t> .
202:260-7151
Fax:202-260-7185
. jett.george@epa.gov
George M. Jett
Chemical Engineer
.U.S. EnYironmental Protection Agency^
Engineering and Analysis Division (4303)"
1200 Pennsylvania Avenue, NW
Washington, D.C. 20460
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DEVELOPMENT DOCUMENT
for
EFFLUENT LIMITATIONS GUIDELINES
NEW SOURCE PERFORMANCE STANDARDS
and
PRETREATMENT STANDARDS
for the
IRON AND STEEL MANUFACTURING
POINT SOURCE CATEGORY
Anne M: Gorsuch
Administrator
Steven Schatzow
Director
Office of Water Regulations and Standards
<*
UJ
(9
Jeffery Denit, Acting Director
Effluent Guidelines Division
Ernst P. Hall, P.E.
Chief, Metals & Machinery Branch
Edward L. Dulaney, P.E.
Senior Project Officer
May, 1982
Effluent Guidelines Division
Office of Water Regulations and Standards
U.S. Environmental Protection Agency
Washington, D.C. 20460
Vm- sale by the Superintendent of Documents. U.S. Government Printing Office, Washington, D.C. 204():>
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SECTION
I
II
III
IV
V
VI
VII
VIII
HOT FORMING SUBCATEGORY
TABLE OF CONTENTS
SUBJECT
PREFACE
CONCLUSIONS
INTRODUCTION
General Discussion
Data Collection Activities
Description of Hot Forming Operations
SUBCATEGORIZATION
Introduction
Factors Considered in Subcategorization
WATER USE AND WASTEWATER CHARACTERIZATION
Introduction
General Discussion
Water Use
Wastewater Characterization
Recycle Water Rates
Wastewater Characteristics
WASTEWATER POLLUTANTS
Introduction
Conventional Pollutants
Toxic Pollutants
CONTROL AND TREATMENT TECHNOLOGY
Introduction
Summary of Treatment Practices Currently
Employed
Control and Treatment Technologies for
BAT, BCT, NSPS, PSES, and PSNS
Evaporation
Summary of Monitoring Data
Plant Visits
Impact of Intake Water Quality
COST, ENERGY, AND NON-WATER QUALITY IMPACTS
Introduction
Actual Costs Incurred by the Plants Sampled
for this Study
PAGE
1
3
11
1 1
11
12
85
85
86
107
107
107
107
108
112
112
131
131
131
132
137
137
137
138
139
139
140
152
241
241
241
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HOT FORMING SUBCATEGORY
TABLE OF CONTENTS (Continued)
SECTION
IX
XI
XII
XIII
SUBJECT
Recommended Control and Treatment Technology
Cost, Energy, and Non-water Quality Impacts
Introduction
Development of Costs
Estimated Costs for the Installation of
Pollution Control Technologies
Energy Impacts
Non-Water Quality Impacts
Summary of Impacts
EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLI- 307
CATION OF THE BEST PRACTICABLE CONTROL TECHNOLOGY
CURRENTLY AVAILABLE
PAGE
241
242
242
242
243
244
245
246
Identification of BPT
Development of the BPT Effluent Limitations
BPT Effluent Limitations
Demonstration of BPT Effluent Limitations
EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLI-
CATION OF THE BEST AVAILABLE TECHNOLOGY
ECONOMICALLY ACHIEVABLE
Introduction
Identification of BAT
Rationale for the Selection of the BAT
Alternatives
Selection of a BAT Alternative
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY
EFFLUENT QUALITY ATTAINABLE THROUGH THE APPLICA-
TION OF NEW SOURCE PERFORMANCE STANDARDS
Introduction
Identification of NSPS
Rationale for Selection of NSPS
Selection of an NSPS Alternative
Demonstration of NSPS
PRETREATMENT STANDARDS FOR DISCHARGES TO
PUBLICLY OWNED TREATMENT WORKS
Introduction
General Pretreatment Standards
307
308
310
310
341
341
341
342
343
353
355
355
355
355
356
356
367
367
367
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NUMBER
II-l
II-2
II-3
II-4
III-l
III-2 to
III-7
II1-8 to
111-12
IV-1
IV-2
V-l to
V-15
VI-1
VI-2
VI-3
VII-1
VII-2 to
VII-9
VII-10
VII-11
VII-12 to
VII-15
HOT FORMING SUBCATEGORY
TABLES
TITLE
BPT/BCT Treatment Model Flows and Effluent
Quality
BPT/BCT Effluent Limitations
Treatment Model Flows and Effluent Quality
Effluent Limitations and Standards
Summary of Sampled Plants
General Summary Tables
Data Base Summary Tables
Examples of Plants with Retrofitted
Pollution Control Equipment
Geographic Location of Subcateogry
Operations
Summaries of Analytical Data from Sampled
Plants: Net Raw Concentrations
Toxic Pollutants Known to be Present
Summary of Net Primary Scale Pit Effluent
Concentrations
Selected Pollutants
List of Control and Treatment Technology
(C&TT) Components and Abbreviations
Summaries of Analytical Data from Sampled
Plants; Raw Wastewaters and Effluents
Summary of Long-Term Data
D-DCP Scale and Oils Generation Data
Net Concentration and Load Analysis Tables
PAGE
6
7
8
9
23
26
71
95
97
114
133
134
135
153
158
181
182
183
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HOT FORMING SUBCATEGORY
TABLES (Continued)
NUMBER
VIII-1
VIII-2
VIII-3
VII1-4
VII1-5 to
VIII-16
VIII-17
VIII-18 to
VIII-29
VIII-30 to
VIII-41
VIII-42
VIII-43
VIII-44
IX-1
IX-2 to
IX-9
IX-10
IX-11
IX-12
IX-13
TITLE
Comparison of Actual Costs Reported by
Industry Versus EPA Estimates
Model Control and Treatment Technology
Summary
Land Requirements Summary: BPT
Treatment Models
Land Requirements Summary: BAT
Treatment Models
BPT Treatment Model Cost Tables
BPT Cost Summary: In-Place and Required
BAT/PSES Treatment Model Cost Tables
NSPS/PSNS Treatment Model Cost Tables
BPT and BAT Energy Requirements Summary
PSES Energy Requirements Summary
BPT and PSES Solid Waste Generation
Summary
Raw Wastewater Characteristics
Applied Flow Determination Tables
Analysis of Recycle Rates from Primary
Scale Pits
Long-Term Data Analysis for Filtration
Systems: Total Suspended Solids
Long-Term Data Analysis for Filtration
Systems: Oil and Grease
BPT Effluent Limitations
PAGE
248
249
251
252
253
265
266
278
301
302
303
312
313
326
328
329
330
IV
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NUMBER
IX-14 to
IX-21
IX-22
X-l
X-2
X-3
XII-1
XII-2 to
XII-8
HOT FORMING SUBCATEGORY
TABLES (Continued)
TITLE
Justification of BPT Effluent Limitations
Examples of Plants in Compliance with BPT
Limitations
BAT Effluent Limitations
Analysis of Overall Recycle Rates
Toxic Metals Concentrations
New Source Performance Standards
Demonstration of NSPS
PAGE
331
339
345
346
350
357
358
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NUMBER
III-l to
II-8
IV-1 to
IV-8
VII-1 to
VII-54
VIII-1
VIII-2
IX-1
X-l
XII-1
HOT FORMING SUBCATEGORY
FIGURES
TITLE
Process Flow Diagrams
Discharge Flow Versus Size and Age Plots
Treatment System Diagrams of Sampled
Plants
BPT/BCT/BAT/PSES Treatment Models
NSPS/PSNS Treatment Models
BPT Treatment Model
BAT Treatment Models
NSPS Treatment Model
PAGE
76
98
187
304
305
340
351
365
VII
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HOT FORMING SUBCATEGORY
SECTION I
PREFACE
The USEPA has promulgated effluent limitations and standards for the
steel industry pursuant to Sections 301, 304, 306, 307 and 501 of the
Clean Water Act. The regulation contains effluent limitations
guidelines for best practicable control technology currently available
(BPT), best conventional pollutant control technology (BCT), and best
available technology economically achievable (BAT) as well as
pretreatment standards for new and existing sources (PSNS and PSES)
and new source performance standards (NSPS).
