TREATMENT OF METAL WASTESTREAMS Fourth Edition

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1 Need for Treatment and Employee Safety ................................................................

1

2 Methods of Treatment............................................................................................. 21 3 Operation and Maintenance (O&M) ...................................................................... 75 Appendices Comprehensive Review Questions and Suggested Answers .................................. 117 How to Solve Treatment of Metal Wastestreams Arithmetic Problems ................. 125 Index .................................................................................................................. 151

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Index

INDEX A Accurate sampling, 88 Acids, 39, 82, 84 Adsorption, carbon, 65 Advanced treatment processes coprecipitation, 52, 70–71 electrocoagulation, 70 reverse osmosis, 61, 71 Aeration, 65 Alarm, 86, 87 Alkaline cleaning, 64 Amenable cyanides, 56 Amphoteric metals, 83 Analytical laboratory support, 106–110 Annual tasks, 93 Anodizing, 6 Arithmetic, 125–149 Atomic adsorption, 86, 109 Automatic sampling devices (auto-samplers), 89 B Bag prefilters, 60 Bases, 39, 84 Basic conversion factors, 131 Basic formulas, 132–134 Basis metal, 6 Batch processes, 30, 31, 36, 39, 58–59 Bearings, 95 Bench tests, 34, 36, 45, 51 Buchner funnel, 36 Buffer capacity, 42 Buffer solutions, 102 Burns, 84 C Calibrating meters, 102–103, 109–110 Carbon adsorption, 65 Cardiopulmonary resuscitation (CPR), 84 Cartridge prefilters, 60 Caustic soda (sodium hydroxide) safety, 82–83 uses, 55, 82, 83 Cavitation, 96 Centrifugal pumps, 97, 105 Chain of custody, 109 Charges, sewer, 5

Chelating agents, 50–51 Chemical equilibrium, 39 Chemical feed systems (feeders), 105–106 calculations, 138–140 Chemical milling, 6 Chemical mixer, 106 Chemical processes, 85 Chemicals characteristics, 7–8, 14 handling and storage, 8–9, 81–85 information on, 10, 12 uses, 81, 82 Chemical solutions, calculations, 137–138 CHEMTREC [(800) 424-9300], 18 Chlorine, 58, 84–85, 93 Chromium, 27, 54–56, 59, 60 Circuit boards, 104 Circuit breakers, 96, 103, 104, 105, 106 Cleaning meters and probes, 101–102 Cleansing agents, 5 Clothing, protective, 9, 82 Coagulants, calculations, 140–143 Coagulation, 45 Coatings, 6 Color comparison kits, 107, 108, 109 Common ion effects, 44 Common metals, 44 filtration, 45, 48, 49 hydroxide precipitation, 44–50 Lamella settler, 45, 46, 47 optimum pH, 44 removal, 44–50 sulfide precipitation, 44, 50 treatment, 27 Complexed metals, 27 chelating and complexing agents, 50–51 coprecipitation, 52 dithiocarbamates (DTC), 52 ferrous sulfate, 52 high-pH precipitation, 51 hydroxide precipitation, 51 insoluble starch xanthate (ISX), 53–54 pH ranges, 51 precipitation, 50–54 calculations, 144 problems, 50–51 reduction, 51 removal, 50–54 sodium borohydride, 53

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Wastewater Treatment

Complexed metals (continued) sulfide precipitation, 51 treatment, 27 trisodium salt, 52–53 Complexing agents, 6, 50–51 Composite (proportional) samples, 88 Conductivity, 39 Constant differential meter, 90, 91 Containers, sampling, 89 Containment procedures, 81 Contamination electrode, 103 polymers, 83 raw wastes, 31 sludge, 5 spills, 81 Continuous processes, 30, 32, 39, 58–59 Controller, pH, 100 Control measures, 9 Control panel, 86, 87 Controls, pump, 95–96 Conversion factors, 131 Coprecipitation, 52, 70–71 Corrosive wastes, 5 Costs, 5, 32, 36, 65, 85, 92 Couplings, 95 CPR (cardiopulmonary resuscitation), 84 Cyanide amenable to chlorination, 56 batch treatment, 30, 31, 58–59 calculations, 147–149 chemistry, 56–57 continuous treatment, 58–59 ferrocyanide complexes, 59 ORP, 57, 58 oxidation, 56–59 refractory, 56 safety, 56, 101 sources, 56 treatment, 27, 56 D Daily tasks, 86, 93 Database information, 5 Degreasing agents, 5 Diaphragm meters, 91 Diaphragm pumps, 105 Differential producers, 91, 92 Diking, 81 Displacement meters, 91, 92 Displacement pumps, 94, 99 Disposal methods, waste, 9 Dithiocarbamates (DTC), 52 DPD method, 59 Dynamic pumps, 94

