EPA 440/1-75/034a Group I, Phase II Development Document for Effluent Limitations G-uidelines and New Source Performance Standards for the PRESSED AND BLOWN GLASS Segment of the GLASS MANUFACTURING Point Source Category UNITED STATES ENVIRONMENTAL PROTECTION AGENCY JANUARY 1975 DEVELOPMENT DOCUMENT for EFFLUENT LIMITATIONS GUIDELINES and NEW SOURCE PERFORMANCE STANDARDS for the PRESSED AND BLOWN GLASS SEGMENT OF THE GLASS MANUFACTURING POINT SOURCE CATEGORY Russell E. Train Administrator James L. Agee Assistant Administrator for Water and Hazardous Materials Allen Cywin Director, Effluent Guidelines Division Robert W. Dellinger Project Officer January, 1975 Effluent Guidelines Division Office of Water and Hazardous Materials U.S. Environmental Protection Agency Washington, D.C. 20460 For sale by the Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402 Price $2.05 ABSTRAC'I This document presents the findings of an extensive study of the pressed and blown glass manufacturing industry by Sverdrup & Parcel and Associates. Inc., for the Environmental Protection Agency for the purpose of developing effluent limitations and guidelines, Federal standards of performance, and pretreatment standards for the industry for the purpose of implementing Sections 301. 304(b) and (c}, 306(b) and 307(b) and (c) of the Federal Water Pollution Control Act, as amended (33 U.S.C. 1251, 1311 and 1314(b) and (c), 1316(b) and 1317(c); 86 Stat. 816 et seq.). Effluent limitations and guidelines contained herein set forth the degree of effluent reduction attainable through the application of the best practicable control technology currently available and the degree of effluent reduction attainable through the application of the best available technology economically achievable which must be achieved by existing point sources by July 1, 1977, and July 1, 1983, respectively. The standards of performance for new sources contained herein are based on the degree of effluent reduction which is achievable through the application of the best available demonstrated control technology, processes, operating methods, or other alternatives. The development of data and recommendations in this document relate to the pressed and blown glass segment of the glass manufacturing point source category. This segment is further divided into six subcategories on the basis of production processes and waste water characteristics. separate effluent limitations are developed for each subcategory on the basis of the raw waste loading and the oegree of treatment attainable by suggested model systems. This technology includes in­ plant modifications, recirculation, precipitation, coagulation, sedimentation, flotation. stripping, filtration, and adsorption. Supportive data and rationale for the development of the effluent limitations guidelines and standards of performance are contained in this document. A portion of the pressed and blown glass segment, the machine pressed and blown glass industry and the remainder of the glass tubing industry, is the subject of further analysis at the present time. The results of this study will be presented as a supplement to this document at a later date. The remaining subcategories of the glass manufacturing point source category not contained in this document comprise the flat glass segment. The flat glass segment is the subject of a previous study {Development Document for Effluent Limitations Guidelines and New source Performance Standards for the FLATGLASS segment of the Glass iii Manufacturing Point Source Category, Effluent Guidelines Division, U.S. Environmental Protection Agency, EPA-440/1-74-001-c, January, 1974). Regulations pertaining to the flat glass segment were set forth in February of 1974 (Federal Register, Volume 39, Number 32, page 5712, February 14, 1974). iv TABLE OF CONTENTS I cone lusions II Recommendations 3 III Introduction 21 Purpose and Authority 21 summary of Methods 23 General Description of Industry 38 Production and Plant Location 39 General Process Description 41 IV ·Industry Categorization 51 V Water Use and Waste Characterization 57 Auxiliary Wastes 57 Glass contaner Manufacturing 58 Machine Pressed and Blown Glass Manufacturing 62 Glass Tubing (Danner) Manufacturing 68 Television Picture Tube Envelope Manufacturing · 72 Incandescent Lamp Envelope Manufacturing 77 Hand Pressed and Blown Glass Manufacturing 81 VI Selection of Pollutant Parameters 89 VII Control and Treatment Technology 103 Applicable Treatment Technology 103 Suggested Treatment Technology 118 Glass Container Manufacturing 118 Machine Pressed and Blown Glass Manufacturing 121 Glass Tubing (Danner) Manufacturing 122 Television Picture Tube Envelope Manufacturing 124 Incandescent Lamp Envelope Manufacturing 127 Hand Pressed