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36 A CASE HISTORY OF A DIE-CASTING WASTEWATER TREATMENT SYSTEM David B. Froula, Project Manager Sam E. Shelby, Jr., Principal The ADVENT Group, Inc. Brentwood, Tennessee 37027 Robert L. Quintilliano, Environmental Manager SPX Corporation Muskegon, Michigan 49443 Murl Hoover, Plant Engineer Contech Division Dowagiac, Michigan 49047 INTRODUCTION A die casting and finishing operation, located in southwest Michigan, was faced with increasing wastewater treatment costs due to increasingly stringent wastewater discharge regulations. Over the last 10 to 15 years, this facility made several attempts at water reuse and recovery by installing oil- water separators and an ultrafiltration/reverse osmosis system. These systems were plagued by problems and never provided satisfactory treatment. In 1988, an arrangement was made with city officials to truck pretreated wastewater to the local POTW. A physical/chemical/biological system was installed to pretreat the wastewater in order to meet U.S. EPA categorical discharge limits. This system was also unable to meet the discharge limits and wastewater pretreatment and trucking to the City were suspended. Wastewater was then hauled to a commercial facility in Detroit for treatment and disposal. A modified two-stage physical/chemical treatment approach followed by biological polishing was conceived, investigated and implemented to achieve the categorical limits and decrease wastewater treatment and disposal costs. This paper presents a case history of the wastewater treatment system development and operation. RAW WASTE CHARACTERISTICS A summary of previous raw waste characteristics, as reported from samples collected over several years, is presented in Table I. The current wastewater flow rate ranges from 5,000 to 10,000 gpd. It can be seen that the wastewater has up to 2,000 mg/L of oil and grease and 1,000 mg/L of TSS. BOD, COD, and TOC, primarily from ethylene glycol, have also been measured at high concentrations. Heavy metals of concern are zinc, and possibly lead and copper. Results from a series of raw wastewater samples collected at the plant over an eight day period in 1989 are also summarized in Table I. These samples consist of 6 daily composite samples and a weekly composite. These results indicate an average total oil and grease content of 764 mg/L, an average soluble oil and grease level of 173 mg/L and, by difference, the sum of free and emulsified oil and grease was 591 mg/L. These samples were collected after the raw waste collection and skimming sump. Very little, if any, free floating oil and grease was observed, indicating that most of the raw waste oil and grease was emulsified. Raw waste TOC levels ranged from 6,279 mg/L to 10,875 mg/L, and averaged about 8,200 mg/L. The daily composite raw waste pH levels varied between 5.65 and 8.88, and the weekly composite pH was 7.19. Heavy metals data indicate that zinc is present at significant levels. Daily total zinc values ranged from 13.90 to 33.10 mg/L, and averaged 21.77 mg/L. Comparisons of the total and soluble zinc analyses indicate that most of the zinc is in the soluble or dissolved form. 46th Purdue Industrial Waste Conference Proceedings, 1992 Lewis Publishers, Inc., Chelsea, Michigan 48118. Printed in U.S.A. 347
Object Description
Purdue Identification Number | ETRIWC199136 |
Title | Case history of a die-casting wastewater treatment system |
Author |
Froula, David (David B.) Shelby, Samuel E. Quintilliano, Robert L. Hoover, Murl |
Date of Original | 1991 |
Conference Title | Proceedings of the 46th Industrial Waste Conference |
Conference Front Matter (copy and paste) | http://e-archives.lib.purdue.edu/u?/engext,42649 |
Extent of Original | p. 347-356 |
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 | 2009-11-24 |
Capture Device | Fujitsu fi-5650C |
Capture Details | ScandAll 21 |
Resolution | 300 ppi |
Color Depth | 8 bit |
Description
Title | page 347 |
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 | 36 A CASE HISTORY OF A DIE-CASTING WASTEWATER TREATMENT SYSTEM David B. Froula, Project Manager Sam E. Shelby, Jr., Principal The ADVENT Group, Inc. Brentwood, Tennessee 37027 Robert L. Quintilliano, Environmental Manager SPX Corporation Muskegon, Michigan 49443 Murl Hoover, Plant Engineer Contech Division Dowagiac, Michigan 49047 INTRODUCTION A die casting and finishing operation, located in southwest Michigan, was faced with increasing wastewater treatment costs due to increasingly stringent wastewater discharge regulations. Over the last 10 to 15 years, this facility made several attempts at water reuse and recovery by installing oil- water separators and an ultrafiltration/reverse osmosis system. These systems were plagued by problems and never provided satisfactory treatment. In 1988, an arrangement was made with city officials to truck pretreated wastewater to the local POTW. A physical/chemical/biological system was installed to pretreat the wastewater in order to meet U.S. EPA categorical discharge limits. This system was also unable to meet the discharge limits and wastewater pretreatment and trucking to the City were suspended. Wastewater was then hauled to a commercial facility in Detroit for treatment and disposal. A modified two-stage physical/chemical treatment approach followed by biological polishing was conceived, investigated and implemented to achieve the categorical limits and decrease wastewater treatment and disposal costs. This paper presents a case history of the wastewater treatment system development and operation. RAW WASTE CHARACTERISTICS A summary of previous raw waste characteristics, as reported from samples collected over several years, is presented in Table I. The current wastewater flow rate ranges from 5,000 to 10,000 gpd. It can be seen that the wastewater has up to 2,000 mg/L of oil and grease and 1,000 mg/L of TSS. BOD, COD, and TOC, primarily from ethylene glycol, have also been measured at high concentrations. Heavy metals of concern are zinc, and possibly lead and copper. Results from a series of raw wastewater samples collected at the plant over an eight day period in 1989 are also summarized in Table I. These samples consist of 6 daily composite samples and a weekly composite. These results indicate an average total oil and grease content of 764 mg/L, an average soluble oil and grease level of 173 mg/L and, by difference, the sum of free and emulsified oil and grease was 591 mg/L. These samples were collected after the raw waste collection and skimming sump. Very little, if any, free floating oil and grease was observed, indicating that most of the raw waste oil and grease was emulsified. Raw waste TOC levels ranged from 6,279 mg/L to 10,875 mg/L, and averaged about 8,200 mg/L. The daily composite raw waste pH levels varied between 5.65 and 8.88, and the weekly composite pH was 7.19. Heavy metals data indicate that zinc is present at significant levels. Daily total zinc values ranged from 13.90 to 33.10 mg/L, and averaged 21.77 mg/L. Comparisons of the total and soluble zinc analyses indicate that most of the zinc is in the soluble or dissolved form. 46th Purdue Industrial Waste Conference Proceedings, 1992 Lewis Publishers, Inc., Chelsea, Michigan 48118. Printed in U.S.A. 347 |
Resolution | 300 ppi |
Color Depth | 8 bit |
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