E Electrical conductivity, 39 Electrical controls, pumps, 95–96 Electrical maintenance, 92 Electrocoagulation, 70 Electrodes, 99–101, 103 Electrodialysis, 61 Electroless plating, 5, 6 Electrolyte, 39, 61 Electroplating, 5–6 Electrowinning, 27 Emergencies, 18, 84 Emergency team, 18 Employee Right-To-Know (RTK) laws, 9–18 Emulsified oils, 64 Environment, 5, 65 Equalization tank, 32, 55 Equivalence point, 42 Errors, sampling, 88, 89, 109 Etching and chemical milling, 6 Evaporation, 59, 61 Exhaust systems, 93 Explosion and fire hazard data, 8 Explosive wastes, 5 Eye protection, 9 F Ferrocyanide complexes, 59 Ferrous sulfate, 52 Filter press cake, 65, 69 Filter presses, 65–69 Filtration, 45, 48, 49 Fire and explosion hazard data, 8 First aid, 13, 84–85 Flammable wastes, 5 Floating oils, 64 Flocculation, 36, 45, 104 Flow conservation and equalization, 135 Flow equalization tank, 32, 55 Flow formula, 90 Flow measurements calibration, 102–103 metering devices, 90–92 operators’ responsibilities, 90 Flowmeters, 90–92 Flumes, 91 Formulas, 132–134 Fuses, 96, 103, 104, 105, 106 G Gas chromatograph, 109 Globally Harmonized System of Classification and Labeling of Chemicals (GHS), 7

Index Gloves, protective, 9 Good housekeeping, 32 Grab samples, 88 Ground-loop problem, 103

regeneration, 60–61, 62, 63 throughput capacity loss, 62 troubleshooting, 62–63 water quality problems, 62–63 Isopropanol, 34, 102 H J

Handling chemicals, 8–9, 81–85 Hazard communication, 9–18 chemical information, 10, 12 first aid, 13 hazardous conditions, 12 hazardous materials, 10, 12, 13 labeling, 9, 10, 11, 12, 15–17 safety data sheets (SDSs), 10, 11, 12, 13–15 training, 11, 17–18 Hazard Communication Standard, 29 CFR 1910.1200, 9, 10 Hazardous chemicals, 81–85 Hazardous conditions, 12 Hazardous ingredients, 7 Hazardous Material Information System (HMIS), 17 Hazardous materials, 10, 12, 13 Hazardous polymerization, 8 Hazardous reactivity, 8 Head area meters, 91 Health hazard data, 8 Hexavalent chromium batch treatment, 30, 31 calculations, 144–147 reduction, 54–56 sources, 54 treatment, 27 High-pH precipitation, 51 Holding time for samples, 89 Hydroquinone, 54, 103 Hydroxide precipitation, 30, 44–50, 51 calculations, 144 Hygroscopic, 83 Hypochlorite, 83 I IDLH (Immediately Dangerous to Life or Health), 93 Immersion plating, 6 Impeller, 96 Industrial sources of wastewater, 5–6 Industrial waste ordinances, 5 Insoluble starch xanthate (ISX), 53–54 Instrumentation, 104 Inventory, 93 Ion exchange chromium recovery, 59, 60 mixed-bed unit, 61 plating wastes, 59–63 precious metals, 59–63 pressure drop, excessive, 63

Jar tests, 34, 36, 45 K (NO LISTINGS) L Labeling, hazard communication, 9, 10, 11, 12, 15–17 Labeling samples, 89 Laboratory, 89, 90, 106–110 Lacrymator, 57 Lamella settler, 45, 46, 47 Landfills, 65 Leak control, 9, 81, 83, 86, 93 LED (light emitting diode), 103 Lime, 82, 83 Lubrication of pumps, 95 M Maintenance electrical, 92 exhaust systems, 93 flowmeters, 90–92 handling of chemicals, 81–85 inventory, 93 meters, 90–92 preventive maintenance program, 92 process wastes, 81 pumps, 94–99 records, 92 safety, 81–85, 92 storage of chemicals, 81–85 typical tasks, 92–93 ventilation systems, 93 Material safety data sheets (MSDSs), 7–9 Mechanical seals, 98 Metal finishing, 5 Metal wastestreams, 5 Meters, 90–92 Methods of treatment batch processes, 30, 31, 36, 39, 58–59 chromium, 27, 54–56 common metals, 27, 44–50 complexed metals, 27, 50–54 continuous processes, 30, 32, 39, 58–59 conventional chemical treatment methods, 29

