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Section 3. METAL WASTES STEEL WELDING WIRE MANUFACTURER MEETS STRINGENT EFFLUENT AND SLUDGE DISPOSAL CRITERIA C. Scott Reece, President Reece Engineering, Inc. Clarksville, Tennessee 37040 After in-house cleanup and procedural changes failed to meet the municipal utilities' revised pretreatment requirements, a steel welding wire manufacturer obtained an outside consultant to make a study of the wastewater discharges. The study included a description of the plant process, waste characterization and treatability study, and a two-phase design and construction project. PLANT PROCESS Various sizes and grades of coiled steel rod were copper plated to produce welding rods for automatic welding machines. Steel rods, the basic raw material, received acid and alkaline cleaning and a borax protective coating. Some rods received heat treatment prior to cleaning. Wire drawing machines produced wire from the clean, boraxed rods, and then the wire was heat treated, acid cleaned and copper plated. Some copper plated wire was further drawn to the finished wire size. Process water was discharged into two separate sewers. Water from buildings 1 and 2 discharged into the same sewer after each stream received pH adjustment with ammonia. The second discharged occurred from Building 3. This water also received neutralization with ammonia. A plan indicating the discharge locations is presented in Figure 1. Building 1 housed a copper plating line for wire. The process is presented in Figure 2. The two spray rinses produced a continuous water discharge of approximately 33,000 gal/day. The hydrochloric acid and copper plating bath required periodic disposal as well as the lubricating soap used for the wire drawing machines. Hydrochloric acid and copper plating solutions were neutralized with ammonia and hauled as a liquid in tank trucks to the landfill. The lubricating soap was discharged to the sewer. Building 2 contained salt annealing, cleaning and plating. The cleaning and plating tanks were moved to building 3 after the waste characterization study. The salt annealing process remained, which included one continuous rinse tank producing a flow of 17,000 gal/day. Building 3 housed a cleaning and copper plating line for steel rods and a number of wire drawing and copper plating lines. The water flow from building 3 was approximately 131,000 gal/day. The wastewater-related processes are indicated in Figure 3. The hydrochloric acid, copper plate and lubricating soap tanks required periodic disposal. The caustic cleaner, borax and 6B soap tanks required disposal approximately once per year. The hydrochloric acid, copper plating, and cleaner solutions were neutralized and hauled to the landfill. Other tanks were hauled without further treatment. WASTE CHARACTERIZATION STUDY Several locations were selected for sampling. Flow information and dumping frequencies had been determined by plant employees and are presented in Table I. The six locations selected for sampling are: 77
Object Description
Purdue Identification Number | ETRIWC198210 |
Title | Steel welding wire manufacturer meets stringent effluent and sludge disposal criteria |
Author | Reece, C. Scott |
Date of Original | 1982 |
Conference Title | Proceedings of the 37th Industrial Waste Conference |
Conference Front Matter (copy and paste) | http://e-archives.lib.purdue.edu/u?/engext,32749 |
Extent of Original | p. 77-84 |
Collection Title | Engineering Technical Reports Collection, Purdue University |
Repository | Purdue University Libraries |
Rights Statement | Digital object copyright Purdue University. All rights reserved. |
Language | eng |
Type (DCMI) | text |
Format | JP2 |
Date Digitized | 2009-07-14 |
Capture Device | Fujitsu fi-5650C |
Capture Details | ScandAll 21 |
Resolution | 300 ppi |
Color Depth | 8 bit |
Description
Title | page 77 |
Collection Title | Engineering Technical Reports Collection, Purdue University |
Repository | Purdue University Libraries |
Rights Statement | Digital copyright Purdue University. All rights reserved. |
Language | eng |
Type (DCMI) | text |
Format | JP2 |
Capture Device | Fujitsu fi-5650C |
Capture Details | ScandAll 21 |
Transcript | Section 3. METAL WASTES STEEL WELDING WIRE MANUFACTURER MEETS STRINGENT EFFLUENT AND SLUDGE DISPOSAL CRITERIA C. Scott Reece, President Reece Engineering, Inc. Clarksville, Tennessee 37040 After in-house cleanup and procedural changes failed to meet the municipal utilities' revised pretreatment requirements, a steel welding wire manufacturer obtained an outside consultant to make a study of the wastewater discharges. The study included a description of the plant process, waste characterization and treatability study, and a two-phase design and construction project. PLANT PROCESS Various sizes and grades of coiled steel rod were copper plated to produce welding rods for automatic welding machines. Steel rods, the basic raw material, received acid and alkaline cleaning and a borax protective coating. Some rods received heat treatment prior to cleaning. Wire drawing machines produced wire from the clean, boraxed rods, and then the wire was heat treated, acid cleaned and copper plated. Some copper plated wire was further drawn to the finished wire size. Process water was discharged into two separate sewers. Water from buildings 1 and 2 discharged into the same sewer after each stream received pH adjustment with ammonia. The second discharged occurred from Building 3. This water also received neutralization with ammonia. A plan indicating the discharge locations is presented in Figure 1. Building 1 housed a copper plating line for wire. The process is presented in Figure 2. The two spray rinses produced a continuous water discharge of approximately 33,000 gal/day. The hydrochloric acid and copper plating bath required periodic disposal as well as the lubricating soap used for the wire drawing machines. Hydrochloric acid and copper plating solutions were neutralized with ammonia and hauled as a liquid in tank trucks to the landfill. The lubricating soap was discharged to the sewer. Building 2 contained salt annealing, cleaning and plating. The cleaning and plating tanks were moved to building 3 after the waste characterization study. The salt annealing process remained, which included one continuous rinse tank producing a flow of 17,000 gal/day. Building 3 housed a cleaning and copper plating line for steel rods and a number of wire drawing and copper plating lines. The water flow from building 3 was approximately 131,000 gal/day. The wastewater-related processes are indicated in Figure 3. The hydrochloric acid, copper plate and lubricating soap tanks required periodic disposal. The caustic cleaner, borax and 6B soap tanks required disposal approximately once per year. The hydrochloric acid, copper plating, and cleaner solutions were neutralized and hauled to the landfill. Other tanks were hauled without further treatment. WASTE CHARACTERIZATION STUDY Several locations were selected for sampling. Flow information and dumping frequencies had been determined by plant employees and are presented in Table I. The six locations selected for sampling are: 77 |
Resolution | 300 ppi |
Color Depth | 8 bit |
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