and Blown Glass Manufacturing 131 TABLE OF CONTENTS Cost, Energy, and Non-Water Quality Aspects Cost and Reduction Benefits 139 Basis of Total Industry Cost Estimates 153 Energy Requirements 153 Non-water quality Aspects 157 IX Best Practicable Control Technology Currently Available 159 Introduction 159 Identification of Technology 159 Effluent Reduction Attainable 162 Rationale for Selection 164 X Best Available Technology Economically Achievable 167 Introduction 167 Identification of Technology 168 Effluent Reduction Attainable 170 Rationale for selection 172 XI New Source Performance Standards 175 Introduction 175 New Source Standards 176 Pretreatment considerations 177 XII Acknowledgements 179 XIII References 181 XIV Glossary 187 Conversion Table 190 vi FIGURES 1 Data Retrieval Form 25 2 Sample Computer Format 28 3 Location of Participating Glass Container Manufacturing Plants 35 4 Location of Participating Pressed and Blown Glass Manufacturing Plants 36 5 Glass Container Manufacturing 59 6 Machine Pressed and Blown Glass Manufacturing 64 7 Glass Tubing (Danner} Manufacturinq 69 8 Television Picture Tube Envelope Manufacturing 73 9 Incandescent Lamp Envelope Manufacturing 78 10 Hand Pressed and Blown Glass Manufacturinq 82 11 Waste water Treatment Glass Container Manufacturing 119 12 Waste Water Treatment Glass Tubing (Danner) Manufacturing 123 13 Waste Water Treatment Television Picture Tube Envelope 125 Manufacturing 14 waste Water Treatment Incandescent Lamp Envelope Manufacturing 128 vii FIGURES (Continued) 15 Waste Water Treatment - Hand Pressed and Blown Glass Manufacturing 133 16 waste water Treatment Hand Pressed and Blown Glass Manufacturing 134 TABLES PAGE l Glass Container Plants 29 2 Pressed and Blown Glass Plants 32 3 Plants Visited 37 Pressed and Blown Glass Manufacturing Production Data 40 5 Raw Wastewater, Glass Container Manufacturing 61 6 Raw Waste Water, Machine Pressed and Blown Glass Manufacturing 66 7 Raw Waste water, Glass Tubing (Danner) Manufacturing 71 8 Raw Waste water, Television Picture Tube Envelope Manufacturing 75 9 Raw waste Water, Incandescent Lamp Envelope Manufacturing 80 10 Raw Waste Water, Hand Pressed and Blown Glass Manufacturing 86 ll Concentration of Waste water Parameters Pressed and Blown Glass Manufacturing 90 12 Concentration of waste Water Parameters Incandescent Lamp Envelope Manufacturing 91 13 concentration of Waste Water Parameters Hand Pressed and Blown Glass Manufacturing 92 14 Current Treatment Practices Within the Hand Pressed and Blown Glass Manufacturing 135 Subcategory ix TABLES (Continued) PAGE 15 Current Operating Practices Within the Hand Pressed and Blown Glass Manufacturing Subcategory 135 16 Water Effluent Treatment Costs Glass Container Manufacturing 141 17 Water Effluent Treatment Costs Glass Tubing (Danner) Manufacturing 143 18 Water Effluent Treatment costs Television Picture Tube Envelope 145 Manufacturing 19 Water Effluent Treatment Costs Incandescent Lamp Envelope Manufacturing 147 20 Water Effluent Treatment Costs Hand Pressed and Blown Glass Manufacturing 150 21 Water Effluent Treatment Costs Hand Pressed and Blown Glass Manufacturing Suspended Solids Removal 151 22 Known Surface Dischargers Glass Container Manufacturing Subcategory 154 23 Known Surface Dischargers Machine Pressed and Blown Glass Manufacturing subcategory 155 24 Known surface Dischargers Glass Tubing Manufacturing Subcategory 155 X TABLES (Continued) NUMBER PAGE 25 Known Surface Dischargers Television Picture Tube Envelope Manufacturing Subcategory 155 26 Known Surface Dischargers Incandescent Lamp Envelope Manufacturing Subcategory 156 27 Known Surface Dischargers Hand Pressed and Blown Glass Manufacturing subcategory 156 28 Recommended 30-Day Average Effluent Limitations Using Best Practicable Control Technology Currently Available 161 29 Recommended 30-Day Average Effluent Limitations Using Best Available Control Technology Economically Achievable 169 xi SECTION I CONCLUSIONS The pressed and blown glass segment of the glass manufacturing category has been classified into six subcategories. The first three subcategories include only the forming of products from molten glass while the last three include both the forming and finishing of glass products. The subcategorization is based on (a) production process and· {b) waste water characteristics. Factors such as raw materials, age and size of production facilities, and applicable treatment technology do not provide significant bases for differentiation. The subcategories indicated are as follows: 1. Glass Container Manufacturing 2. Machine Pressed and Blown Glass Manufacturing 3. .Glass Tubing Manufacturing a. Glass Tubing - Danner process 4. Television Picture Tube Envelope Manufacturing 5. Incandescent