This part of the Development Document highlights the technical aspects
of EPA's study of the Hot Forming Subcategory of the Iron and Steel
Industry. Volume I of the Development Document addresses general
issues pertaining to the industry, while other volumes contain
specific subcategory reports.
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HOT FORMING SUBCATEGORY
SECTION II
CONCLUSIONS
Based upon the current study, a review of previous studies, and
comments received on the regulation proposed on January 7,1981 (46 FR
1858), the Agency has reached the following conclusions:
1. The Agency has combined all hot forming operations into one
subcategory. The four major subdivisions of the subcategory
reflect significant differences in production processes and
wastewater flows. To further account for product related flow
differences, three of the subdivisipns have been segmented on the
basis of process differences (scarfing), type of metal (carbon or
speciality), and type of product (plate or strip). All hot
forming wastewaters are similar in character and can be treated
to the same effluent levels. The hot forming subcategory is
subdivided as follows:
Hot Forming - Primary
Carbon and Specialty Operations wo/scarfers
Carbon and Specialty Operations w/scarfers
Hot Forming — Section
Carbon Operations
Specialty Operations
Hot Forming - Flat
Hot Strip and Sheet Operations
Carbon Plate Operations
Specialty Plate Operations
Hot Forming - Pipe and Tube
2. The BPT, BCT, and NSPS, limitations and standards are based upon
model plant flow rates (applied and discharge) and effluent
quality determined from the expanded data base of the industry
that the Agency obtained as part of this study. While these
model flow rates are different than those used to develop the
limitations promulgated in 1976, they are more representative of
the wastewater flows of the industry. Thus, the Agency believes
it is appropriate to the wastewater flows of establish effluent
limitations based upon these flow data.
3. During this study, the Agency found that untreated wastewaters
from . hot forming operations contain significant levels of
conventional and toxic metal pollutants. Toxic organic
pollutants were found only at low levels and only.in some hot
forming wastewaters. As shown below, the Agency finds that
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discharges of these pollutants can be controlled by the BPT model
treatment system. These technologies are well demonstrated
throughout the hot forming subcategory.
Direct Discharge
Effluent Loadings (Tons/Year)
Raw Waste BPT
Flow, MGD
TSS
Oil and Grease
Toxic Metals
3,680
5,878,201
174,540
49,460
1,419
15,081
3,078
114
Indirect Discharge
Effluent Loadings (Tons/year)
Flow, MGD
TSS
Oil and Grease
Toxic Metals
Raw Waste
295
444,156
13,777
3,505
Current Discharge
118
1,284
449
32
Although several toxic metal pollutants were identified in the
untreated wastewaters from hot forming operations, BAT effluent
limitations have not been promulgated for these pollutants. The
Agency has concluded the discharge of toxic metals is adequately
controlled by the the model BPT treatment system. Thus, BAT
limitations and pretreatment standards have not been promulgated
for hot forming . operations. The Agency did not promulgate
pretreatment standards for hot forming operations because there
are relatively few indirect hot forming dischargers; all indirect
hot forming discharges are treated to a level where significant
quantities of toxic metals will not enter POTWS; and, because of
the user fees for POTWs, the Agency does not expect that any
untreated discharges of hot forming wastewaters will be directed
to POTWs.
The Agency estimates that the industry will incur the following
costs to comply with the BPT limitations for facilities in place
as of July 1, 1981. The Agency has determined that the effluent
reduction benefits associated with compliance with the effluent
limitations justify the costs presented below:
Costs (Millions of July 1, 1978 Dollars)
Investment Annual
BPT
In-place
380.1
Required
94.9
In-place Required
-40.8 12.0
The Agency has also determined that the effluent reduction
benefits associated with compliance with new source performance
standards (NSPS) justify those costs.
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6. Information provided by the industry indicate that recycle
components included in the Agency's BPT and NSPS model treatment
systems, are in use at hot forming plants and present no
significant problems pertaining to scaling, fouling, or plugging.
7. The model new source.performance standards treatment system is
based upon high rate (96%) recycle of hot forming wastewater.
8. With regard to "remand" issues, the Agency concludes that;
a. The age of a plant has little or no effect upon the ease or
cost of retrofitting pollution control equipment.
Therefore, neither relaxed limitations for "older" plants
nor less stringent limitations based upon retrofit costs are
established for hot forming operations.
b. The BPT model wastewater treatment system does not include
evaporative cooling systems. Hence, BPT limitations
promulgated for the hot forming subcategory will not
increase the consumptive use of water to any significant
degree. The NSPS treatment system includes an evaporative
cooling system but the amount of water consumed as a result
of the installation of this technology will be minimal. The
Agency concludes that the effluent reduction benefits
associated with NSPS justify the minor consumptive water
losses which new source plants would incur both on a
national basis, and on an "arid" and "semi-arid" regional
basis. Recycle systems including evaporative cooling towers
and evaporative cooling ponds are in use at plants located
in arid and semi-arid regions of this country. Additional
details on these and other remand issues are presented in
Volume I and in Section VIII of this report.
Table II-l presents the treatment model flow and effluent quality
data used to develop the promulgated BPT and BCT effluent
limitations for the hot forming subcategory, and Table I1-2
presents these limitations. Table I1-3 presents the treatment
model flow and effluent quality data used to develop the
promulgated NSPS. Table I1-4 presents the standards contained in
the regulation for NSPS.
10. The cost data presented above are different than those used by
the Agency in the economic impact analysis completed for this
regulation. The Agency found an error in the model treatment
system flow rate for carbon steel section mills.
resulted in an overstatement of the required cost of
used in the economic impact analysis (about $1.1 million in
investment costs, and $0.15 million in annual costs). The Agency
does not consider these differences significant in terms of
whether or not the effluent reduction benefits are justified, or
in terms of the economic impact analysis.
9.
The error
compliance
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TABLE II-l
Subdivision
1. Primary
a. wo/scarfers
b. w/scarfers
2. Section
a. carbon
b. specialty
3. Flat
a. hot strip
b. carbon plate
c. specialty plate
4. Pipe & Tube
BPT/BCT TREATMENT MODEL FLOWS AND
EFFLUENT QUALITY - HOT FORMING SUBCATEGORY
30-Day Average and Daily Maximum
Flow
(GPT)
897
1326
2142
1344
2560
1360
600
TSS
Avg
15
15
15
15
15
15
15
Max
40
40
40
40
40
40
40
0&G(1)
10
10
10
10
10
10
10
Concentrat ions.
PH
6
6
6
6
6
6
6
(Units)'
- 9
- 9
- 9
- 9
- 9
- 9
- 9
1270
15
40
10
6-9
(1) Daily maximum concentration only.
