PROCESS ECONOMICS PROGRAM

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1 PROCESS ECONOMICS PROGRAM SRI INTERNATIONAL Menlo Park, California Expires: July 1, 1981 PRICE SCHEDULE FOR REPORTS PHASES I THROUGH XI (PEP'75) (Offered Only to Clients of PEP'79 and PEP'80) Any report in above phases -- US$lOO PEP COST INDEX UPDATES: Extra copies of the PEP COST INDEX volume (and subsequent PEP COST INDEX UPDATES during active membership) are offered to current clients for a one-time charge of US$lOO.

2 PROCESS ECONOMICS PROGRAM SRI INTERNATIONAL Menlo Pd. California Abstract Process Economics Program Report No. 137 WASTE TREATMENT COSTS (September 1980) The past decade has seen the introduction of comprehensive legislation by industrialized nations to control and reduce the pollution of air, land, and water. Consequently, pollution abatement costs to the chemical and related industries have risen sharply in real terms since These costs are likely to continue to rise at least until The technology for pollution abatement Is generally the same as that for mineral beneficiation and chemical production. The application of SRI-developed modular capital and operating costs to these operations provides a simple means to estimate waste treatment costs for specific chemical plants. PEP '78 GEH

3 Report No. 137 WASTE TREATMENT COSTS by GEORGE E. HADDELAND September 1980 A private report by the PROCESS ECONOMICS PROGRAM Menlo Park, California 94025

4 For detailed marketing data and information, the reader is referred to one of the SRI programs specializing in marketing research. The CHEMICAL ECONOMICS HANDBOOK Program covers most major chemicals and chemical products produced in the United States and the WORLD PETROCHEMICALS Program covers major hydrocarbons and their derivatives on a worldwide basis. In addition, the SRI DIRECTORY OF CHEMICAL PRODUCERS services provide detailed lists of chemical producers by company, product, and plant for the United States and Western Europe. ii

5 CONTENTS A INTRODUCTION... SUMMARY... Pollution Abatement Legislation... Pollution Abatement Rxpenditures... Capital Costs... Operating Costs... Waste Treatment Technology... Modular Waste Treatment Costs... Fixed Capital Investment... Operating Costs... Examples of Module Cost Estimates... POLLUTION ABATEMENT LEGISLATION AND EXPENDITURES... Legislation in the United States... Air Pollution... Water Pollution... Land Pollution (Solids Disposal)... Selected Reactions to U.S. Antipollution Legislation.. Information Sources... Legislation in Japan... Air Pollution... Water Pollution... Land Pollution... Chemical Substances Control Law... Rxpenditures in the United States... Capital Expenditures... Operating Costs... Expenditures in Japan... WASTEWATER TREATMENT TECHNOLOGY... Pretreatment... Primary Treatment--Chemical... Objective... IonExchange... Electrodialysis... Reverse Osmosis... Neutralization... Oxidation and Reduction... Chemical Addition... Hydrolysis... Primary Treatment--Physical... Sedimentation... Hydrocycloning iii

6 CONTENTS 4A WASTEWATER TREATMENT TECHNOLOGY (continued) Filtration and Centrifuging Flotation Solvent Extraction Crystallization Adsorption on Activated Carbon SecondaryTreatment Air-Activated Sludge Oxygen-Activated Sludge Facultative Lagoons Trickle Filters 85 Nitrification-Den;t;i;ila;i&: Sand Filters Tertiary Treatment Foam Fractionation Chlorination Ozonation Toxic Liquids Disposal B GASEOUS WASTE TREATMENT AND DISPOSAL TECHNOLOGY Pretreatment DrySystems Gas-Solid Separation Adsorption on Activated Carbon Liquid Systems Water and Solvent Scrubbing Acid or Ammonia Neutralization Limestone Desulfurization Waste Gas Disposal Steam Generation and Incineration Emergency Flaring Dispersion by a Stack c SOLID WASTE TREATMENT AND DISPOSAL TECHNOLOGY Waste Solids Treatment Dewatering Drying Incineration Combustion Waste Solids Disposal LandFarming Stacking... i.' Sanitary Landfill Hazardous-Waste Landfill Other Disposal Methods iv

7 CONTENTS 5 COST CALCULATIONS FOR WASTE TREATMENT MODULES... Capital Cost Methods Used in This Study... Operating Costs... Module Cost Curves... 6 WASTE TREATMENT COSTS FOR SELECTED CHEMICAL INDUSTRIES... Methanol Plant Wastes,... Treatment Methods... Treatment Costs... Discussion of Costs... Ethylene Plant Wastes... Treatment Methods... Treatment Costs... Discussion of Costs... Multiplant Wastes... Treatment Methods... Treatment Costs... Discussion of Costs... Phosphoric Acid Plant Wastes... Treatment Methods... Treatment Costs... Discussion of Costs... Conclusion APPENDIX A Cost Basis. 211 APPENDIX B Calculations for the Equalization of a Waste Stream Flow Variable. APPENDIX C Design Steps for a Completely Mixed Activated Sludge System APPENDIX D Fixed Bed Active Carbon Adsorber Capacity. 223 CITEDREFERENCES. e 225 V

