Water Reuse and Treatment
At an Integrated Wire and Cable Plant
LAWRENCE C. TROPEA, JR.
BRUCE S. HULCHER
Reynolds Metals Company
Richmond, Virginia
FRANCIS X. BROWNE
Betz Environmental Engineers, Inc.
Plymouth Meeting, Pennsylvania
INTRODUCTION
The Reynolds Metals Company operates a wire and cable plant, known as the Chester
Plant, in Chester, Pennsylvania. This plant is the largest facility in the Reynolds Electrical
Division.
Covering an area of more than 700,000 square feet, with an additional 80,000 square
feet of warehouse space, the Chester Plant manufactures a complete range of wire and cable
products; plus bare and insulated aluminum and copper conductor cables for utilities and
the construction industry.
Approximately 450 people are employed on a three-shift, five-day basis. A unique
feature of the Chester Plant is the Vertical Continuous Vulcanizing Tower. The Tower rises
approximately 200 feet in the air and is designed to produce high voltage cable.
RECENT PLANT ENVIRONMENTAL HISTORY
In late 1972, it was decided that an in-depth industrial waste study should be performed
at the Chester Plant. The purpose of the study was to develop an environmental program
that would ensure that the plant would be in compliance with all existing and anticipated
regulations. It was decided at the beginning of the project that particular emphasis should
be placed upon developing a program that would provide maximum wastewater reuse.
The Environmental Control Department of Reynolds Metals Company supplemented
the plant engineering department in selecting the program objectives and by providing
specialized expertise in the environmental control field.
In January 1973, Betz Environmental Engineers, Inc. was retained to undertake the
comprehensive water reuse and treatment study. The basic study objectives were to: 1)
Characterize the plant wastewater discharges; 2) Evaulate wastewater reuse possibilities;
and 3) Develop a comprehensive wastewater reuse and treatment program.
To accomplish the study objectives, composite samples of each of the plant wastewater
discharges were analyzed. Additionally, samples were taken at various production
operations in the plant to identify significant pollutant sources. Flow rate information was
determined for each direct discharge and for the significant pollutant sources. Data from
these studies provided the basis for the environmental program that was eventually
developed.
CHARACTER AND SOURCES OFTHE DIRECT DISCHARGES
Plant wastewaters are discharged to the Delaware River through five outfalls. The
locations of the discharges are shown in Figure 1. The Chester Plant direct discharges can be
characterized as being relatively uncontaminated cooling waters. However, some of the
waters do pick up small quantities of contaminants during use.
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