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TABLE II-2
BPT/BCT EFFLUENT LIMITATIONS
. HOT FORMING SUBCATEGORY
30-Day Average and Daily Maximum
Effluent Limitations (kg/kkg of Product)
Subdivision
1. Primary
a. wo/ scarfers
b. w/ scarfers
2. Section
a. carbon
b. specialty
3. Flat
a. hot strip
b. carbon plate
c. specialty plate
4. Pipe & Tube
CD
Avg
0.0561
0.0830
0.134
0.0841
0.160
0.0851
0.0375
0.0795
Max
0.150
0.221
0.357
0.224
0.427
0.227
0.100
0.212
O&G
0.0374
0.0553
0.0894
0.0561
0.107
0.0567
0.0250
0.0530
pH (Units)
6-9
6 - 9
6-9
6-9
6-9
6-9
6-9
6 - 9
(1) Daily maximum effluent limitations only.
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TABLE I1-3
TREATMENT MODEL FLOWS AND EFFLUENT QUALITY
HOT FORMING SUBCATEGORY
Subdivision
1. Primary
a. w/o Scarfers
b. w Scarfers
2. Section
a. Carbon
b. Specialty
3. Flat
a. Hot Strip & Sheet
b. Carbon Plate
c. Specialty Plate
4. Pipe & Tube
Flow Rates (gal/ton)
BAT
90
140
200
130
260
140
60
NSPS
90
140
200
130
260
140
60
PSES
897
1326
2142
1344
2560
1360
600
PSNS
897
1326
2142
1344
2560
1360
600
220
220
1270
1270
30-Day Average and Daily Maximum Concentrations
Pollutant
TSS
O&G
pH (Units)
BAT«>
Avg Max
Avg
15
6.0
NSPS
Max
40
10
to 9.0
PSES2)
Avg Max
PSNS(2)
Avg Max
Note: Concentrations apply to all hot forming subdivisions and are
expressed in mg/1 unless otherwise noted.
(1) BAT limitations have not been promulgated.
(2) Only the General Pretreatment Regulations (CFR Part 403) apply.
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HOT FORMING SUBCATEGORY
SECTION III
INTRODUCTION
General Discussion
Hot forming is the process in which hot steel, initially in solid
ingot form or in intermediate shapes, is reduced in cross-section
through a series of forming steps, ultimately producing finished and
semi-finished steel products. These products have numerous
cross-sections, lengths and tonnages. While several different types
of hot forming mills are in use today, the hot forming processes have
been grouped into one subcategory with the following manor
subdivisions.
Primary Mills
Section Mills
Flat Mills
Pipe and Tube Mills
Figure III-l
operations.
illustrates the sequences involved in hot forming
Process wastewaters originating in the hot forming processes require
treatment prior to discharge to receiving waters. Those wastewaters
contain large amounts of suspended solids, oil and grease, and to a
lesser extent, toxic metal pollutants. Toxic organic pollutants have
been detected in some hot forming wastewaters. This report reviews
wastewater treatment systems used at hot forming operations and
presents model treatment systems and applicable effluent limitations
and standards.
Data Collection Activities
The Agency sampled a total of 101 hot forming operations to obtain
process information and wastewater quality data. The originally
promulgated limitations for hot forming operations were based
primarily upon data obtained through field sampling at 52 mills.
Sixty operations were sampled during the recent toxic pollutant
surveys (eleven operations were resampled). Table III-l presents a
short description of each mill sampled.
The general methodology and approach for data collection is described
in Volume I. Information regarding applied and discharge flow rates,
treatment systems in use, production capacities and modes of operation
were provided by the industry for 485 mills. Tables III-2 through
III-7 summarize the information received for the respective hot
forming processes.
11
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In an effort to gather additional data, the Agency issued detailed
data collection portfolios (D-DCPs) for thirty-one hot forming
operations. These questionnaires were designed to gather information
on long-term effluent quality, treatment costs and other operating
data.
Tables II1-8 through II1-12 summarize the data base for this report.
Description of Hot Forming Operations
Primary Rolling Mills
The hot forming, primary mill is used to produce semi-finished
products from re-heated steel ingots. Primary mills produce either
blooms or slabs. Slabs are oblong shapes with cross-sections varying
from 2" to 6" thick and 24" to 60" wide. Blooms are square or
slightly oblong and are generally in the range of 6" x 6" to 10" x
12". These product dimensions are typical reference sizes. A wide
range of cross-sections are produced in primary mills. Blooming, and
slabbing mills are generally identified1 by the number of rolls or by
the roll diameter and length, such as a two high reversing mill or a
45" x 90" slabbing mill. Blooming mills may be coupled with billet
mills so that the semi-finished bloom can immediately be rolled in the
billet mill without reheating.
The operation of a typical primary mill is described below:
The hot steel ingots are transferred to the primary mills from soaking
pit furnaces which uniformly heat the steel ingots to the desired
rolling temperature, usually 1180 to 1340°C (2,156 to 2,444°F>. The
soaking pits also act as storage areas to compensate for production
variations in the flow of steel ingots between the steelmaking
facilities and primary rolling mills. The soaking pit furnaces are
square, rectangular, or circular, fuel fired (i.e., oil, gas),
refractory lined pits constructed with the top of the pits several
feet above ground level. The soaking pits are usually arranged in
rows and are installed in a building adjacent to or within the primary
mill. The ingots are placed into the soaking pits in an upright
position through openings in the top. Removable covers are used to
close the pit openings. The pits are spanned by one or more cranes
equipped with ingot lifting tongs for placing and removing the steel
ingots. The crane removes the properly heated steel ingots and places
them into an electrically driven ingot transfer car which
automatically delivers the ingots to the primary rolling mill.
The mill approach tables transport the ingot to the front table or
roller table in preparation for rolling. Some mills are equipped with
a scale in the ingot receiving table or mill approach tables for
weighing the ingot prior to rolling. Depending upon the type of
primary mill (i.e., reversing, tandem), the hot ingot is passed
between the mill rolls and reduced in cross-section. In a reversing
mill, the ingot is rolled through the same mill stand a number of
times. A tandem mill is comprised of several mill stands such that
12
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the ingot is continuously rolled forward in one direction. Mill
speeds are generally 200 to. 400 feet per minute. During the rolling
cycle, the ingot is transported to and from the mill stands bv
reversing rolls. The rolls are 12 to 21 inches in diameter and are
spaced 2 to 3 feet apart. These rolls are driven by line shafts.
After the ingot is rolled to the desired size, the end of the bloom,
slab, or billet is cut off or "cropped." A crop shear is also used to
cut long rolled sections into several shorter pieces.
The industry is paying increased attention to the conditioning of
semi-finished products as the demand for high quality steel products
increases. The removal of surface defects from blooms, billets, and
slabs prior to final rolling is a major consideration. Defects such
as rolled seams, light scabs, and checks generally retain their
identity during subsequent forming processes and result in products of
inferior quality. These surface defects may be removed by hand
chipping, machine chipping, scarfing, grinding, milling, and hot steel
scarfing. The various mechanical means of surface preparation are
common to all metal working and machine shop operations. Scarfing is
a process of supplying streams of oxygen as jets to the surface of the
steel product under treatment, while maintaining high surface
temperatures, which results in the rapid oxidation and localized
melting of a thin layer of the metal. The process may be done
manually (involving the continuous motion of an oxyacetylene torch
along the length of the product) but in recent years automatic hot
scarfing has come into wide use. The scarfing machine is located at
the mill run out tables or at the.shear approach tables.
