Arsenic Cadmium Chromium Copper Lead Mercury Nickel Selenium Silver Zinc Number of detections Range of detections Median of detections Ammonia Sodium Bromide Solutions Mean of detections 10,000 –26,000 12,000 17 –12,000,000 120,000 16,000 1,900,000 12,000 –140,000 68,000 73,000 79,000 –140,000 120,000 110,000 Number of samples Number of detections Range of detections Median of detections Mean of detections 2 3 5 2 3 2.5– 310,000 ,10– ,10 ,1 – ,20 ,5 – ,50 100,000– 790,000 ,10– 100 ,0.2– 15,000 80– 260,000 ,2 – 24,000 ,10– ,20 60– 1,000 40 100,000 ,10 ,10 ,20 420,000 37 5,000 57,000 8,000 ,15 510 ,5 370,000 ,10 ,0.2 1,500 ,2 500 Source: USEPA Wang © 2006 by Taylor & Francis Group, LLC Treatment of Power Industry Wastes 13.3.8 611 Wet Flue Gas Cleaning Blowdown The readers are referred to another source for more detailed information regarding wet flue gas cleaning blowdown characteristics and treatment [2,3] 13.4 WASTE TREATMENT 13.4.1 End-of-Pipe Treatment Technologies Wastewater effluents discharged to publicly owned treatment facilities are sometimes treated by physical or chemical systems to remove pollutants potentially hazardous to the POTW or which may be treated inadequately in the POTW Such treatment methods are numerous, but they generally fall into one of three broad categories in accordance with their process objectives These include pH control, removal of dissolved materials, and separation of phases The following is a summary of end-of-pipe treatment technologies commonly employed in the steam electric power generation industry, their objectives, equipment and processes required, and efficiency [12 –22] Neutralization This is a process for pH adjustment, usually to within the range – Acid or base is used as required; this is usually in the form of sulfuric acid or lime Chemical Reduction This is a process mainly used in power plants for reduction of hexavalent chromium to trivalent chromium Sulfur dioxide, sodium bisulfite, sodium metabisulfite, and ferrous salts are common reducing agents to be used in the process A pH range of 2– should be controlled The process efficiency of removal is about 99.7% Precipitation This is a process mainly used in power plants for removal of ions by forming insoluble salts Common precipitating agents are lime, hydrogen sulfide, organic precipitants, and sods ash Optimum pH depends on the ions to be removed The removal efficiency for inorganic pollutants is as follows: Copper, 96.6%; Nickel, 91.7%; Chromium, 98.8 %; Zinc, 99.7%; Phosphate, 93.6% Ion Exchange This is a process mainly used in power plants for removal of ions by sorption on the surface of a solid matrix Synthetic cation and/or anion exchange resins are required depending on the pollutants to be removed It may require pH adjustments The removal efficiency for inorganic pollutants is as follows: Cyanide, 99%; Chromium, 98%; © 2006 by Taylor & Francis Group, LLC 612 Wang Copper, 95%; Iron, 100%; Cadmium, 92%; Nickel, 100%; Zinc, 75%; Phosphate, 90%; Sulfate, 97%; Aluminum, 98% Liquid/Liquid Extraction This is a process mainly used in power plants for removal of soluble organics or chemically charged pollutants The required chemicals are immiscible solvents that may contain chelating agents It may require pH adjustments The removal efficiency for inorganic pollutants is as follows: Phenol, 99%; Chromium, 99%; Nickel, 99%; Zinc, 99%; Fluoride, 68%; Iron, 99%; Molybdenum, 90%; Disinfection This is a process for destruction of microorganisms Chlorine, hypochlorite salts, phenol, phenol derivatives, ozone, salts of heavy metals, chlorine dioxide, and so on are effective disinfectants It may require pH adjustments Adsorption This is a process mainly used in power plants for removal of sorbable contaminants Activated carbon, synthetic sorbents are the common adsorbents to be used in the process It may require pH adjustments The process removal efficiency depends on the nature of the pollutants and the composition of the waste Chemical Oxidation This is a process mainly used in power plants for destruction of cyanides using chlorine, hypochlorite salts, or ozone The process removal efficiency is about 99.6% [12 – 19] Distillation This is a process mainly used in power plants for separation of dissolved matters by evaporation of the water Multistage flash distillation, multiple-effect vertical long-tube vertical evaporation, submerged tube evaporation, and vapor compression are effective process equipment It may require