Document 3eGXk09Mx8wL3dXRD7V9d67X3

UNITED STATES ENVIRONMENTAL PROTECTION AGENCY ` WASHINGTON. D.C. 20460 . September 9, 1975 Mr. Donald Sargent Program Manager ' Versar, Inc. 6621 Electronic Drive, Springfield, Virginia 22151 * . Subject: Contract No. 68-01-3259 Dear Mr. Sargent: This is to assign delivery order II under the subject contract for the . "Assessment of wastewater management and treatment technology, and associated costs in practice or available, to determine toxic pollutant effluent concentrations and daily load achievable in the manufacture of PCB's and by selected users of PCB's. The abbreviation, PCB's means polychlorinated, biphenyls." The subtask under this delivery order are outlined in the attach ment. Reports: Deliver the draft interim reports on subtask 1 on or before October 1, 1975. Deliver the interim reports on subtasks 2 and 3 on or before October 15, 1975. Deliver the EPA-approved final report on or < before October 31, 1975. .. The information gathered in delivery order II shall be incorporated I and used in delivery order I. Sincerely, '- cc: Mr. W.M. Rugemer, Jr.' R&D- Procurement Section David Garpet't, P.E., Chief, Special TProjects Branch * 1 oSNN 330378 *1 *U' l,'M- ?: < "5V 3 STLCOPCB4077022 I I .. T I.Jt- 1 i ' Sks^Xfisa^si^usikrr- y^ ~ , o 'V* /'^/^JTask-l - Manufacturing of PCB''s I. f'v a- Completely describe the manufacturing process including methods used in storing, handling, and < i- shipping the finished product. Describe the chemical composition of the PCS's being fv liii. J w . : b. manufactured. As available identify the businesses to which the PCli's are being sold. . ^ . Completely describe the wastewater management . treatment and effluent disposal practices currently ,1 i in use and planned including materials handling, I: . process controls and "good housekeeping" measures designed to prevent or reduce the introduction of j j . PCD's in process wastewater, cooling water discharges and stormwater runoff. Ascertain the . rates of flow, PC3's concentrations, pH and oils j and greases in each of these and any other v/aste iU i I streams such as sewage and laundry wastes based on monitoring and other information obtained from the manufacturer. Federal, State c-r local enforcement agencies or other sources. In addition, describe ii fc : '\y i ;- #; #, '. ti't. I ^ solid wastes, air pollution, groundwater pollution control practices particularly as they relate to PCli's. ______ flow r!w?f[r?.:^s of pro__c_e__s__s_e__s_ indicating current and suggested u-oints of ~monxorins concentratior.s and * f ate Assemble, examine and technically evaluate alternative wastewater management treatment and ; / i: effluent disposal methods that could be implemented by the manufacturer to achieve or approach liv achieving effluent limitations identified by the project officer as necessary to meet the purpose of Section 307(a) including zero aqueous discharge to . t ;<* navigable waters and prohibition. These #;< . alternatives should include, if appropriate, but i ;i. a l.v : I. : pr I` i; i 'U `i DSW 330379 vi vi STLCOPCB4077023 ,1 \ ' I II ' ,b lit ^ I` i . *4^4Jka4 V5 -I :i !{ not limited tos (1) manufacturing process, materials handling modification, and substitute products; (2) treatment and affluent disposal measures practiced by l;CD*s users or other industries tnat might be successfully transferable; ' and (3} treatment and effluent disposal measures practiced by foreign manufacturers of PCB*s. Assess, evaluate and compare the alternatives examined in terms of.their effectiveness and reliability in achieving specified concentrations and amounts of PC3*s in their ultimate disposal of PC3's in aqueous navigable water discharges and the resulting introduction, if any, of PCB's into the .air, soil or groundwater, their operation and maintenance characteristics, and their capacity for being installed and put into operation within one year after promulgation and within three years after promulgation of Section 307(a) effluent standards. Flow diagrams should be included where applicable to show process methods and/or systems involved. . d. . Assess the costs of each of the alternative v;astewater management, treatment and effluent disposal methods and systems in terms of capital costs