Table 15 Phosphate Manufacturing Industry Wastewater Treatment Practises and Unit Removal Efficiencies and Effluent pH unit

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Phosphorus Phosphorus- Defluorinated Defluorinated Sodium Pollutant and production consuming Phosphate phosphate phosphoric phosphate method__(A)__(B)__(C) rock (D) acid (E) (F)

Lime treatment and sedimentation3 TSS

Lime treatment and sedimentationa Flocculation, clarification, and dewatering Total phosphate Lime treatment and sedimentationa Phosphorus Lime treatment and sedimentationa Flocculation, clarification, and dewatering Sulfate

Lime treatment and sedimentationa Fluoride Lime treatment and


sedimentation3 pH (effluent level)_______

Lime treatment 6-8b 6-8b 6-8b and sedimentationa (neutralization)

aPreceded by recycle of phossy water and evaporation of some process water in subcategories A, B, and C.

TDS, total dissolved solids; TSS, total suspended solids. bpH values in units. Source: Ref. 8.

point of mixing of lime addition and on the constancy of pH control. Fluosilisic acid reacts with lime and precipitates calcium fluoride in this step of the treatment.

The wastewater is again treated with a second lime addition to raise the pH level from 8 to at least 9 (where phosphate removal rates of 95% may be achieved), although two-stage dosing to pH 11 may be employed. Concentrations of phosphorus and fluoride with a magnitude of 6500 and 9000 mg/L, respectively, can be reduced to 5-500 mg/L P and 30-60 mg/L F. Soluble orthophosphate and lime react to form an insoluble precipitate, calcium hydroxy apatite [17]. Sludges formed by lime addition to phosphate wastes from phosphate manufacturing or fertilizer production are generally compact and possess good settling and dewatering characteristics, and removal rates of 80-90% for both phosphate and fluoride may be readily achieved [13].

The seepage collection of contaminated water from phosphogypsum ponds and reimpoundment is accomplished by the construction of a seepage collection ditch around the perimeter of the diked storage area and the erection of a secondary dike surrounding the first [8]. The base of these dikes is usually natural soil from the immediate area, and these combined earth/gypsum dikes tend to have continuous seepage through them (Fig. 10). The seepage collection ditch between the two dikes needs to be of sufficient depth and size to not only collect contaminated water seepage, but also to permit collection of seeping surface runoff from the immediate outer perimeter of the seepage ditch. This is accomplished by the erection of the small secondary dike, which also serves as a backup or reserve dike in the event of a failure of the primary major dike.

The sulfuric acid plant has boiler blowdown and cooling tower blowdown waste streams, which are uncontaminated. However, accidental spills of acid can and do occur, and when they do, the spills contaminate the blowdown streams. Therefore, neutralization facilities should be supplied for the blowdown waste streams (Table 15), which involves the installation of a reliable pH or conductivity continuous-monitoring unit on the plant effluent stream. The second part of the system is a retaining area through which non-contaminated effluent normally flows. The detection and alarm system, when activated, causes a plant shutdown that allows location of the failure and initiation of necessary repairs. Such a system, therefore, provides the continuous protection of natural drainage waters, as well as the means to correct a process disruption.

Mixed fertilizer (subcategory G) treatment technology consists of a closed-loop contaminated water system, which includes a retention pond to settle suspended solids. The water is then recycled back to the system. There are no liquid waste streams associated with the blend fertilizer (subcategory G) process, except when liquid air scrubbers are used to prevent air pollution. Dry removals of air pollutants prevent a wastewater stream from being formed.

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