pH adjustment The process removal efficiency is about 100% Reverse Osmosis (RO) This is a process mainly used in power plants for separation of dissolved matter by filtration through a semipermeable membrane Tubular membrane, hollow filter modules, or spiral-wound © 2006 by Taylor & Francis Group, LLC Treatment of Power Industry Wastes 613 flat sheet membrane can be adopted for the RO process Total dissolved solids (TDS) removal efficiency is about 93% [20] Electrodialysis (ED) This is a process mainly used in power plants for removal of dissolved polar compounds Solute is exchanged between two liquids through a selective semipermeable membrane in response to differences in chemical potential between the two liquids The process removal efficiency for TDS is about 62 –96% Freezing This is a process mainly used in power plants for separation of solute from liquid by crystallizing the solvent Either direct refrigeration, or indirect refrigeration can be used The process removal efficiency is over 99.5% 13.4.2 Solid – Liquid Separation Technologies The solid/liquid separation technologies commonly employed in the steam electric power generation industry include the following Skimming This is a process for removal of floating solids from liquid wastes It requires between about and 15 minutes of retention time, and has a removal efficiency of 70 –90% Clarification (Conventional) This is a process for removal of suspended solids by settling Typical examples are settling ponds and settling clarifiers It requires 45 minutes to hours retention time (RT), and can reduce TSS to 15 mg/L or below Flotation This is an innovative separation process for removal of suspended solids and oil and grease by flotation followed by skimming It requires very short RT (less than 30 minutes), and can achieve 90 –99% removal efficiency [15,18] Microstraining This is mechanical separation process for removal of suspended solids by passing the wastewater through a microscreen A removal efficiency for TSS is 50– 80% depending on the pore size of the microscreen to be used Filtration This is physical operation for removal of suspended solids by filtration through a bed of sand and gravel TSS removal efficiency is 50 – 90% depending on the type of filter media used and the filtration rate © 2006 by Taylor & Francis Group, LLC 614 Wang Screening This is a unit operation for removal of large solid matter by passing through screens The efficiency for large solid removal is 50 – 99% depending on the type of coarse screen or bar screen to be used Thickening This is a process for concentration of sludge by removing water Either gravity thickening or dissolved air flotation thickening can be used The thickening efficiency depends on the nature of sludge to be processed [15] Pressure Filtration This is a unit operation for separation of solid from liquid by passing through a semipermeable membrane or filter media under pressure It requires to hours of RT, and reduces 50% of moisture content Heat Drying This is a process for reducing the water content of sludge by heating Flash drying, spray drying, rotary kiln drying, or multiple hearth drying can be used Ultrafiltration This is a separation process for removal of macromolecules of suspended matter from the waste by filtration through a semipermeable membrane under pressure Total solids removal of 95% and above can be achieved Sandbed Drying This is a process for removal of moisture from sludge by evaporation and drainage through sands The RT is as long as to days It is practiced extensively by industry due its low cost Vacuum Filtration This is a process for solid – liquid separation by vacuum It requires about to minutes RT, and can produce 30% solid in filter cake Centrifugation This is a liquid/solid separation process using centrifugal force The moisture of the sludge can be reduced to 65 –70% Emulsion Breaking This process is effective for separation of emulsified oil and water It requires to hours of RT Over 99% removal efficiency can be achieved if aluminum salts, iron salts, and other demulsifiers are used at optimum pH conditions It is practised extensively by the industry [21,22] © 2006 by Taylor & Francis Group, LLC Treatment of Power Industry Wastes 13.4.3 615 Cleaner Production, Industrial Ecology, and Other Issues Traditional industries operated in a one-way, linear fashion: natural resources from the environment are used for producing products for our society, and the generated wastes are