and annual operating costs in tabulae:, graphic and narrative form as appropriate including terms such as total annual cost par 1000 gallons and increased cost per unit of production. A . description of monitoring costs should be included. . All findings in the report shall be documented with . : references to published literature, information and data : obtained from the manufacturer or other sources. Complete I descriptions of cost assumptions and computations used shall . be included. One or more site visits should be made to the manufacturing facility to directly observe manufacturing, materials handling and wastewater management practices. Attempt should be made to obtain any and all information . possessed by the manufacturer pertaining to the above sub task.- rri**-i* ?r i * ' ` ! .i ;i - * ./ DSW 330380 j STLCOPCB4077024 W % i:'- i $I <it.1 tA. l* 1 '4 I /i i; i ' I*. i A. i. <- . Ij; ---- Task 2 *-'All Types of Transformer and Capacitor Manufacturing Using PCB1s . Prepare a report on the jjower and electronic transformer arid capacitor manufacturing industry relative to its use of PCB1 s and PCB's wastewater .manaaeaent, treatment, and effluent disposal. a. Completely describe the typical usa of PC3*s in the ! . manufacture of power and electronic types of transformers and capacitors including a description of the formulations and amounts of PCB's used and the methods of handlingPCB*s and waste streams containing PCB's. Describe the ultimate use and . disposition of manufactured transformers and capacitors in terms of expected period of use, x frequency of replacement of the FCB's, the . -treatment and ultimate disposal of replaced PCB's and the typical disposal of discarded transformers ' and capacitors. ' '. ` b. Describe in tabular and narrative form the transformer and capacitor manufacturing industry located in the U.S. in terras of ownership, name, location and size of plants, and their annual use of PCB13 and as available, the disposal of wastewaters generated in each. .' c. Completely describe the typical wastewater management, treatment, and effluent disposal measures used and potentially useful to reduce PCB's in wastewaters or prevent the loss of PCB's including process wastewater, stormwater, cooling waters or other wastewater generated in and discharged from the various types of facilities. Ascertain the rates of flow, PCB's concentrations, and pH and oil and greases in each of the streams. Identify the direct or indirect means by.which PCB's are introduced into such effluents regardless of transport media. '. . . d. Assemble, examine and technically evaluate the full array of alternative wastewater management, treatment and effluent disposal measures that could >M ' .7 * ` .i . i* 'j IV i' .i DSW 330381 rr.T STLCOPCB4077025 ' t. I ? $. .id aii.*l!.`..-. ! .1 . -MJA'.L I . *>. ... Urt: *&* 1 <: . i:1Pu.i. I ,| ' .j'hiiu. be implemented by the manufacturer to achieve or )approach achieving effluent limitations identified 6 by the project officer as necessary to meet the purposes of Section 307(a) including zero aqueous `discharge to navigable waters and prohibition. Ehese alternatives should include, if appropriate, but not limited to: (1) `'good housekeeping", treatment, PCS's loss prevention, and effluent I 1 disposal measures normally practiced within the industry; (2) wastewater management, treatment and effluent disposal measures practiced by other industries that might be transferable; (3) manufacturing process and/or materials handling and modification that might be used to eliminate or reduce the direct or indirect introduction of PCB's into wastewaters; and (4) use of alternative n . * et ;t materials or less polluting types of PC3's to wholly or partially substitute the current use of < (. r-CB * s. - . Assess the costs of each of the alternative v/astev/ater treatment management, and effluent disposal methods and systems in terms of capital costs and annual operating costs in tabular, graphic and narrative form as appropriata including terms such as total annual coat per 1000 gallons and increased cost per unit of p reduction. A description of monitoring costs should be included. All findings in the report should be documented with references to published literature, information and data obtained from the manufacturer or ether sources or complete descriptions of computations used, as appropriate. One or more site visits should be made to each of at least two major manufacturers of electronic type transformers and capacitors. 