The automatic hot scarfing process first uses flames generated by the
burning of oxygen and fuel (either acetylene or natural gas) to
preheat the semifinished product surface to steel melting
temperatures. A continuous stream of pure oxygen is then directed
onto the reheated steel surface and the semifinished product is then
moved at a controlled speed through the scarfing machine. The oxygen
applied to the entire surface of the billet, bloom or slab oxidizes
the steel surface, and removes a surface layer to a predetermined
depth, typically not in excess of 1/8 inch.
The automatic scarfing machine scarfs steels at speeds between 50 to
200 feet per minute. A typical operating cycle for an automatic hot
scarfer is shown below.
a.
b.
c.
d.
e.
Position product
Close scarfing units
around product
Preheat product surface
Scarf (Oxygen on)
Retract scarfing units
Total
7 seconds
3 seconds
5 seconds
30 seconds
5 seconds
50 seconds
The scarfing machine is mounted on a motor driven carriage on rails
and can be moved in and out of the primary rolling mill run out table
13
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line. The removal of the surface metal results in a continuous
production of molten slag. The quantity of slag generated depends
upon the section size and depth of cut and is removed by high pressure
water sprays.
Scarfing also results in appreciable quantities of smoke. The
quantity and density are dependent upon the type of steel, oxygen
pressure, and the efficiency of slag water jets. Hoods are placed
over the scarfing roll table to collect the fumes which contain solids
consisting mainly of iron oxides with traces of the alloying elements
found in the steel being scarfed. The solids are submicron in size,
and are produced at an approximate rate of 36 grains per pound of
product surface metal removed.
The exhaust gases are comprised mainly of air with some quantities of
CO and CO2 (2%). These gases are saturated at a temperature of 60°C
(140°F) when exiting the scarfer hood. Because these gases are
saturated, three types of gas cleaning equipment systems are generally
used:
1. Wet Precipitator - Intermittent Spray Wash
2. Wet Precipitator - Continuous Wash
3. High Energy Venturi Scrubber
The wet precipitator - intermittent spray wash uses a spray water wash
on a timed cycle to cleanse the fume residue which is collected dry on
the precipitator plates. The wet precipitator - continuous wash, uses
a continuous water wash to cleanse the collected fume residue from
precipitator plates. The high energy scrubber requires 45 to 50
(inches water column) pressure drop to clean the gases, and requires
scrubbing water at a rate of 7 to 12 gallons per 1000, cubic feet of
saturated gas exhausted. The effluent wastes from these gas cleaning
systems are generally discharged to the primary mill wastewater
treatment system. At many mills, scarfer wastewaters are recycled
continuously with only a blowdown discharged to the primary mill
treatment system.
Many primary mills are being replaced with continuous casting
operations referred to as billet, bloom or slab casting machines. The
casting machines, in turn, furnish the steel slabs or blooms to the
section mills.
See Figures
diagrams.
III-2 and III-3 for primary rolling mill process flow
Section Rolling Mills
The section rolling mill uses the semi-finished product from the
primary mill as a raw material and produces either an intermediate
finished product called a billet, which is further reduced in other
finishing mills, or rolls the bloom directly to a finished product.
Most billets are rolled directly from the primary mill without
14
-------
reheating furnaces but some steel plants employ furnaces between the
primary and section mills.
Reheating is necessary for section operations whenever the temperature
of the steel falls below that temperature required to maintain
plasticity. Reheating furnaces are either batch or continuous. Batch
furnaces are those in which the charged material remains in a fixed
position on the hearth until heated to rolling temperature.
Continuous furnaces are those in which the charged material moves
through the furnace and is heated to rolling temperature as it
progresses toward the exit. Batch furnaces vary in size from those
with hearths of only a few feet square to those 20 ft in depth by 50
ft long. Some modern continuous furnaces have hearths 80 to 90 feet
long.
Automatic hot scarfing is used at five section mills. The automatic
hot scarfer used for the section mill operations is the same as
described for primary rolling mills.
The intermediate and finished products produced from section mills
include rails, joint bars, I-beams, channels, angles, wide flanged
beams, H-beams, sheet piling, and billets which are further processed
into tube rounds, bar and rod, wire, and numerous special sections.
Following is a brief description of the various section mills.
Billet Mills
There are several types of billet mills. One is the three high mill
with lifting and tilting tables. This mill consists of three rolls
mounted on a single roll housing stand, one roll above the other.
Billets are rolled in one direction between the bottom and middle
rolls and in the opposite direction between the middle and top rolls.
The lifting and tilting tables move the billets to the two different
pass levels. Mills of this type can produce only a limited number of
product sizes.
Another billet mill design is the cross-country mill which is composed
of several roll stands so arranged that the billet is never in more
than one stand at the same time. The roll stands may be placed side
by side and the billet transferred to the various roll tables. The
direction of rolling can be reversed in each stand. The cross country
billet mill is faster and more flexible than the three high mill and
can roll a wide range of billet sizes.
A third billet mill design is the continuous billet mill in which a
series of roll stands continuously reduce the billet in size, rolling
in only one direction through the mill stands. Continuous billet
mills have high production rates and minimal scrap losses since blooms
of any length can be rolled.
Following the billet mill operation, the product is cut to the desired
finished piece length. The cutting is accomplished by stationary
shears, movable gang shears, flying shears, flame cutting, or saws.
15
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Shears are faster but distort product ends while flying shears are
used on small billets to eliminate long tables and transfers. Saws
and flame cutting eliminate distorted ends but are slower and require
maintenance and expensive fuels.
The billets are subsequently transferred to bar mills or merchant
mills for processing into finished products. The billets are heated
to rolling temperature in continuous reheat furnaces where they are
fed into one end and moved through the furnace by a billet pusher. A
walking beam furnace is sometimes used to eliminate the slide marks on
the underside of the billets. A billet ejector, normally a pusher bar
type, pushes the end billet out of the side of the furnace. A shear
then cuts the heated billets to size or removes bent ends prior to
conveying the billet to the bar mill.
Bar Mills
Modern bar mills are normally arranged in a cross-country design or
continuous design. Both types have in-line roughing stands, . however,
the cross-country mill has side by side intermediate and finishing
stands whereas the continuous mill has all stands in-line. The
continuous mill is more efficient for production runs but requires
more space and individual motors on each stand. Descaling and cooling
water sprays are employed at the mill stands with the discharge
draining to trenches under the mill into collection systems.
Various products are rolled in the bar mills such as angles, channels,
flats, other small sections, rebar, window sash, fence posts, rounds,
wire, and flat narrow strips. These products are sheared to proper
length, marked for identification, sometimes straightened, bundled or
coiled, and weighed for shipment or further processing.
Rail Mills
Rails are formed from heated blooms in various mill arrangements, but
the forming generally takes place in three steps or stages. The first
stage is the roughing stage where the bloom is reduced in cross
section and elongated. High pressure sprays are used at the discharge
of the roughing stands for scale removal. The second, or intermediate
stage, proceeds with the forming of the rail and involves a
combination of slabber, dummy, former, - edger, and leader passes,
depending upon the mill layout. The third stage is the finishing pass
which then completes the formation of the desired rail section.
The rails are conveyed from the finishing stand on a runout table to
hot saws which cut the product to the standard 39 ft. rail length or,
at modern mills, to 80'ft. After sawing, the rails are stamped,
cambered, and weighed before they are advanced to cooling beds. Rails
intended for railroad service must be control cooled in containers to
prevent the formation of internal thermal ruptures or cracks. After
cooling, the rails are conveyed to finishing operations which consist
of inspection, removal of saw burrs, straightening, drilling, grinding
of ends, leveling, inspection, classification, and painting.