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Wastewater Treatment

Methods of treatment (continued) coprecipitation, 52, 70–71 cyanide, 27, 56–59 electrocoagulation, 70 hexavalent chromium, 27, 54–56 neutralization, 39–43 oily wastes, 27, 64 precious metals, 27, 59–63 reverse osmosis, 61, 71 sludge, 65–69 solvent control, 64 toxic organics control, 27, 64–65 Mixer, chemical, 106 Monitor, ORP, 101 Monthly tasks, 87, 93 Mother circuit boards, 104 Motors, 95 MSDSs (material safety data sheets), 7–9 N National Fire Protection Association (NFPA) 704 Hazard Rating, 17 National Pollutant Discharge Elimination System (NPDES), 5 Need for treatment, 5 Neutralization, 39–43 acids and bases, 39 batch processes, 39 calculations, 143–144 continuous processes, 39 optimum pH, 44 pH measurement, 106, 107, 108, 109 safety, 43 Noisy pumps, 96 O Observations, 86 Oil and grease removal, probes, 102 Oil separation, 64, 86 Oil wastes, 27, 64 Operation daily, 86 first aid, 84–85 flow measurements, 90–92 handling of chemicals, 81–85 laboratory, 89, 90, 106–110 meters, 90–92 monthly, 87 observations, 86 polymer calculations, 36–39 preservation of samples, 89 process chemicals, 81 process wastes, 81 records, 86 safety, 81–85

sampling, 88–90 storage of chemicals, 81–85 weekly, 87 Operator’s tasks, 81 Ordinances, sewer-use and industrial waste, 5 Organic solvents, 5 Orifice meters, 91 ORP See Oxidation-reduction potential OSHA’s Hazard Communication Standard, 29 CFR 1910.1200, 9, 10 Oxidation, cyanide, 56–59 Oxidation-reduction potential (ORP), 53, 54 cyanide, 57, 58 hexavalent chromium treatment, 55 meters and probes, 101 calibration, 103, 109–110 cleaning, 101–102 hydroquinone, 54, 103 monitor, 101 scales, 109–110 sensors, 101 standard buffer solutions, 102 troubleshooting, 103–104, 106 P Palmer-Bowlus, 91 Parshall flumes, 91 Parts, spare, 93 Passivating, 6 Pass-through, NPDES effluent limitations, 5 Pattern plating, 6 pH adjustment See Neutralization pH meters and probes, 99 calibration, 102–103, 109–110 cleaning, 101–102 controller, 100 scales, 109–110 troubleshooting, 103–104, 105–106 Phone numbers, emergency, 18 Physical/chemical characteristics, 7–8, 14 Piston meters, 91 Pitot tubes, 92 Plate and frame filter presses, 65–69 Plating, 5–6 Plug valve, 98 Pollutants, need for control, 5 Polyelectrolytes, 33 Polymerization, 8 Polymers, 33–39 calculations, 36–39, 140–143 coagulation, 45 contamination, 83 flocculation, 45

Index Polymers (continued) flow rate, 104 properties, 34 safety, 82 sedimentation, 45 Positive displacement pumps, 99, 105 Potting compounds, 102 POTW (publicly owned treatment works), 5 Precious metal recovery electrodialysis, 61 electrolyte, 61 evaporation, 59, 61 ion exchange, 59–63 reverse osmosis, 61 treatment, 27 Precipitate removal, probes, 102 Preservation of samples, 89 Pressure drop, excessive, 63 Pretreatment, 5 Pretreatment standards, 28 Preventive maintenance, 92 Printed circuit board manufacturing, 5, 6 Probes, 99–104 Process chemicals, 81, 82 Process upsets, 104 Propeller meters, 91 Proportional samples, 88 Protective clothing, 9, 82 Protective gloves, 9 Publicly owned treatment works (POTW), 5 Pumps cavitation, 96 driving equipment, 95 electrical controls, 95–96 lubrication, 95 noise, 96 starting, 95, 97–98, 99 stopping, 95, 97, 98, 99 troubleshooting, 96, 105 types, 94 Q Quality control in laboratory, 90 Quicklime, 82, 83 R Reactivity data, 8 Records, 86, 92 Recycling of water, 32 Redox, 54 Reducing agents, 55 Reduction processes complexed metals, 51 hexavalent chromium, 54–56