'FF' s I. . I* lfI - ' *i ; Mi Jr U "l I, / ..r i v i ; DSW 330382 4 STLCOPCB4077026 PROCURxHiiDJT -REQUEST RATIONALE 1. Title of Project; Assessment of v/astewatar management and traataenc technology, and associated costs in practice or available, to determine toxic pollutant effluent concentrations and daily load achievable in. the manufacture of PCS1s and by selected users of PCS's* The abbreviation, PCS'3 means polychlorinated biphenyls* 2* Estimated Period of Perforracce; Dependent upon senedoling ox required nearing. ' . 3* Project Officer; Ralph Eoltja. 4. Background: - Proposed toxic pollutant effluent standards ware puoiished by fi?A on December 27, 1973, pursuant to Section 307(a) of the Federal water Pollution Control . Act Junendments* Evidence presented at the required . adjudicatory hearing which followed publication resulted ' in the conclusion that the standards were based on .inadequate data, leaving the Agency with no choice but to reconsider the entire matter. One inadequacy of the proposed standards was the evident lack of treatment technology capable of achieving the . required effluent concentrations within the' time allowed. ; 5- Purpose: Additional information is required concerning specific wastewater management and treatment processes and associated costs in use in_specific facilities, in . the pilot--demonstration stage or which might be successfully transferable in order to assemble and x- assess alternatives and to identify the best treatment methods resulting in the highest quality affluents and then to establish enforceable toxic pollutant effluent standards for industrial dischargers. - *' * ... The information sought through issuance of the subject procurement is of high priority as it is basic to the . femulation of toxic pollutant standards and any technological and/or environmental variance judgments that may ba necessary. . 6. Procurement Abstract; Implementation of Section 307(a) of tiie FWPCA requires EPA to promulgate effluent standards controlling the discharge of toxic pollutants. ft % *- ; fc: U 1 DSW 330383 .} STLCOPCB4077027 / Data concerning wastewater management technology and associated costs are essential to the formulation of feasible, defensible, enforceable effluent standards. 7. Score of Work: Task 1 -- Manufacturing of PCB's a. Completely describe the manufacturing process including methods used in storing, handling, and ' shipping the finished product. Describe the chemical composition of the PC3*s being manufactured. As available identify the businesses to-which the PCB's are being sold. b. Completely describe the wastewater management treatment and affluent disposal practices currently in use and planned including materials handling, process controls and "gccd housekeeping" measures designed to prevent or reduce the introduction of PCB's in process wastewater, cooling water discharges and stormwater runoff. Ascertain the rates of flow,.PCB's concentrations, pH and oils and greases in each of these and any other waste streams such as sewage and laundry wastes based on monitoring and other information obtained from the manufacturer, Federal, State or local enforcement agencies or other sources. In addition, describe solid wastes, air pollution, groundwater pollution control practices particularly as they relate to PCB's. Include flow diagrams of processes . indicating current and suggested points of monitoring as well as PCB's concentrations and " rates of flow. . c. Assemble, examine and technically evaluate alternative wastewater management treatment and effluent disposal methods that could be implemented by the manufacturer to achieve or approach . achieving effluent limitations identified by the project officer as necessary to meet the purpose of Section 307(a) including zero aqueous discharge to navigable waters.and prohibition. These alternatives snould include, if appropriate, but \ iv: & I i ; t v: y:v V- - v ti-\ K r i;. I !, j ;; ; : DSW 330384 I STLCOPCB4077028 - . ' ' not United to: (i) manufacturing