16
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Rail-Joint Bars
Joint bars are rolled from heated blooms or billets similar to rails.
Additional passes are required if the joint bar has a depending
flange, or long toe. The finishing operation consists of hot-working
and oil-quenching the joint bars. In this operation, the product is
cold sheared to length and then reheated for hot-working which
consists of punching, slotting, straightening, and quenching in an oil
tank.
Structural and Other Section Mills
Structural sections include standard items such as I-beams, channels,
angles, and wide-flange beams, and special sections such as zees,
tees, bulb angles, and car-building center sills. Other sections
include miscellaneous shapes such as sheet piling, tie plates, and
cross ties.
Blooms are heated in a continuous reheat furnace and then conveyed to
the roughing, intermediate, and finishing stands. Passes in actual
use range from fifteen roughing and nine intermediate on sections
requiring heavy overall work, to two fine roughing and three
intermediate on the sections requiring a minimum of work. In all
cases, the intermediate passes are followed by a single finishing
pass. In rolling wide-flange beams it is customary to roll a bloom
which has, as nearly as possible, the same proportions as the finished
beam.
Rolled material from the structural mills is delivered by a roller
table to the hot saw. This equipment consists of a circular saw over
which large quantities of cooling water are passed to maintain the
cutting edges. Cuts are usually made at the hot saw to remove the
crop ends, to part the usable material into lengths that can be
handled for further processing, and to provide short test pieces. The
shapes are then cooled on a cooling bed. After cooling, the shapes
are conveyed to the finishing area where they are straightened, cold
sheared or cold sawed, and inspected prior to separating and
assembling for shipment.
Merchant-bar, rod, and wire mills produce a wide variety of products
in continuous operations ranging from shapes of small size through
bars and rods. Mill designation and product classification are not
well defined within the industry. In general, the small
cross-sectional area and long lengths distinguish the products of
these mills. Raw materials for these mills are reheated billets.
Many older mills included hand looping operations in which the
material is passed from stand to stand manually. Newer mills use
mechanical methods of transferring the material from stand to stand.
As with other rolling operations the billet is progressively squeezed
and shaped.to the desired product dimensions in a series of rolls.
Water sprays are used throughout the operation to remove scale.
17
-------
See Figure
mills.
II1-4 for the process flow diagram for section rolling
Flat Rolling Mills
Plate Mills
Plates are classified according to size limitations to :distinguish
them from sheet, strip, and flat bars. According to this
classification, plates are generally considered to be those flat
hot-rolled finished products .that are more than 8 inches wide and
generally 0.23 inches or more thick, or over 48 inches wide and at
least 0.18 inches thick. The sequence of operations for plate mills
is reheating of slabs, descaling, rolling, leveling, cooling and
shearing. Most plate mills use continuous heating furnaces.
Descaling in modern plate mills is accomplished by hydraulic sprays
impinging on both top and bottom surfaces and operating at pressures
up to 1,500 Ibs per sq. in. Temperature variation in the plate from
the front to the back is a problem of particular importance in rolling
plates, as is the care that must be exercised in cooling the rolled
product so as to avoid distortion.
The basic operation of a plate mill is the reduction of a heated slab
to the weight and dimensional limitations defining plates. Slabs are
received from slabbing mills or continuous casters and then stored in
slab yards. Slabs are removed from storage by overhead cranes and
placed on a charging table at the entry end of the reheat furnaces.
The slabs are moved through a continuous type reheat furnace by
pushing the last piece charged with a pusher at the entry end of the
furnace. The reheat furnace heats the slabs to a rolling temperature
of approximately 1,220°C (2,230°F). As each cold slab is pushed into
the furnace against the line of material already in the furnace, a
heated piece exits the furnace. The heated slab is discharged from
the furnace by gravity upon a roller table which feeds the mill.
Heated slabs are conveyed on a roller table to a scale-breaker stand.
As the slab leaves the scale-breaker, primary descaling is completed
with top and bottom high pressure water sprays operating at 1,000 psi
to 1,500 psi. The scale-breaker and water sprays flush away iron
oxide or mill scale which forms on the surface of the hot slabs.
Generally, about 4% of the spray water evaporates and the balance is
discharged through a trench under the mills to a mill scale and
wastewater collection system. Mill scale may amount to 1.5-4% of the
steel production. During rolling operations, cooling water is sprayed
externally over the table arid mill stand rolls. Additional
lubrication between product and mill stand rolls is provided at
intervals by sprays of water soluble oil.
The descaled slabs are conveyed on roller tables to the plate mill.
There are various types of plate mills such as three high mills, four
high reversing mills, tandem mills, semi-continuous and continuous
mills. Cooling water, spray water, and water soluble oil is sprayed
externally over the mill stand rolls. Hydraulic sprays on both sides
18
-------
of the mill stands, operating at high pressure, are employed for top
and bottom secondary scale removal. The plates are conveyed on a
run-out table to a leveler. A portion of the run-out table is
equipped with a series of cooling sprays. After leveling, the plates
•are cooled uniformly to avoid localized stresses which would set up
permanent distortions. After cooling, the plates are conveyed to end
and side shears where they are cut to proper size, transferred to a
shipping or storage building, or sent to heat treating furnaces.
More information on plate mill
III-5.
operations is presented in Figure
Mill
The continuous hot strip mill uses slabs that are reheated to rolling
temperatures (2000-2400°F) in continuous reheat furnaces. Slabs are
provided either from a storage yard or are delivered hot directly from
the slabbing mill, thus bypassing the reheat furnaces. Slab casting
machines are also used to produce slabs. Slabs are generally provided
in sizes of 2 to 7 inches thick, one to five feet in width and, more
than twenty feet in length.
The basic operation of a hot strip mill is the reduction of slabs to
flat strip steel in thicknesses of 0.04 inches to 1.25 inches, widths
of 24 inches to 96 inches, and lengths up to 2,000 feet. The modern
hot strip mill produces a product which may be up to 96 inches wide,
although the most common width in newer mills is 80- inches. The
product of the hot strip mill may be sold as produced, processed in
cold reduction mills, plated or coated.
The continuous hot strip mill rolling train consists of a scale
breaker stand, several roughing stands, a finishing scale breaker
several finishing stands, a run-out table and coilers. Motor driven
rolls convey the hot slabs from the reheat furnaces to the mill stands
and also from mill stand to mill stand. If the mill is to produce
strip or sheets greater than the maximum width of available slabs the
first roughing acts as a broadside mill stand in which the width of
the slab is increased in a single pass by cross rolling. Turntables
ahead and following the roughing stand rotate the slab 90° for
cross-rolling. The roughing roll stands are separated from the
finishing roll stands by a holding table while the finishing stands
are a closely grouped, tandem rolling train of scale breakers and
finishing mill stands. High pressure (500-1500 psi) water sprays used
to remove .scale from the hot slabs are located after the two
scalebreaker stands and the roughing stands. Roll stand spray coolinq
water is provided for cooling of each roll in the stands.
Following the last finishing stand, there is usually a flying shear
for cutting the rolled product into sheets. A flying shear moves with
the strip as it cuts the strip into sheets. As the hot strip exits
the last finishing stand it is carried over long tables called run-out
tables. Mill speeds approximate 600 meters/minute (1970 -feet/minute)
Two or more coilers, which are located at the end of the run-out
19
-------
tables, serve to coil the hot strip when continuous long lengths are
required. If sheets are being cut by the flying shear, the coilers do
not operate. Instead, the steel sheets pass over the coilers onto a
sheet piler at the end of the run-out tables.