dumped back into our environment However, natural resources such as minerals and fossil fuels are present in finite amounts, and the environment has a limited capacity to absorb waste The field of industrial ecology has emerged to address these issues in the power industry The thermal energy generated from the power industry, for instance, may be reused for many domestic and industrial applications, for cost saving as well as thermal pollution control The greenhouse gas, carbon dioxide, in flue gas is a pollutant, but can also be reused as a chemical agent in wastewater treatment [8] An extension of the concept of sustainable manufacturing – industrial ecology – seeks to use resources efficiently and regards “wastes” as potential products [11,23] All electric power plants should practice cleaner production and industrial ecology strategies Additional issues of air and thermal pollution for electric power generation are addressed in detail by Wisconsin Public Service Commission [9] The World Nuclear Association [10] provides detailed technical information on nuclear electricity and related environmental, health and safety issues 13.5 TREATMENT TECHNOLOGY COSTS The investment cost, operating and maintenance costs, and energy costs for the application of control technologies to the wastewaters of the steam electric power generating industry have been analyzed These costs were developed to reflect the conventional use of technologies in this industry Several unit operation/unit process configurations have been analyzed for the cost of application of technologies and to select BPT and BAT levels of treatment A detailed presentation of the applicable treatment technologies, cost methodology, and cost data are available in the literature [6,7] 13.6 13.6.1 PLANT-SPECIFIC EXAMPLES Example Plant 1226 is a bituminous coal-, oil-, and gas-fired electricity plant [1] The recirculator cooling water system influent was sampled from a stream taken from the river and the effluent from the cooling tower blowdown stream The effluent stream is used again in the ash sluice stream Table presents the data The following additives are combined with the cooling tower influent: chlorine (biocide); calgon Cl-5 (corrosion inhibitor); sulfuric acid (scale prevention) The addition is necessary for the control of pipe corrosion © 2006 by Taylor & Francis Group, LLC 616 Wang Table Plant-Specific Treatment Data for Plant 1226 Recirculating Cooling Water Pollutant Influent Effluenta Classical pollutants (mg/L) TDS TSS TOC Phenolics TRCb Aluminum Barium Boron Calcium Cobalt Manganese Magnesium Sodium Titanium Iron Vanadium Flow (L/s) 190 14 10 0.01 ND 0.7 0.02 ND 6.9 0.007 0.2 4.5 33 0.02 2.0 ND 745 1,000 11 0.008 ,0.01 0.4 0.02 0.06 6.9 0.008 0.1 4.9 210 0.02 3.0 0.03 630 2.1 10 11 0.5 14 1.3 40 1.8 20 48 0.2 0.7 38 NA NA NA NA ,1 150 8.2 58 Toxic pollutants (mg/L) Toxic metals Antimony Arsenic Cadmium Chromium Copper Lead Mercury Nickel Silver Zinc Toxic organics Chloroform Bromoform Dichlorobromomethane Chlorodibromomethane a Percent removal not meaningful because water does not undergo any treatment Total residual chorine Source: USEPA b 13.6.2 Example Plant 1245 is an oil- and gas-fired electric generating facility The samples chosen are the influent and effluent from a once-through cooling tower stream The influent sample was taken from the makeup stream comprised of river water, with the effluent stream being a direct discharge from the condensers to the river The cooling water does not undergo any treatment to remove pollutants The data reflect the changes that may occur to such a stream due to evaporation and pipe corrosion Table presents plant-specific data for plant 1245 © 2006 by Taylor & Francis Group, LLC Treatment of Power Industry Wastes 617 Table Plant-Specific Treatment Data for Plant 1245 Once-Through Cooling Water Pollutant Influent Effluenta Classical pollutants (mg/L) TDS TSS TOC Phenolics TRCb Flow (L/s) 35,000 14 ,5 ,10 4,380 33,000 14 25 ,5 120 4,380 a Percent removal is not meaningful due to the fact that the water does not undergo any treatment b Total residual chlorine Source: USEPA Table Plant-Specific Treatment Data for Plant 3920 Fly Ash Pond Water Pollutant Influent Classical pollutant (mg/L) TDS 220 TSS 12 TOC Phenolics 0.04 Barium 0.03 Boron 0.08 Calcium 28 Cobalt ND Manganese 0.05 Magnesium 7.2 Molybdenum ND Sodium 18 Tin ND Aluminum ND Iron 0.5 Flow (L/s) 61.3 Toxic pollutants (mg/L) Toxic metals Cadmium Chromium