process, materials handling modification, and substitute products; (2) treatment and effluent disposal measures practiced by i'CS's users or other industries taat night be successfully transferable; and (3) treatment and effluent disposal measures practiced by foreign manufacturers of PCB's. Assess, evaluate and compare the alternatives examined in terns of their effectiveness and reliability in achieving specified concentrations and amounts of PCB's in their ultimata disposal of PC3's in aqueous navigable water discharges and the . resulting introduction, if any, of PCS * s into the air, soil or groundwater, their operation and maintenance characteristics, and their capacity for ' being installed and put into operation withinone year after promulgation and within three years after promulgation of Section 307(a) effluent standards. Flew diagrams should be included where applicable to shew process methods and/or systems involved. d. Assess the costs of each of the alternative - wastewater management, treatment and effluent . disposal methods and systems in terms of capital costs and annual operating costs in tabular, . graphic and narrative form as appropriate including . terms such as total annual cost par 1000 gallons and increased cost per unit of production. A description of monitoring costs should be included. All findings in the report shall be documented with references to published literature, information and data . obtained from the manufacturer or other sources. Complete _ descriptions of cost assumptions and computations used, shall be included. . ' . .' '...... * . . * ` . . One or raora site visits should be made to the manufacturing facility to directly observe manufacturing, materials handling and wastewater management practices. Attempt should be made to obtain any and all information possessed bv the manufacturer pertaining to the above subtasks. f. ' $ r- f V. - DSW 330385 STLCOPCB4077029 . Ta3k 2 - All Types of Tran3former and Capacitor lianuf ecturing Using PCS's Prepare a report on the power and electronic transformer and capacitor manufacturing industry relative to its use of PCS'5 and PCS*3 wastewater management, treatment, and effluent disposal- .. ` - a. '. Ccsr.pletaly describe the typical use-of PCB * 3 in the manufacture of power and electronic type3 of transformers and capacitors including a description of the formulations and amounts of FCB's used and the methods of handling PC3*s and waste streams containing PCB's. Describe the ultimata use and disposition of manufactured transformers and capacitors in terms of expected period- of use, frequency of replacement of the PCB*3, tha treatment and ultimate disposal cf replaced FC3'3 and the typical disposal of discarded transformers and capacitors. b. ' Describe in tabular and narrative form the transformer and capacitor manufacturing industry located in the U.S. in terms of ownership, name, location ana size of plants, and their annual use of PCS's.and as available, the disposal of wastewaters generated in each. c. ' Completely describe the typical wastewater management, treatment, and effluent disposal measures used and potentially useful to reduce PC3*s in wastewaters or prevent the less of PC3*s including process wastewater, stormwater, cooling waters or other wastewater generated'in and discharged from the various types of facilities. Ascertain the rates of flow, PCB's concentrations, and pH and oil and greases in each of the streams. Identify the direct or indirect means by which PCB*3 are introduced into such effluents regardless of transport media. - - ` d. Assemble, examine and technically evaluate the full array of alternative wastewater management, treatment and effluent disposal measures that could DSW 330386 l j" r . ,: }> j.r: * j j i ! t [ : i STLCOPCB4077030 be implemented by the manufacturer to achieve or approach achieving effluent limitations identified by the project officer as necessary to meet the purposes of Section 307(a) including zero aqueous ` discharge to navigable waters and prohibition. these alternatives should include, if appropriate, but not limited to; (1) "good housekeeping", treatment, PC3*s loss prevention, and effluent disposal measures normally practiced within tha industry; (2) wastewater management, treatment