# WWT Sludge:

Solution that is generated during the zinc phosphate conversion coating process of automobiles is sent

to WWT treatment plant. This solution contains the following components:

Iron Oxide (Fe

2 

# O 3 

# or FeO ) (36.97%),

Calcium Oxide (10.62%),

Aluminum Oxide (0.55%),

Magnesium Oxide (3.93%),

Zinc O xide (8.56%)

Nickel O xide (4.43%)

During the WWT treatment process NaOH is used to convert metals to hydroxides and then a

flocculating agent (ferric chloride or polymeric substance) is used to precipitate these metals

.

# Description Honda (Greensburg, In.)

Date 7/28/10

Constituent % TSCA Chemical CAS No.

CaO 

# 10.62 Calcium hydroxide (Ca(OH)2) 1305620

SiO2 

# 2.62

Al203 

# 0.55 Aluminum hydroxide (Al(OH)3) 21645512

Fe2O3 

# 36.97 Iron hydroxide (Fe(OH)3) 1309337

MgO 

# 3.93 Magnesium hydroxide (Mg(OH)2) 1309428

SO3 

# 0.45

Na2O 

# 1.96

K2O 

# 1.28

TiO2 

# 1.28

P2O5 

# 25.26

Mn2O3 

# 1.68

SrO 

# 0.08

Cl 

# 0.24

F 

# ND

V2O5 

# ND

CR2O3 

# ND

ZnO 

# 8.56 Zinc Hydroxide (Zn(OH)2) 20427581

CuO 

# ND

Br 

# ND

NiO 

# 4.43 Nickel hydroxide (Ni(OH)2) 12054487

ZrO2 

# ND

Ga2O3 

# ND

Co3O4 

# ND

SnO2 

# 0.1

Bi2O3 

# ND

Y2O3 

# ND

I 

# ND

HfO2 

# ND

Nb2O5 

# ND

As2o3 

# ND

PbO 

# ND

GeO2 

# ND

Rb2O 

# ND

MoO3 

# ND

TI2O3 

# ND

SeO2 

# ND

WO3 

# ND

CeO2 

# ND

Sb2O3 

# ND

CeO2 

# ND

Sb2O3 

# NDPre-Cleaning Degrease Rinse Rinse Conditioning Phosphate RinseRinseRinseDip RinseTo E/CoatPPre-Cleaning Degrease RinseTo E/Coat ProcessConditioning Phosphate RinseRinseDip RinseFromWeldJetSprayRegulated metals (Zn, Ni) in current PA processrequire industrial wastewatertreatment in plant FACFirst coating processin paint shop is aconversion coating(zinc phosphate)Chemistry of phosphatingFe + 2H3PO4Fe(H2PO4)2+ H2Zn(H2PO4)2ZnHPO4+ H3PO43ZnHPO4Zn3(PO4)2+ H3PO4Zn(H2PO4)2,Ni(NO3)2, HFPlant FACIndustrialWastewaterTreatmentSystemLow concentration ofZn, Ni etc. in normal rinsedischarge to plant FACduring productionHigh concentration ofZn, Ni etc. in tank-cleaningdischarge to plant FACduring Dec/Jul Shutdown1100FCorrosion preventionSituation AnalysisHM Global ProcessPrimer/Surfacer PitClearcoat PitTopcoat Pit#1 DIW Rinse#2 DIW RinseInfluent MetalsSumpTreatmentChemicalsPP(2) Pumps(3) Raw Metals Batch Treatment Tanks150,000 Gallon Capacity EachPPFlow Meter(2) PumpsGravity Settler55 Gal.DrumPolymer FeedSystemPP(2) PumpsPolymerAdditionCombined Sludge Tank35,000 Gallon CapacitySandFilterTreatedWastewaterTransferInfluentSumpPP(2) Pumps(2) Treated Effluent Tanks150,000 Gallon Capacity EachPotentialChemicalTreatmentPP(2) PumpsFlow Meter(1) Flow Equalization Tank500,000 Gallon CapacityPretreated Process Wastewaterdischarged to City of MarysvilleSanitaryEffluent“Filter Cake”Sent OffsiteSludgeDe-wateringFilterPressAnionicCationicFlow Meter(1) Recycled Water Tank30,000 Gallon CapacityIndustrialWaterRecycled WaterDistributed to Toilets(3) PumpsPPPE-Coat Tank#1 Permeate#2 Permeate#3 Permeate#4 PermeateStage 8 #4 Water RinseStage 9 #5 Water RinseStage 7 #3 Water RinseStage 6 PhosphateStage 5 Surface ConditionerStage 4 #2 Water RinseStage 3 #1 Water RinseStage 2 Main CleanStage 1 Pre-CleanBumper Paint PlantAnolyte#4 DIW Rinse#3 DIW RinseHonda of America Manufacturing, Inc.ELP-002SamplingLocationpH AdjustmentAvg.=118,465GPDChemistry of waste treatmentZn+++ NaOHZn(OH)2+ Na+Metal hydroxide sludge generationMAP & ELP FAC Industrial Wastewater Treatment Process FlowPAFACCityENVChelationofheavymetalsbyEDTA inPA Degreasermakes it verydifficult andcostlyto break the bonds,andcapture from solution asmetal hydroxide precipitate

# Honda Marysville

Line 1 Pretreat