Development Document for 1987 Effluent Limitations Guidelines and Standards for OCPSF ...

719 Pages·2006·25.37 MB·English

TCARTSBA
This document describes the technical development of the U.S.

Environmental Protection Agency's promulgated effluent limitations guidelines

and standards that control the discharge of pollutants into navigable waters

and publicly owned treatment works (POTWs) by existing and new sources in the

organic chemicals, plastics, and synthetic fibers point source category. The

regulation establishes effluent limitations guidelines attainable by the

application of the "best practicable control technology currently available"

(BPT) and the "best available technology economically achievable" (BAT),

Pretreatment standards applicable ot existing and new discharges to POTWs

(PSES and PSNS, respectively), and new source performance standards (NSPS)

attainable by the application of the "best available demonstrated control

technology." The regulation was promulgated under the authority of Sections
301, 304, 306, 307, 308, and 501 of the Clean Water Act (the Federal Water
Pollution Control Act Amendments of 1972, 33 U.S.C. 1251 et seq., as amended).
It was also promulgated in response to the Settlement Agreement in Natural
Resources Defense Council, Inc. v. Trian, 8 CRE 2120 (D.D.C. 1976), modified,
12 CRE 1833 (D.D.C.).
DEVELOPMENT DOCUMENT

FOR

EFFLUENT LIMITATIONS GUIDELINES

NEW SOURCE PERFORMANCE STANDARDS

AND

PRETREATMENT STANDARDS

FOR THE

ORGANIC CHEMICALS

AND THE

PLASTICS AND SYNTHETIC FIBERS

POINT SOURCE CATEGORY

Volume II

Lee .M Thomas

Administrator

Lawrence .J Jensen

Assistant Administrator for Water

William .A Whittington

Director

Office of Water Regulations and Standards

Devereaux Barnes, Director

Industrial Technology Division

Marvin .B Rubin

Chief, Chemicals Industry Branch

Elwood .H Forsht

Senior Project Officer

Frank .H Hund

Hugh .E Wise

Janet .K Goodwin

Wendy .D Smith

Project Team

October 1987

Industrial Technology Division

Office of Water Regulations and Standards

U.S. Environmental Protection Agency

Washington, D.C. 20460
TABLE OF CONTENTS

VOLUME II

VIII. ENGINEERING COSTS AND NON-WATER QUALITY ASPECTS
A. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . VIII-1

I. BPT Costing Methodology . . . . . . . . . . . . . . VIII-2

2. TAB Costing Methodology . . . . . . . . . . . . . . VIII-7

3. PSES Costing Methodology . . . . . . . . . . . . . VIII-24

4. Other Factors• ; . . . . . . . . . . . . . . . . . VIII-25

B. BPT TECHNOLOGIES . . . . . . . . . . . . . . . . . . . VIII-40

I• Activated Sludge . . . . . . . . . . . . . . . . . VIII-40

2• Biological Treatment Upgrades . . . . . . . . . VIII-56

3. Chemically Assisted Clariftcationl ........ VIII-67

4. Filtration Systems . . . . . . . . . . . . . . . . VIII-77

5. Polishing Ponds . . . . . . . . . . . . . . . . . . VIII-78

6 Algae Control VIII-84

• • • • • • • • • • • • • • • • • • • •
C. BAT AND PSES TECHNOLOGIES . . . . . . . . . . . . . . . VIII-95

I• Steam Stripping . . . . . . . . . . . . . . . . . . VIII-95

2. Activated Carbon Systems . . . . . . . . VIII-If9
noit;cifir;lC/noitaluccolP/noltalugaoC ,yS tem ...
3. VIII-139

4. Cyanide Destruction ..................
VIII-180
5. In-Plant Biological Treatment .... .......
VIII-187
D. ADDITIONAL COSTS . . . . . . . . . . . . . . . . . . .
VIII-!97
1. Contract Hauling . . . . . . . . . . . . . . . . .
VIII-197
2. Monitoring Costs . . . . - . .- .- . . -
. . . VIII-198
3. Sludge Disposal and•Incineration . . . . . . . . .
VIII-203
4. RCRA Baseline Costs . . . . . . . . . . . . . . . .
VIII-222
E. WASTEWATER AND AIR EMISSION LOADINGS .........
VIII-236
I. BPT Conventional Pollutant Wastewater Loadings
. • VIII-236
2. TAB and PSES Toxic Pollutant Wastewater

Loadings . . . . . . . .
VIII-236
3. TAB and PSES Toxic Poilutant Air Emission

Loadings . . . . . . . . . . . . . . . . . . . .
VIII-270
IX. EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICATION OF

BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE

A. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . IX-i

1. Regulated Pollutants . . . . . . . . . . . . . . . . IX-2

2. BPT Subcategorization . . . . . . . . . . . . . . . IX-2

iii
TABLE OF CONTENTS (Continued)

B. TECHNOLOGY SELECTION . . . . . . . . . . . . . . . . . . IX-2

C. BPT EFFLUENT LIMITATIONS GUIDELINES . . . . . . . . . . . IX-5

D. COST AND EFFLUENT REDUCTION BENEFITS . . . . . . . . . . IX-9

E. IMPLEMENTATION OF THE BPT EFFLUENT LIMITATIONS

GUIDELINES . . . . . . . . . . . . . . . . . . . . . . IX-9

F. NON-WATER OUALITY ENVIRONMENTAL IMPACTS . . . . . . . . . IX-12

I. Air Pollution . . . . . . . . . . . . . . . . . . . . IX-12

2. Solid Waste . . . . . . . . . . . . . . . . . . . . . IX-13

3. Energy Requirement . . . . . . . . . . . . . . . . . IX-I3

.X EFFLUENT OUALITY ATTAINABLE THROUGH THE APPLICATION OF

BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE

A. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . X-I

B. BAT SUBCATEGORIZATION . . . . . . . . . . . . . . . . . . X-I

C. TECHNOLOGY SELECTION . . . . . . . . . . . . . . . . . . X-2

I. Option I . . . . . . . . . . . . . . . . . . . . . .
3-'X
2. Option II . . . . . . . . . . . . . . . . . . . . . . X-3

3. Option III . . . . . . . . . . . . . . . . . . . . . X-4

D. POLLUTANT SELECTION . . . . . . . . . . . . . . . . . . . X-4

E. BAT EFFLUENT LIMITATIONS GUIDELINES . . . . . . . . . . . X-IO

i. Volatiles Limits . . . . . . . . . . . . . . . . . . X-ll

2. Cyanide Limitations . . . . . . . . . . . . . . . . . X-If

3. Metals Limitations . . . . . . . . . . . . . . . . . X-12

4. Other Organic Pollutants . . . . . . . . . . . . . . X-28

F. COST AND EFFLUENT REDUCTION BENEFITS IMPLEMENTATION

OF THE BAT EFFLUENT . . . . . . . . . . . . . . . . . . X-31

G. LIMITATIONS GUIDELINES . . . . . . . . . . . . . . . . . X-31

i. NPDES Permit Limitations . . . . . . . . . . . . . . X-31

2. NPDES Monitoring Requirements . . . . . . . . . . . . X-32

iv
TABLE OF CONTENTS (Continued)

egaP
H. NON-WATER QUALITY ENVIRONMENTAL IMPACTS . . . . . . . . . X-36

1. Air Pollution.. . . . . . . . . . . . . . . : . . . X-37

2. Solid Waste. . . . . . . . . ..... X-37
3. Energy Requirements . . . . . . . . . . . . . . . . . X-37

XI. EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICATION OF
NEW SOURCE PERFORMANCE STANDARDS (NSPS) ''
A. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . XI-I

B. POLLUTANT AND TECHNOLOGY SELECTION . . . . . . . . . . . XI-I

XII. EFFLUENT QUALITY ATTAINABLE THROUGH THE PRETREATHENT

STANDARDSFOR EXISTING SOURCES AND PRETREATMENT

STANDARDS FOR NEW SOURCES

A. INTRODUCTION ;': .. . .~.. ~ ~::. . . ~ ..... ~ . ... XII-I

B. POLLUTANT SELECTION . . . . . . . . . . . . . . . . . . . . XII-I

C. TECHNOLOGY SELECTION ..... . . . . . . . . . . . . . Xil-2

.D PSES AND PSNS . . . . . . . . . .... . : . ...... xii-3

E. COST AND EFFLUENT REDUCTION BENEFITs ...... ~ .... XII-6

F. NON-WATER QUALITY ENVIRONMENTAL IMPACTS. ; ........ XII-6

I. Alr Pollution . . . . . . . ; . . .'.. . . . . . . . XII-7

2. Solid Waste . . . . . . . . . . . , . . . . ..... XII-7

3. Energy Requirements XII-7

XIII. BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY . ". ..... XIII-I

XIV. ACKNOWLEDGEMENTS . . . . . . . . . . . . . . . . . . . . . . XIV-I

XV. GLOSSARY . . . . . . . . . . . . . . . . . . . . . . . . . . XV-I

APPENDIX III-A: PRODUCT LISTINGS BY INDUSTRIAL SEGHENT ...... III-AI

APPENDIX IV-A: RATIONALE FOR THE FORM OF THE BPT BOD 5

REGRESSION MODEL . . . . . . . . . . . . . . . . . IV-A1

APPENDIX VI-A: LIST OF THE 126 PRIORITY POSLUTANTS.. . ..... VI-AI

APPENDIX VII-A: BPT LONG-TERM AVERAGE BOD 5 AND TSS PLANT-

SPECIFIC TARGETS VII-A1
TABLE OF CONTENTS (Continued)