and effluent disposal measures practiced by other industries that night be transferable? (3) manufacturing process and/or materials handling and . modification that might ba used to eliminate or reduce the direct or indirect introduction of PCS*s into wastewaters; and (4) use of alternative . materials or less polluting types of ?CS*3 to . wholly or partially substitute the current use of FCB's. ~ e. Assess the costs of each of.the alternative wastewater treatment management, and effluent disposal methods and systems in terms of capital costs and annual operating costs in tabular, . graphic and narrative form as appropriate including terms such as total annual cost per 1000 gallons : and increased cost per unit of production. A description of monitoring costs should be included. Ail findings in the report should be documented with references to published literature, information, and data obtained from the manufacturer or ether sources or complete descriptions of computations used, as appropriate. One or more site visits should be made to each of at least two major manufacturers of electronic type transformers and capacitors. ' P Proposed Budget; 9. Kaports: Deliver 10 copies of draft interim report on Task 1 on or before September 15, 1975. Deliver 100 codes of EPA-aporoved final report on or before September 30, 1975. ' OSC < ~ XtAs DSW 330387 STLCOPCB4077031 Deliver 10 copies of draft interim report on Tasks 2 and 3 on or before September 30, 1375. Deliver 100 copies of ZPA-approved final reporr on or before October 15, 197o. . ^ 10. Clearance Required; I-ione hJ/Jyf/Jo/rj -- i s*t- w ' i^GGsr* -tZ* Py' ?Sr- J*, /I / l r / * 1. r. ). Ai . fc: Vff: r. V. C. / DSW 330388 . t : - STLCOPCB4077032 PLANT WASTE ANALYSIS 1. COMPANY;_________________________________________________ 2. PLANT LOCATION._________________________________ 3. AVERAGE ANNUAL THRU PUT lbs (tons) 4. PRODUCT(S) - (name) DATE PLANT AGE (a) (b) (c) (*0 5. PROCESS SOLID WASTE _________ ____________________________________________ . ___________________ lbs/year Ibs/year Ibs/year lbs/year Ibs/year (dry basis) 6. PROCESS DESCRIPTION - including methods used in storing, handling, and shipping the finished product. dsnn STLCOPCB4077033 Page 2 7. Process Flow Diagram (block diagram) indicating water Flow through the system including current and suggested points of monitoring as well as PCB concentration and rate of flow. (Please include location of waste streams) * DSW 330390 STLCOPCB4077034 Page 3 7 A. COMPOSITION OF EFFLUENT STREAMS BEFORE TREATMENT Constituents Present Stream No. 1 Stream No. 2 Stream No. 3 Process Source Quantity GPP Acidity_______ Alkalinity Ammonia BOD Carbonate Chloride COD Color Fluoride Hardness Iron, ferrous Nitrate Nitrite Nitrogen-Kjeldahl Oil PCB EH______________ Phosphates______ Settleable Solids Silica Specific Conductance Sulfate TOC =tf4 STLCOPCB4077035 Page 4 Constituents PresentStream No. 1 Stream No. 2 Stream No. 3 Total Dissolved Solids __________________________________________________ Totaj Solids' ______________ ;; Total Suspended Solids; Total Volatile Solids _______________ .______________________________________ Turbidity _________ _____________ '. Trace Metals Aluminum______ ____;_______________________________________________________ Arsenic_______ _____ _______________________ ; ~ Barium _____________________, Boron_________ Cadmium______ _; Chromium _____________ __ . Copper____________ Iron (total & dissolved) __________________________;____________________ i_____________ Lead ________ ___;_____________________________ _________________________________ Magnesium_____ _' Manganese ____________________________________________ __________ __________ Mercury ____________________________________________________________ ________ Molybdenum ________________ . Nickel ___________________ .; Potassium _____________________________ Selenium _____________________________________ _______________________________ Sodium;________________________________ Strontium. ^*nc _______________!__________________________________ DSW 330392 STLCOPCB4077036 8. SOURCE RAW MATERIAL Page 5 9. WATER INPUTS TO PLANT Type Quanty GPP Comments (a) River (b) Lake (c) Municipal (d) Well (e) Mi ne/Quarry (f) Other 10. WATER USAGE Type _______________ .