An alternate arrangement of a hot strip mill uses reversing roughing'
stands with tandem continuous finishing roll stands. This arrangement
allows for more passes in one roughing stand, thus decreasing the
length of the mill. However, mill production capacity is less than
the tandem mill arrangement.
A rotary crop shear is located between the roughing and finishing mill
stands so that the front and rear ends of the strip can be squared off
before finishing. Scrap strip steel from the hot strip mill is known
as "cobble."
Strip product is conveyed from the finishing stands to a run-out table
with automatic spray water coolers. The cooling water sprays
continuously cool the product on the run-out tables. As does
wastewater from the mill stands and tables, the spray water drains
through a trench under the mill stands to the wastewater collection
system. The coiled strip product is conveyed to storage for shipping
or further processing.
More information
III-6.
on hot strip mill operations is presented in Figure
Combination Sheet, Strip and Plate Mills
Several hot forming-flat rolling mills produce a variety of finished
products including sheet, strip and plate. Product classification is
based upon thickness and width as shown below:
Width
6"-12"
12"-48"
Over 48"
Thickness Greater Than
0.05" 0.18" 0.230"
Strip
Sheet
Sheet
Strip
Sheet
Plate
Plate
Plate
Plate
Some mills are capable of producing all of the above products.
Because of the similarities between combination mills and strip mills,
the combination mills have been included in the hot strip mill data
base for the purpose of developing effluent limitations.
Pipe and Tube Mills - Hot Worked
Butt-Welded Pipe
Welded tubular products are classified as butt-weld. Butt-weld pipe
or tube -is made from a hot rolled strip, with square or slightly
beveled edges, called skelp, the width of which corresponds to the
20
-------
haMnn +.°f.^the ;pfpe' and the gau9e to the wall thickness. By
heating skelp to its welding temperature in a reheat furnace and
S^VJ th™ugh a die or roll, the skelp is bent into a £lindriXl
shape and its edges pressed firmly together into a butt-weld, thus
-*he butt-welding process is used to manufacture 'pipe?
nChSS n dameter. Skelp is conveyed from storage
«v 1S fharg?d int? a continuous reheat furnace. Modern mills
Sk?lp- SJriP-1D C0lls to feed continuous butt-welding operations
JrS P n* ^^ Dreading machine which feeds it through ' the
h™S6' Onc? the fading end is in the forming and welding unit, the
threading rolls release the skelp. The leading end of the next skein
lslded ^° the trailing *™ of the first strip by a flwh t™
f £10r t0 6^ry int° the reheat furnace/ The skelp strip
lUrTCe ^t0.3 continuous forming and welding mill
fh ™ stand /oils force the skelp into a welding stand, where
-the edges are pressed firmly together. The last stands of th4 mill
?2suftani-r±ning- ^^ ^°^ Provide for reduction of diameter and a
resultant change in wall thickness. A rotary flying saw cuts the
lpe int° len^ths- The cut lengths a?e reduced to thl
S1Z! °!?ua Slzing mil1' The hot Pipe is delivered to a
ndh then PafSeS tO a Water bosh tank for fast cooling.
« €T Plpe to straighteners in the finishing bay.
Details of a typical operation are depicted in Figure III-7.
Seamless Tubular Products
nnnn
cupping
of
tubular products are made by two processes; piercing and
In the piercing process, a solid round bar or billet is
h-and afterwards shaped to the desired diameter and wall
TH 1S process is used today for most seamless pipe
Then^PPing Pr°cess is used primarily for the manufacture
^ u S nd gas cylinders. A circular sheet or plate is
forced by successive operations through several pairs of conical dies
r?«ii* n ,Plate ,takeS the form of a tube' orcylinder S?Jh one end
closed. Details of a typical mill are shown in Figure III-8.
The production of seamless pipe and the mills required for this
operation .vary depending on the diameter of the product pipe. The
heltinSTsoffd hi?r?UCe-pip? UP fc? 4 inCheS in diamefcer consist of
rJdur?nn solid billet, piercing plug rolling, reeling, reheating and
reducing or sizing. The production of pipe up to 1 6 inches in
diameter is similar except a second piercing and reheating operltioS
is required. Pipe up to 26 inches in diameter is produced in a manne?
similar to the preceding 16 inch operation except for the addition of
a rotary rolling mill and a third reheating operation.
A solid bar or billet of the proper length and diameter to make the
size and weight of the tube desired is heated to rolling temperaturl
?n Trhor^onJyi1'?30°CH(2;25^FK The heated. billet is9 tSSSSrreS
in a horizontal trough to the piercing mill, which consists of two
21
-------
contoured horizontal rolls and a piercing mandrel. The roll surfaces
are contoured so that, in the horizontal plane through the centerline
of the pass, the space between the rolls converges toward the delivery
side and then diverges to form the pass outlet. The point of the
centerline of the pass is determined by guides between the rolls.
Between these guides in the pass outlet, a projectile shaped piercing
mandrel is held in position on the end of a water-cooled mandrel
support bar, located on the delivery side of the mill. The heated
billet is drawn over a mandrel, thus forming a hollow shell. As the
billet is drawn and compressed, the spreading of the metal sets up a
lateral tension which may cause its particles to be drawn away from
the center, and for this reason the nose of the mandrel is at a point
preceding the forming of the cavity to insure a smooth inner surface.
The initial piercing produces a hollow tube with a comparatively heavy
wall. The second piercing mill further reduces the wall thickness and
increases the diameter and length of the piece required in the
production of large diameter product.
In the plug mill, a plug on a support bar is rammed into the end of
the shell, which is then drawn over the plug by revolving rolls,
slightly reducing its wall thickness and increasing its diameter and
length. In the rotary rolling mills, which are used for large
diameter pipe, conical rolls grip and spin the pipe, feeding it
forward over a large tapered mandrel, thereby decreasing the thickness
of the pipe wall and increasing its diameter. The length of the tube
remains essentially unchanged by this operation.
The reeling machine, consisting of rolls and a mandrel similar to the
piercing mill, reduces the thickness of the wall slightly. This
reduction has the effect of burnishing the inside and outside surfaces
of the tube and slightly increasing its diameter. After reeling, the
tube is reheated and conveyed to the sizing rolls, the grooves ot
which are slightly smaller than the reeled tube. This reduces the
tube diameter which insures uniform size and roundness throughout its
length. After sizing, the product is straightened, its ends cropped,
inspected, and finished as required for its eventual «se.
The properties of hot rolled seamless pipe may be improved by cold
working. One method is the seamless pipe method in which the hot
rolled pipe (after cooling) is conveyed to a cold expander mill. The
hot rolled pipe is dropped into an expander trough, clamped with one
end held firmly against a backstop. A long ram is positioned at the
opposite end of the pipe and an expander plug is forced through the
pipe under extreme pressure. The plug is lubricated through the ram
head with a water soluble oil. After cold expansion, the seamless
pipe enters a rotary straightener after which it is hydrostatically
tested. Cold working the pipe increases its yield strength and
generally improves the product. The cold worked operations are
included in the cold forming subcategory.