Copper Lead Nickel Zinc Beryllium Silver ND, not detected NM, not meaningful Source: USEPA © 2006 by Taylor & Francis Group, LLC ND 11 20 25 ND ND ND Effluent Percent removal 880 73 0.04 0.06 120 0.007 0.3 6.7 10 35 ND 61.3 NM NM 40 NM NM NM NM NM NM NM NM NM NM ND 30 30 18 140 ND NM NM NM 60 28 NM NM NM Plant-Specific Treatment Data for Plant 1742 Ash Pond Water and Once-Through Cooling Water Ash Pond Pollutant Classical pollutant (mg/L) TDS TSS TOC Phenolics TRC Aluminum Barium Boron Calcium Cobalt Manganese Magnesium Molybdenum Sodium Tin Titanium Iron Vanadium Flow (L/s) Toxic pollutants (mg/L) Toxic metals Cadmium Chromium Copper Lead Nickel Silver Zinc Mercury Once-Through Cooling Water Influent Effluent Percent removal Influent Effluent Percent removal 340 100 10 0.006 370 15 150 0.01 NM 85 NM NM ND 0.05 0.2 51 0.05 0.3 20 0.05 26 0.03 ND 20 4.38 99 17 NM NM NM NM 13 NM NM 99 NM NM 1,200 90 0.260 830 NA NA NA NA NA NA NA NA NA NA NA NA NA 1,440 NM 10 10 NM NM 0.06 0.09 51 0.01 0.2 23 0.009 21 0.03 0.04 ND 4.38 340 100 10 0.006 NA 0.06 0.09 51 0.01 0.2 23 0.009 21 0.03 0.04 ND 1,440 40 22 20 17 ND 70 ND 10 1,000 78 470 ND ND 1.5 75 NM NM NM 99 NM 40 22 20 17 ND 70 NA NA NA NA NA NA NA NA Wang ND, not detected; NM, not meaningful; NA, not analyzed Source: USEPA © 2006 by Taylor & Francis Group, LLC 618 Table 10 Treatment of Power Industry Wastes Table 11 619 Plant-Specific Treatment Data for Plant 3001 Multiple Ash Ponds Water Pollutant Percent removal Influent Effluent 530 170 25 NA 0.5 0.04 0.06 38 0.04 ND 23 ND 57 ND 0.2 ND 23.3 490 30 24 0.01 0.2 64 ND 0.008 11 0.03 70 0.007 ND 0.02 unknown 82 NM NM NM NM NM 99 NM 52 NM NM NM 99 NM Toxic metals Chromium Copper Lead Nickel 10 10 ND 190 ND 35 NM 99 NM NM Toxic organics 1, 1, 2, 2-Tetrachloroethane 24 ND 99 Classical pollutant (mg/L) TDS TSS Oil and grease Phenolics Aluminum Barium Boron Calcium Manganese Cadmium Magnesium Molybdenum Sodium Tin Iron Vanadium Flow (L/s) Toxic pollutants (mg/L) Analytic methods: V.7.3.31, Data set 2; ND, not detected; NM, not meaningful; NA, not analyzed Source: USEPA 13.6.3 Example Plant 3920 is a bituminous coal- and oil-fired plant with a generating capacity of 557 MW This plant uses 1,220,000 Mg/year of coal An ash settling pond was used to remove wastes from coal pile runoff, regeneration wastes, and fly ash The influent data were obtained from the pond inlet whereas the effluent data were from the discharge stream to the river The results of this treatment are shown in Table 13.6.4 Example Plant 1742 is a bituminous coal- and oil-fired plant producing 22 MW of electricity Table 10 represents data that are from both the ash pond and the once-through cooling tower 13.6.5 Example Plant 3001 is a coal- and gas-fired facility with a generating capacity of 50 MW The plant uses approximately 277,000 Mg/year of coal The fly ash and bottom ash from the boiler are © 2006 by Taylor & Francis Group, LLC 620 Wang combined and put through a series of three settling ponds The effluent from the ponds is discharged to the river Table 11 shows the effectiveness of this treatment technology 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Kopko, S.P City of Cape Coral Reverse Osmosis Water Treatment Facility; U.S Department of Commerce, National Technical Information Service: Springfield, VA, 1997; 15p., www.afssociety.org/publications, Association of Filtration Society Wang, L.K Evaluation and Development of Physical – Chemical Techniques for the Separation of Emulsified Oil from Water, Project Report No 189; Veridian Engineering (formerly Arvin Calspan Corp.): Buffalo, NY, 1973; 31 p., May Wang, L.K Separation of emulsified oil from water Chem Indust 1975, 562 – 564 Van Berkel, C.W.M Cleaner production: a profitable road for sustainable development of Australian industry Clean Air 1999, 33 (4), 33– 38 © 2006 by Taylor & Francis Group, LLC ... explanation without intent to infringe Library of Congress Cataloging -in- Publication Data Waste treatment in the process industries / editors, Lawrence K Wang … [et al.] p cm Includes bibliographical... sustain; (d) conserving and restoring ecosystem health and maintaining biodiversity; (e) maintaining the economic viability of systems for industry, trade, and commerce; (f) coordinating design over... framework for designing and operating industrial systems as sustainable living systems interdependent with natural systems, understanding and achieving sustainable agriculture and industry will be