__________ _________ ._____ ________________ _______________ ___________ __________________ _______________ ^ ____________ _ _______________________ _______________________ ____________________ __ Total Quantity-- GPP % Recycle (a) Process (b) Cooling (c) Boiler (d) Sanitary (e) Dust Control (f) Hydraulic (g) Other _______________ _________ _______________ _______________ _______ ________ _______________ _______________ _______________________ _______________________ _______________________ ______________ ________ .. _______________________ (h) Comments # DSW 330393 STLCOPCB4077037 Page 6 11. EFFLUENTS FROM PROCESS AND/OR PROPERTY * . Outfall No. Source GPP .1. 2 3. 4. 5. . * Includes drainage and runoff >. COMPOSITION OF : EFFLUENT STREAMS AFTER TREATMENT Constituents * Present Stream No. 1 Ave. Range Stream No. 2 Ave. Range Stream No. 3 Ave. Range INTAKE Intake Water Ave. Range Acidity Alkalinity Ammonia BOD Carbonate Chloride COD Color Fluoride Hardness Iron, ferrous . ' . Nitrate Nitrite Nitrogen-Kjeldahl Oil PCB pH Phosphates . Settleable Solids * See attached list on next page for additional applicable constituents and tests. Use back of this sheet if more room is needed. .. dS\N 330394 STLCOPCB4077038 Page 7 >. COMPOSITION OF : EFFLUENT STREAMS AFTER TREATMENT INTAKE (cont Constituents Present Stream No. 1 Ave. Range Stream No. 2 Ave. Range Stream No. 3 . Intake Water Ave. Range Ave. Range Silica ' Specific Conductance Sulfate TOC Total Dissolved Solids Total Solids Total Suspended Solids Total Volatile Solids Turbidity Trace Metals Aluminum Arsenic Barium Boron Cadmium Chromium Copper Iron (total & dissolved) * Lead Magnesium Manganese - --- - - Mercury Molybdenum i Nickel Potassium t DSW 330395 STLCOPCB4077039 Page 8 12. COMPOSITION OF Constituents Present Selenium Sodium Strontium Zinc Calcium Temp, (winter) F Temp, (summer) F EFFLUENT STREAMS AFTER TREATMENT INTAKE (cont.) Stream No. 1 Ave. Range Stream No. 2 Ave. Range Stream No. 3 Intake Water Ave. Range Ave. Range # DSW 330396 STLCOPCB4077040 13. PROCESS WASTE TREATMENTS Waste Stream Origin (a) (b) (c) (J> (e) Describe present treatment and disposal Page 9 14. PRESENT TREATMENT INFORMATION Description of Method* When Installed Capital Costs . (a) (b) (c) 15. PERFORMANCE OF TREATMENT METHODS Method Qualitative Rating (a) (b) (c) Operating Costs Raw Wastes Streams Treated Waste Reduction Accomplished* *lnclude equipment, facilities, etc., including sizes and quantitative description. **% reduction in waste load as measured by such quantities as Total Suspended or Dissolved Solids, Chlorides, Sulfates, pH, BOD, PCBs, other Organics, etc. DSW 330397 STLCOPCB4077041 Page 10 16. COST EFFECTIVENESS INFORMATION List technology and rough cost estimates for elimination of your remaining plant wastes. (Recycle or zero waterborne waste basis) Please include isolation, containment, chemical treatment, settling ponds, filtrations, centrifuging, reverse osmosis, deminerali zation, evaporation, solids handling.and disposal or other pertinent treatments. Additional Treatment Stream Treated .% Waste Reduction Estimated Capital Costs Estimated Operating Costs (a) <b) (c) (d) 17. FUTURE TREATMENT PLANS Method Estimated Installation Time . . Esti mated Cost Estimated Performance (a) <b) (c) 18. GENERAL .. (a) Do you foresee any changes in your waste load in the next few years (raw material or process changes, product purity, etc.)? (b) Can the present process be modified or changed to significantly reduce effluent waste loads? $ DSW 330398 STLCOPCB4077042 Page (c) Do "Good Housekeeping" practices have a major bearing on your effluent compositions or are they compositions determined entirejy by by-products of the process or quality of raw materials used? <0 Does this plant have any unique waste situations as compared to other plants producing the same products (raw material supply, process, geographical location, other)? (e) Are the treatment processes now used 0) sensitive to surges? (2) shutdown and startup? (3) maintenance requirements? (0 Will the installation of projected waste control facilities cause air, noise, thermal or other pollution effects? ' (g) Are space or land requirements factors in future waste control projects? (Explain) I 0S\N 330399 STLCOPCB4077043