PROJECTED INORGANIC CHEMICAL INDUSTRY ANNUAL OPERATING COSTS FOR WASTE TREATMENT, 1969-74 Costs in Millions of Current Dollars 1/ 1/ Based on an average 3.6% annual increase in the price level Contaminated wastewater from the inorganic chemical industry comes primarily from electrolysis and crystallization brines, washings from filter cakes, spent acid and alkalies, and washings from raw materials. These wastewaters are generally characterized by dissolved solids and suspended solids. In addition to contaminated waste streams, process cooling discharges occur, accounting for 40 to 80% of the total discharge on the average. Treatment practices vary but involve in-plant segregation of contaminated wastes from uncontaminated cooling waters. Many waste treatment methods are available depending on the degree of treatment required, however, equalization, neutralization, sedimentation and lagooning processes are most widely used. Biological treatment is not applicable since the contaminants are primarily dissolved or suspended inorganic materials. Plants with small discharges tend to employ only equalization and neutralization with total discharge to municipal sewer systems for joint treatment. It is estimated that between 10 and 20% of the process wastewater discharge from the industry is to municipal systems (4.2% of the total discharge). No significant percentage changes in this regard are expected through 1974. The inorganic chemical industry has generally found that in-plant, separate treatment has economic advantages, particularly when significant quantities of wastewater are involved. Data from 59 inorganic chemical plants were obtained and formatted according to the Industrial Waste Treatment Practices Data Form, which was developed for the study "The Cost of Clean Water and Its Economic Impact, Volume IV," United States Department of the Interior, January, 1969. The data obtained are given in some detail in the report in terms of bar graphs and various calculated parameters relating wastewater volumes, plant production, and costs. Key parameters of interest regarding waste treatment costs are the following: Average capital cost Average operating cost/yr. Average capital cost Average operating cost $223/1000 gpd 16.73 gpd/annual ton of pro- $3.74/annual ton of production $0.98 per year/annual ton of production An examination of the survey data showed that the reported bases of waste treatment decisions were generally least cost, or minimum compliance with pollution control regulations. The costs of unit wastewater treatment methods were developed and are presented in the report as a series of mathematical models and cost function graphs. These data were used to calculate capital costs of waste treatment facilities versus two levels of pollutant removal for a series of typical plants. Treatment Level I was chosen to represent the average treatment employed in the industry as a whole and is judged to be equivalent to 27% removal of suspended and dissolved solids. Treatment Level II represents complete removal of contaminants. Only two levels were selected because the industrial wastes are principally inorganic solids that respond only to physical treatment processes. Because there are no intervening technologies, intermediate levels of efficiency are not distinguishable. The two levels then may be viewed as a range bounded on the one side by the current level of efficiency and on the other by universal application of advanced treatment practices. An almost infinite number of intermediate positions are possible for the industry as a whole within the range, but only as the treatment II technology is applied to individual units of the population. Unlike the case of organic waste, there is no series of technological plateaus through which the whole population may progress. The following table summarizes the capital and operating costs in 1969 dollars for the two levels of treatment chosen: Since the effective and efficient treatment of wastewater rests with the operators of the waste treatment facility, qualitative as well as quantitative manpower requirements have been projected for the inorganic chemical industry. This report concentrates on the requirements for operation and maintenance since, while administrative and technical support is requisite to effective treatment of wastewater, the qualitative nature of these support requirements will undergo less of a change in future years than will the treatment processes and the skills required for operating and maintaining them. Manpower projections have been made through 1974 with respect to both the degree of commitment necessary to achieve specified levels of effluent quality and the number of persons who must be specially trained to insure effective waste treatment. The several projections should be useful primarily for their planning implications, both to the industry and to affected government agencies. The following table summarizes the estimated trained manpower needs through 1974: ESTIMATED NUMBER OF TRAINED OPERATION AND MAINTENANCE It must be noted in connection with the above numbers that they are based upon 100% of the indicated size plant utilizing the treatment level shown. There is no estimate of the fraction of large plants utilizing either treatment level except for 1969 where other considerations indicate that on the average all large plants employ Treatment Level I. CHAPTER II INTRODUCTION This study was performed pursuant to Contract No. 14-12592 with the Federal Water Pollution Control Administration, United States Department of the Interior, and is part of the annual National Requirements and Cost Estimate Study required for presentation to Congress by the Federal Water Pollution Control Act. The primary objective of this study was to acquire data and develop cost estimates on the waste treatment practices of selected industrial categories within the inorganic chemicals industry over the 1970 to 1974 period, and to develop manpower planning criteria for each of the waste treatment practices identified. A secondary objective of the study was to further test and refine as necessary the generalized methodology for establishing and projecting industry costs which was developed in the course of work under FWPCA Contract No. 14-12-435 "Projected Wastewater Treatment Costs in the Organic Chemicals Industry." This report was transmitted to the Congress in January, 1969 as The Cost of Clean Water, Volume IV. The information contained in this report is not intended to reflect the cost or waste load situations for any particular plant. A generalized framework for analyzing waste treatment practices has been provided instead. The data and conclusions should be useful to industry and to government in their efforts to find and implement the most efficient ways to reduce pollution of the nation's water bodies. The study utilized on subcontract the services of Resource Engineering Associates, Inc., Stamford, Conn., Datagraphics, Inc, Allison Park, Pa., and Gurnham, Bramer, and Associates, Inc., McMurray, Pa. Assistance from the Manufacturing Chemists Association in supplying data, comments, and suggestions is gratefully acknowledged. |