APPENDIX VII-B:
RAW WASTEWATER AND TREATED EFFLUENT BOD_, TSS,

COD, AND TOC DATA BEFORE AND AFTER ADJUSTMENT

BY PLANT-SPECIFIC DILUTION FACTORS .......
VII-B1

APPENDIX VII-C:
LISTING 'FO 69 BPT DAILY DATA PLANTS INCLUDED

AND EXCLUDED FROM BPT VARIABILITY

FACTOR CALCULATIONS . . . . . . . . . . . . . .
VII-C1

APPENDIX VII-D:
BPT STATISTICAL METHODOLOGY . . . . . . . . . . .
VII-D1

APPENDIX VII-E:
DISTRIBUTIONAL HYPOTHESIS TESTING ........
VII-E1

APPENDIX VII-F:
BAT STATISTICAL METHODOLOGY . . . . . . . . . . .
VII-F1

APPENDIX VII-G:
EVALUATION OF THE VALIDITY OF USING FORM 2C

DATA TO CHARACTERIZE PROCESS AND FINAL

EFFLUENT WASTEWATER JUNE 17, 1985 .......
VII-G1

APPENDIX VIII-A:
METHODOLOGY FOR CALCULATING BPT TARGETS AND
IMPUTING MISSING ACTUAL BOD 5 AND TSS
EFFLUENT VALUES . . . . . . . . . . . . . . . . VIII-A1

APPENDIX VIII-B:
BPT, BAT, AND PSES COMPLIANCE COST ESTIMATES

AND TECHNOLOGY BASIS . . . . . . . . . . . . . .
VIII-B1

APPENDIX VIII-C:
BPT PLANT-BY-PLANT BOD 5 AND TSS LOADINGS .....
VIII-C1

APPENDIX VIII-D:
BAT AND PSES PLANT-BY-PLANT TOXIC POLLUTANT

WASTEWATER LOADINGS . . . . . . . . . . . . . .
VIII-D1

APPENDIX VIII-E:
BAT AND PSES PLANT-BY-PLANT AIR EMISSION

LOADINGS . . . . . . . . . . . . . . . . . . . .
VIII-E1

vi
LIST OF FIGURES
VOLUME II
t
VIII-I Annualized Capital Cost Versus Additional
BOD Removal. ......... . . VIII-64

VIII-2 Annuallzed Unit Capital Cost Curve Versus Additional
BOD s Removal . . ~ .... ..... , VIII-65

VIII-3 Total Capital Cost Curve Versus Flow for Chemically
Assisted Clarification Systems ..... .... ~ . . VIII-72

VIII-4 Annual O&M Cost Curve Versus Flow for Chemically
Assisted Clarification Systems ..... ~ . ..... VIII-73

VIII-5 Land Requirements Curve Versus Flow*for Chemically
Assisted Clarification Systems~ ....... VIII-74

VIII-6 Total Capital Cost Curve Versus Flow for Multi-
media Filter Systems . :. .......... VllI-81

VIII-7 Annual O&M Cost Curve Versus Flow for Muiti-media
Filter Systems . . . .... VIII-82

VIII-8 Land Requirements CurveVersus Flow for Multi-
media Filter Systems .... . . . . . . . . . . . . . VIII-83

VIII-9 Total Capital Cost Curve Versus Flow foe Polishing
Pond Systems ....... i " ~ • • ~ • ~ ~" ..... VIII-86

VIII-10 Annual O&M Cost Curve Versus Flow for Polishing
Pond Systems ........ ; . ~.. ......... VIII-87

VII~-II Land Requirements Curve Versus Plow for Polishing
Pond Systems .......... . .......... VIII-88

VIII-12 Annual O&M Cost Curve Versus Flow for Algae
Control in Polishing Ponds Systems ........... Vlll-91

VIII-13 Capital Cost Curve Versus Flow for Benzene at
Effluent Concentration of 0.01 mg/l .......... Vlll-lll

VIII-14 Capital Cost Curve versus Flow for B~nzene at
Effluent Concentration of 1.0 mg/l VIII-II2

Vlll-15 Capital Cost Curve Versus Flow for Hexachloro-
benzene at Effluent Concent'ration of 0.01 mg/i .... Vlll-l13

VHI-16 Capital Cost Curve Versus Flow for Hexachloro-
benzene of Effluent Concentration of 1.0 mg/! ..... Vlll-l14

vii
LIST OF FIGURES (Continued)