Refractory cyanides, 56 Regeneration, ion exchange, 60–61, 62, 63 Representative samples, 88–89 Respiratory protection, 9 Reverse osmosis, 61, 71 Right-To-Know (RTK) laws, 9–18 Rinse water treatment, 31, 32, 33, 56, 58 Rotameter, 90, 91 S Sacrificial anodes, 70 Safe handling and use, 8–9 Safety acids, 43, 82, 84 bases, 43, 84 caustic (sodium hydroxide), 82–83 chemicals, 81–85 chlorine, 58, 84–85 cleaning probes, 101 cyanide, 56, 101 first aid, 84–85 Hazard Communication Standard (HCS) and Worker Right-To-Know (RTK) Laws, 9–18 maintenance, 81–85, 92 MSDSs, 7–9 neutralization, 43 operation, 81–85 pH adjustment, 43 polymers, 82 troubleshooting, 81–85 Safety data sheets (SDSs), 10, 11, 12, 13–15 Sampling accuracy, 88 analysis, 136 automatic sampling devices (auto-samplers), 89 calculations, 136 chain of custody, 109 composite (proportional) samples, 88 containers, 89 devices, 89 errors, 88, 89, 109 grab samples, 88 holding time, 89 importance, 88 labeling, 89 laboratory, 89, 90 preservation, 89 quality control in laboratory, 90 representative samples, 88–89 split samples, 109 time of, 89 types, 88 Scales, pH and ORP, 109–110 SDSs (safety data sheets), 10, 11, 12, 13–15 Sedimentation, 45

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Wastewater Treatment

Segregation, wastestreams, 6, 27, 32, 64 Semiannual tasks, 93 Sensors, ORP, 101 Sewer service charges, 5 Sewer-use ordinances, 5 Sludge cake, 65, 69 containers, 65 contamination, 5 disposal, 65 plate and frame filter presses, 65–69 polymer dose, 36 source, 31, 65 treatment, 36, 65–69 calculations, 149 Sodium borohydride, 53 Sodium hydroxide (caustic soda) safety, 82–83 uses, 55, 82, 83 Solenoid valve, 105 Solvent control, 32, 64 Source control, 32 Sources of wastewater, 5–6, 54, 56, 61, 64 Spare parts, 93 Specific gravity, 7, 105 Spectrophotometer, 107 Spill control, 8–9, 81, 86 Storage of chemicals, 8–9, 81–85 Sulfide precipitation, 44, 50, 51 Surface preparation, printed circuit board manufacturing, 6 Suspended solids, 31, 45, 56, 58 T Tab plating, 6 Threshold limit value (TLV), 7 Throughput capacity loss, 62 Time of sampling, 89 Titration curve, 42–43 Toxicology data, 8, 14 Toxic organics control, 27, 64–65 Toxic wastes, 5 Training, hazard communication, 11 Treatment batch processes, 30, 31, 36, 39, 58–59 chromium, 27, 54–56 common metals, 27, 44–50 complexed metals, 27, 50–54 continuous processes, 30, 32, 39, 58–59 conventional chemical treatment methods, 29 coprecipitation, 52, 70–71 cyanide, 27, 56–59 electrocoagulation, 70 hexavalent chromium, 27, 54–56 methods, 27 need, 5 neutralization, 39–43 oily wastes, 27, 64

precious metals, 27, 59–63 reverse osmosis, 61, 71 sludge, 65–69 solvent control, 64 toxic organics control, 27, 64–65 Treatment process chemicals, 81, 82 Trisodium salt, 52–53 Trivalent chromium treatment, 55 Troubleshooting calibrating probes, 103–104 cleaning meters and probes, 101–102 instrumentation, 104 ion exchange, 62–63 ORP meter, 103–104, 106 pH meter, 103–104, 105–106 pumps, 96, 105 safety, 81–85 waste not flocculating, 104 Types of samples, 88 U UN Globally Harmonized System of Classification and Labeling of Chemicals (GHS), 7 Upset processes, 104 V Valves, 97, 98, 105 Velocity meters, 91, 92 Ventilation, 9, 55, 82, 93 Venturi tubes, 91 Volatilization, 65 W Waste disposal methods, 9 Waste not flocculating, 104 Wastewater segregation, 6 Wastewater sources, 5–6, 54, 56, 61, 64 Water hammer, 95, 98 Water quality problems, 62–63 Water quality standards, 5, 28 Weekly tasks, 87, 93 Weirs, 91 Worker Right-To-Know (RTK) laws, 9–18 X (NO LISTINGS) Y (NO LISTINGS) Z (NO LISTINGS)