22
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TABLE III-l
SUMMARY OF SAMPLED PLANTS
HOT FORMING SUBCATEGORY
Sample
Code
Plant
Reference
Code
Type of
Mill
Steel
Type
PRIMARY MILLS
E
L-2
282A
A-2
B-2
081
R & 285A (Revisited)
H
D
K
0286A
M« (1)
08211'
082
288A
289A
Q
C-2&088(Revisi ted)
290A
291
2 93 A
083
294A
D-2
A-2
D-2
E-2
F-2
G-2
H-2
1-2
C
H
K
M
0020B
0060
0088D
0112B(01 & 02)
01128(03)
0176
0240A
0248A
0248B
0256K
043 2C
043 2 J
0496(140"only)
0496(140", 206"
0584F
0684B
0684D
0684H
0856R
0856B
0856N
0860H(03)
0920N
0946A
01128(03)
0291C
0196A(09&10)
0384A(06)
0640A(01&02)
0432A(04)
08560
0424(01-03)
0248A
0256K
0432J
Slab
Slab
Bloom
Bloom Mills (2)
Slab
Bloom
Bloom
Bloom
Slab
Slab/Bloom
Slab
Slab/Bloom
Slab/Rough Plate
in tandem) Slab/Rough Plate
Bloom
Bloom
Bloom
Bloom
Slab/Bloom
Slab
Slab/Bloom
Slab/Bloom
Bloom
Bloom
SECTION MILLS
Rail Mill
Nos.2,5 and 6 Mills
Bar Mill & Rod Mill
12" Bar Mill
10"&12" Mills
Rod Mill
Rod Mill
Bar Mills(3)
Merchant Mill
Bar Mill
Billet Mill
Specialty
Carbon
Specialty
Carbon
Carbon
Specialty
Specialty
Specialty
Specialty
Specialty
Carbon
Specialty
Carbon
Specialty
Carbon
Carbon
Specialty
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Specialty
Specialty
Specialty
Specialty
23
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TABLE III-l
SUMMARY OF SAMPLED PLANTS
HOT FORMING SUBCATEGORY
PAGE 2
Sample
Code
0 & 081(Revisited)
0
Q
R & 285B( Revisited)
R
083
087
088
088
282B
283
290B
293B
o
E S 281 (Revisited)
D
J-2 & 292( Revisited)
L-2
M-2
N-2
086 & 2 84 A( Revisited)
087
286B
287
288B
289B
294B
Plant
Reference
Code
0176(01-04)
0176(04)
0684D
0240A(01)
0240A(02)
0860H(02&03)
0432A(02)
0684H(02)
0684H( 01 , 03 , 05 , 06 , 07 )
0088D
0112(01,02,03,06,10)
0856R
0856N(01,02)
HOT STRIP &
0176
0020B
0248B
0860B(01)
0060
0384A(02)
0396D(02)
0112D(02)
043 2 A
0432C
0584B
0584F
0684B
0920K
Type of
Mill
Bar Mills(3)
Wire/Rod Mills
Bar Mill
Bar Mill
Bar Mill
34" & Rod Mills
14" Mill
34" Mill
36", 32", 14", 10", 11" Mills
22" Bar Mill
18", 32", 42", 48", Combination
Mill
#5 Bar Mill
10"/12" Bar Mill
SHEET MILLS
#4 Hot Mill
HSM
HSM
84" HSM
Hot Strip & Sheet Mill
80" HSM
#4 HSM
80" HSM
44" HSM
80" HSM
80" HSM
54" HSM
56" HSM
80" HSM
Steel
Type
Special ty
Specialty
Special ty
Specialty
Special ty
Carbon
Special ty
Special ty
Carbon
Special ty
Carbon
Carbon
Carbon
Special ty
Special ty
Special ty
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
PLATE MILLS
F
K-2
082
082
083
086 &
284B(Revisited)
0856H(03)
0868B
0496(01&03)
0496(02&04)
0860H(01)
0112D(01)
160" Plate Mill Specialty
160" Plate Mill Carbon
140",112"/120",and Carbon
140"/206" Mills
112"/120" and 140" Mills Specialty.
30" Plate Mill Carbon
160" Plate Mill Carbon
24
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TABLE III-l
SUMMARY OF SAMPLED PLANTS
HOT FORMING SUBCATEGORY
PAGE 3
Sample
Code
Plant
Reference
Code
Type of
Mill
Steel
Type
PIPE & TUBE MILLS
E-2
GG-2
II-2
JJ-2
KK-2
087
088
293C
295
0196A(01)
02408(05)
0916A
0728
0256G
0432A(01)
0684H
0856N
0948A
Seamles s
Seamless
Butt Weld
Butt Weld
Butt Weld
Butt Weld
Seamless
Seamless
Seamless
Carbon
Specialty
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
Carbon
(1) Plant 082 consists of a 206" and a 140" set of mill stands which are part of the same
line, and can work as a single unit or as separate mills. The line was sampled while
operating in two different configurations as shown. This same complex also functions
as a Hot Forming - Flat/Plate Mill.
25
-------
3S to
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z
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GU E-* A* I
S3 S!
e>
os
= 1
i
i a
os •
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o. i
,BS,
o
UJ
H H
G O
•S 4
CO 03 O3
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CM
I
a
o
H
s
J3
e
•H
CH
1
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u u H
cn'so1 ^
in so so
as as as
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a) a) vo o
11 oJ u
u 53 n <-i
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TABLE III-3
HOT FORMING SECTION
SUMMARY TABLE
PAGE 4
Plant
Code
0112B
ni
Ul
0112B
02
0112B
03
0112B
0112B
05
0112B
06
0112B
O7
U/
0112C
01
0112C
02
0112C
03
0112C
04
0112C
05
0112C
06
Products
HP-Beams
I-Beara, Channel,
Zee, Sheet Piling
Angle, Buldozer
Track Shoe
Billets, Rail
Round
Billets
Rounds , Flat
Bar, Hinge Bar,
Leaf Spring
Round , Flat Bar
Rebar
Round, Flat Bar
Wheel Blanks
RR. Wheels
Billets, Round
Slab
Rounds
Billets
Round Corner
Squares, Tie Clips
Bearing Segments
Age Production
Steel 1st yr. Capacity Fl<
Types of Prod. Ton/Day Applied
CS100 1926 3321 UNK
CS85 1926 1461 UNK
LAI 5
CS80 1928 1563 UNK
LA20
CS80 1930 2538 UNK
LA20
CS76 1940 711 UNK
LA24
CS74 1946 900 UNK
LA26
CS76 1976 444 UNK
LA24
CS87 1920 180 UNK
AS13
CS99 1920 375 UNK
AS1
CS92 1940 1728 UNK
ASS
CS92 1950 849 UNK
AS8
CS87 1952 3234 UNK
AO1 O
*U)1 J
CS95 1918 105 UNK
ASS
Treatment Components
>w (Gallons/Ton) Process Central
Process Discharge Treatment Treatment
UNK UNK PSP CNT(l)
(UNK)T,
FDSP
UNK UNK PSP CNT(l)
(UNK),T,
FDSP
UNK UNK PSP CNT(l)
(UNK),T,
FDSP
UNK UNK PSP CNT(l)
(UNK),T,
FDSP
UNK UNK PSP CNT(l)
(UNK),T,
FDSP
UNK UNK PSP CNTtl)
(UNK),T,
FDS(UNK)
UNK UNK PSP CNT(l)
(UNK),T,
FDSP
UNK UNK PSP CNT(UNK)
SSP,SS,T,
FDS(UNK)
UNK UNK PSP CNT(UNK),
SSP,SS,T,
FDS(UNK)
UNK UNK PSP CNT(2)
(UNK)SSP.SS
T,CT,A,NC,
FDS(UNK)
UNK UNK PSP CNT(UNK)
SSP.SS.T,
FDS(UNK)
UNK • UNK PSP CNT(2)
(UNK),SSP,SS
T,CT,A,NC,FDS
(UNK)
UNK UNK PSP CNT(2)
(UNK),SSP,SS,
T,CT,A,NC,FDS
(UNK)
Operating
Mode
RET(UNK)
BD(UNK)
RET(UNK)
BD(UNK)
RET(UNK)
BD(UNK)
RET(UNK)
BD(UNK)
RTP(UNK)
RET(UNK)
BD(UNK)
RTP(UNK)
RET(UNK)
RTP(UNK)
RET(UNK-)
BD(UNK)
OT
OT
OT
OT
OT
OT
Discharge
'Mode
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
-------
r
TABUS III-3
HOT FORMING SECTION
SUMMARY TABLE
PAGE 5
Plant
Code
0112C
07
0112C
08
0112C
09
0112C
10
0112E
01
0112E
02
0112E
03
0112F
01
0112F
02
0112G
01
0112G
02
01121
0112J
01
Product!