VIII-17 Annual O&M Cost Curve Versus Flow for Benzene
and Hexachlorobenzene ................. VIII-II5

VIII-18 Total Capital Cost Curve Versus Flow for Large BAT
In-Plant Control Carbon Treatment Systems;
Medium Carbon Adsorption Capacity ........... VIII-143

Vlll--19 Total Capital Cost Curve Versus Flow for Large PSES
In-Plant Control Carbon Treatment Systems;
Medium Carbon Adsorption Capacity ........... VIII-144

VIII-20 Annual O&M Cost Curve Versus Flow for Large BAT
In-Plant Control Carbon Treatment Systems;
Medium Carbon Adsorption Capacity ........... VIII-145

VIII-21 Annual O&M Cost Curve Versus Flow for Large PSES
In-Plant Control Carbon Treatment Systems;
Medium Carbon Adsorption Capacity ........... VIII-146

VIII-22 Total Capital Cost Curve Versus Flow for Large BAT
In-Plant Control Carbon Treatment Systems;
Low Carbon Adsorption Capacity ............ VIII-147

VIII-23 Total Capital Cost Curve Versus Flow for Large PSES
In-Plant Control Carbon Treatment Systems;
Low Carbon Adsorption Capacity ............ VIII-148

VIII-24 Annual O&M Cost Curve Versus Flow for Large BAT
In-Plant Control Carbon Treatment Systems;
Low Carbon Adsorption Capacity ............ VIII-149

VIII-25 Annual O&M Cost Curve Versus Flow for Large PSES
In-Plant Control Carbon Treatment Systems;
Low Carbon Adsorption Capacity ............ VIII-150

VIII-26 Total Capital Cost Curves Versus Flow for Large
End-of-Pipe Carbon Treatment Systems (On-site
Carbon Regeneration Systems) ............. VIII-151

VIII-27 Annual O&M Cost Curves Versus Flow for Large
End-of-Pipe Carbon Treatment Systems (On-site
Carbon Regeneration Systems) ............. VIII-152

VIII-28 Total Capital Cost Curve Versus Flow for Small
In-Plant and End-of-Pipe Carbon Treatment
Systems (Low, Medium, High Carbon Adsorption
Capacities) . . . . . . . . . . . . . . . . . . . . . . VIII-157

viii
LIST OF FIGURES (Continued)

VIII-29 Annual O&M Cost Curve Versus Flow for Small BAT
In-Plant Control Carbon Treatment Systems;
Medium Carbon Adsorption Capacity... ...... ..... VIII-158
VIII-30 Annual O&M Cost Curve Versus:Flow. for Small PSES
In-Plant Control Carbon Treatment Sys,tems;
Medium Carbon Adsorption Capacity.~ ' . . VIII-159
VIII-31 Annual•,O&M Cost Curve Versus~ Flow for Small BAT
In-Plant Control Carbon Treatment Systems;
Low Carbon Adsorption Capacity... ,.. ~ .... VIII-160
VIII-32 Annual O&M Cost Curve Versus Blow for Small PSES ~'
In-Plant Control Carbon Treatment Systems; ' /
Low Carbon Adsorption Capacity ..... ~ ..... ~.,.. VIII-161
VIII-33 Annual O&M Cost Curves Versus Flow for Small s
End-of-Pipe Carbon Treatment Systems .......... VIII-162
VIII-34 Land Requirements Curve Versus Flow for Activated
Carbon Treatment Systems " VIII-163
VIII-35 Total Capital Cost Curve Versus Flow for
Coagulation/Flocculation/Clarification Systems ..... VIII-166
"T
VIII-36 Land Requirements Curve VersUs Flow for ' ~" .....
Coagulation/Fi8cculation/ClarificationSystems ..... VIII-168
•
VIII-37 Annual M & O COSt Curve Versus Flow for
Coagulation/Flocculation/Clarificatfon Systems.. ~... Vlii-169
VIII-38 Comparison of Actual Systems Capital Cost and EPA's
Estimates for Coagulation/Flocculation/
Clarification . ....... ./.~...... ..... :VIII-173
VIII-39 Total Capital Cost Curve Versus Flow for Sulfide
Precipitation Systems VIII-177
"
VIII-40 Annual O&M Cost Curve Versus Flow for Sulfide
Precipitation Systems ................. VIII-178
VIII-41 Total Capital Cost Curve Versus Flow for Cyanide
Destruction Systems . . . . . VIII-185
VIII-42 Annual O&M Cost Curve Versus Flow for Cyanide
Destruction Systems ........ .......... VIII-186
VIII-43 Total Capital Cost Curve Versus Flow for Small
In-Plant Biological Treatment Systems ......... VIII-190
ix