8 ILLUSTRATIONS Annual Capital Expenditures by the U.S. Chemical Industry for Pollution Abatement... Annual Operating Costs of the U.S. Chemical Industry for Pollution Abatement... Annual Capital Expenditures by the Japanese Chemical Industry for Pollution Abatement as a Percentage of Total New Capital Investment... Wastewater Treatment Alternatives... Multiple-Chamber Alternate-Membrane Electrodialysis Cell... Settling Curves at Various Suspended Solids Concentrations Batch Suspended Solids Flux Curve for Design... Approximate Solid Size Range for Solid-Liquid Separation Equipment... Schematic Diagram of Dissolved-Air Flotation Tank with Recycle... Activated Sludge System... Waste Gas Treatment Alternatives... C&npressor Horsepower for Various Air Flow Rates... Pressure Drop for Air Flow Through Active Carbon at 70 F and 760 mm Hg... Waste Solid Treatment Alternatives... Effect of Feed Size on Drying Centrifuge Capacity... Effect of Feed Rate and Size on Drying Centrifuge Product Moisture... Stacking Procedure for Waste Gypsum... Guthrie Method for Modular Cost Estimates... Tanks... Thickener, Clarifier... Settling Lagoon... Oil Separator8... Filters... Module Gost: Centrifuges-... Hydraulic Cyclones Vii

9 ILLUSTRATIONS Distillation System... Evaporators... Stripper, Steam or Flue Gas... Lime Neutralizer... System for Chemical Reaction or Precipitation... Ion Exchange System Electrodialysfs and Reverse Osmosis Cells... Dissolved-Air Flotation Cell... Crystallization System... Active Carbon Adsorber for Liquid Stream... Solvent Extraction System... Biological Oxidation System Including Sludge Separation... Faculative Lagoon... Filters, Dual Media and Sand... Foam Fractionator... Ozonation System... Denitrification System... Hydrolyzer... Chlorinator for Ammonia Removal... Chlorinator for Disinfection and Equipment for Water Quality Control... Pumping System and Deep-Welling System... Liquid Incinerator... Steam and Cooling Water Utilities... Gas Combustor for Steam Generation... Gas Incinerator... Module Cost Flue Gas Desulfurization System... Hydrocarbon Gas Flare... Gas Dispersion Stack Viii

10 ILLUSTRATIONS 5.37 Annnonia Neutralizer Acid Gas Neutralizer Scrubbers, Hydrocarbon or Water Active Carbon Adsorber for Gaseous Stream Gas Compressor Dust Separator Gas Coolers Gas Refrigeration System Rotary Direct Dryer Dewatering Centrifuge Solids Incinerator Solids Cambustor Disposal Cost: Land Farming Disposal Cost: Gypsum Stacking Disposal Cost: Sanitary Landfill Disposal Cost: Hazardous-Waste Landfill Transportation Cost Treatment of Methanol Plant Wastes Treatment of Ethylene Plant Wastes (Ethane/Propane Pyrolysis) Treatment of Multiplant Wastes Treatment of Process Phosphoric Acid Plant Wastes (Pihydrate Wet Process) B.l Probability Plot of BOD Value c.1 Determination of BOD Removal Rate Coefficient c.2 Determination of Oxygen Utilization Coefficient c.3 Determination of Sludge Production Coefficient D.l Breakthrough Curves for Three Columns in Series D.2 Service Time ss a Function of Bed Depth ix

11 . TABLES 2.1 A Comparison of Modular Waste Treatment Estimates With Independently Estimated Values U.S. National Ambient Air Quality Standards Typical Effluent Limitations Promulgated by U.S. EPA According to the Federal Water Pollution Control Act Amendments of U.S. EPA List of Priority Toxic Pollutants as of December U.S. EPA-Proposed Water (Micrograms/Liter) Quality Criteria for Selected Toxic Pollutants Major Pollution Control Legislation by the U.S. Congress U.S. Pollution Abatement Expenditures for Air, Water, and Solids, by Chemical Industry Segment U.S. Pollution Abatement Operating Costs for Air, Water, and Solids, by Chemical Industry Segment Japanese Pollution Abatement Expenditures, Typical Thickener and Clarifier Design Criteria Water Pollutant Treatment Methods Toxic Inorganic and Organic Pollutants and Methods for Their Control Materials Rejected by Reverse Osmosis Commercial Oxidizing and Reducing Agents and Their Possible Applications to Waste Treatment Typical Flocculants and Coagulants and Their Applications Some Typical Filter Applications Typical Centrifuge Performance Characteristics Activated Sludge Process Characteristics Typical Compounds Susceptible to Ozonation Applications of Gas-Solid Separation Equipment Vapors Adsorbed by Activated Carbon U.S. EPA-Sponsored Waste Incineration Demonstration Plants.ll7 Xi

12 TABLES B.l SRI Module Investment Estimation Factors Comparison of Chemical Equipment Module Costs Estimated by Different Methods, SRI Module Maintenance Cost Estimation Factors Treatment Costs for Methanol Plant Wastes Treatment Costs for Ethylene Plant Wastes Treatment Costs for Combined Multiplant Wastes Treatment Costs for Phosphoric Acid Plant Wastes (Dihydrate Wet Process) Cumulative Normal Probability Distribution xii

WASTEWATER TREATMENT OBJECTIVES

WASTEWATER TREATMENT OBJECTIVES The student will do the following: 1. Define wastewater and list components of wastewater. 2. Describe the function of a wastewater treatment plant. 3. Create a wastewater