Water Reuse and Treatment System
Operating Experiences
FRANCIS X. BROWNE, Project Engineer
Betz Environmental Engineers, Inc.
Plymouth Meeting, Pennsylvania 19462
LAWRENCE C. TROPEA, Jr., Director of Water Quality
BRUCE S. HULCHER, Director of Environmental Control
Reynolds Metals Company
Richmond, Virginia 23261
INTRODUCTION
The Reynolds Metals Company Electrical Division operates three wire and cable
plants of which the Chester Plant, located in Chester, Pennsylvania, is the largest. More
than 700,000 square feet are occupied by the Chester Plant with an additional 80,000 square
feet of warehouse space. A complete range of wire and cable products is produced at the
plant. About three million pounds of product per month are shipped including bare and
insulated aluminum and copper conducted cables for utilities and the construction
industry. The Chester Plant employs about 450 persons on a three-shift, five-day basis.
In late January, 1973, Reynolds Metals Company retained the services of Betz
Environmental Engineers, Inc. to perform a wastewater characterization and reuse
feasibility study at the Chester Plant. The basic study objectives were to: 1) Characterize the
plant discharges; 2) Evaluate wastewater reuse possibilities; and 3) Develop a
comprehensive wastewater management program.
To accomplish the study objectives, a series of flow measurements were made at the
direct discharges to the Delaware River and at significant sources within the plant. Flow
measurements were made at the direct discharges by installing weirs in the manholes. Using
these flow measurements, a water balance was prepared which was able to account for 98
percent of the plant intake water. In addition, composite samples were collected on the
direct discharges and on various water sources within the plant. Analysis of these samples
provided data for the wastewater characterization and subsequently for the design of a
comprehensive wastewater reuse and treatment system.
WASTEWATER INVENTORY
Effluents from the Chester Plant are discharged to the Delaware River through five
outfalls as shown in Figure 1. Average wastewater flows, before implementation of the
wastewater management program, for each of the discharges are presented in Table I.
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