Bulb Angle, Bail
Round , Square ,Flat
Bar,Tee Bar,Hine
Ties ,Rim Section
Brake Beam
Round, Square
Hexagon, Flat Bar
Flat Bar, Auto
Leaf Sprg Band
Tie Clip, Rail
Anchor
Round, Square,
Hexagon , Speci al
Shapes
Billets, Rail
Billets, Rounds
Flat Bar, Misc.
Rebar
I -Beam .Channel
Angles .Rounds
Square, Flat Bar
Round, Square
Hexagon, Flat
Bar, Rebar
I -Be am, Channel
Zee, Angle, Round
Flat Bar
I -Beam, Channel ,
Angle, Round,
Square, Flat
Bar, Rebar
Rounds , Squares
Flat Bars
I -Beam .Channel
Angle, Square,
Flat Bars, Billet
Steel
Type«
CS89
AS11
CS88
AS12
CS91
AS9
CS81 '
AS19
CS100
CS97.2
LAI. 4
BS1.4
CS100
CS79
LA21
CS97
LA3
N/A
N/A
CS92
LAS
CS9S
LAS
Age
1st yr.
of Prod.
1926
1926
1926
1963
1914
1918
1960
1922
1948
1914
1938
1926
1924
Production
Capacity
Ton/Day
648
849
204
999
3705
1200
2259
567
669
417
675
711
378
Flow (Gallons/Ton)
Applied Procem Discharge
UHK UNK UNK
UNK UNK UNK
UNK UHK UNK
DHK UNK UNK
UNK UNK UNK
UNK UNK UNK
UNK UNK UNK
UNK UNK UNK
UNK UNK UNK
UHK UNK UNK
UNK UNK UNK
UNK UNK UNK
UNK UNK UNK
Treatment
Process
Treatment
PSP
PSP
PSP
PSP
PSP
PSP
PSP
PSP
PSP
PSP
SS
PSP
SS
PSP.SS
P.SS.E
CT.FDS
(UNK)
PSP
Component!
Central
Treatment
CHT(2)
(UHK).SSP
SS,T,A, HC,
FDS(UNK)
CNT(2)
(DNK)SSP,
SS,T,A,HC
FDS(UNK)
CNT(2)
(UNK)SSP,SS,
T,A,NC,FDS
(UNK)
CHT(2)
(UNK)SSP,
SS,T,A,NC,
FDS(UNK)
CNT(2)
(UHK)SSP,SS,
03,SL(UNK)
CNT(2)
(UNK)SS,
03,SL(UNK)
CNT(2)
(UNK)SS,
SL(UNK)
CNT(2)
(UNK)SSP,
SS.CL.CT
CNT(2)
(UNK)SSP,
SS.CL.CT
CNT(2)
(UNK)SSP
SS
CNT(2)
(UNK)SSP
SS
t
t
CNT(l)
(UNK)SSP>SS
CT>SL(UNK)
Operating
Mode
or
or
or
or
(RTP)
(RTP)
SUP(UNK)
BD(UNK)
(RTP)
RUP(UNK)
BD(UNK)
RTP(UNK)
BEP(UNK)
BD(UNK)
RTP (UNK)
REP(UNK)
BD(UNK)
RTP(UNK)
REP(UNK)
BD(UNK)
RTP (UNK)
REP(UNK)
BD(UNK)
RUP(UNK)
BD(UNK)
RTP (UNK)
REP (UNK)
BD(UNK)
Discharge
Mode
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
-------
TABLE III-3
HOT FORMING SECTION
SUMMARY TABLE
PAGE 6
PI anf-
r lane
Code
0112J
02
0112J
03
0136B
01
0136B
02
0136C
0176
01
0176
02
0176
03
0176
04
0188B
0188C
0196A
01
0196A
02
0196A
03
Products
I-Beara, Channel,
Angle, Flat Bar
Tail Dat*
jail uar
Channel, Angle
Hot Strip
Channel, Angle
Round , Square , Flat
Bar, Rebar
Channel, Angle
Round, Square, Flat
Bar, Rebar
Rebar, Flat Bar
Round , Square ,Hex ,
Flat Bar, Octagon
Flutes
Rounds ,Square, Hex,
Flat Bar, Octagon
Round , Square ,Hex
Flat Bar, Flutes
Hire
Round, Rebar
Round, Rebar
**
**
**
Steel
Types
CS100
CS100
CS96
LA4
CS96
LA4
CS100
N/A
All
Special
N/A
All
Special
N/A
All
Special
N/A
All
A1&
Special
CS100
CS100
**
**
**
Age
1st yr.
of Prod.
1924
1915
1908
1967
1913
1918
1927
1928
1953
1940
1956
44
**
**
Production
Capacity
Ton/Day
339
177
522
(Closed
354
411
30.2
10.5
78
168
804
462
**
**
**
Flow (Gallons/Ton)
Applied
UNK
UNK
8372
11/77)
[22,942]
11,859
Process Discharge
UNK
UNK
8372
[22,942]
11,859
UNK
UNK
100
[121]
581
Treatment
Process
Treatment
PSP
PSP
PSP
PSP
SSP
PSP, SSP
Components
Central
Treatment
CNT(l)
(UNK)SSP,SS,
CT,SL(UNK)
CNT(i)
(UNK)SSP.SS
CT,SL(UNK)
SSP
Operating
Mode
RTP(UNK)
RET(UNK)
BD(UNK)
RTF (UNK)
RET(UNK)
BD(UNK)
RTP(98.8)
BD(1.2)
.RTP(99.5)
BD(0.5)
RTP(95.1)
(SS,CT,02 BD(4.9)
PSP CNT(2)(14) /
SRP RS T
-------
TABLE II1-3
HOT FORMING SECTION
SUMMARY TABLE
PAGE 7
Plant
Code
0196A
04
0196A
05
0196A
06
0196A
07
0196A
08
0916A
09
0196A
10.
0196A
11
0240A
01
0240A
02
0256K
0256N
01
0256N
02
0256N
03
Products
**
**
**
**
**
**
**
**
Round , Square
Round, Square
Hex, Flat Bar
Wire
Billets ,Round
Billets , Round
Square, Flat Bar
Billets .Round
Square, Hex, Flat
Steel
Types
**
**
**
**
**
**
**
**
CS25
U75
CS25
LA75
**
**
**
**
Bar
Age
let yr.
of Prod.
**
**
**
**
**
**
**
**
1943
1941
1936
1950
1920
1920
Production
Capacity
Ton/Day
**
**
**
**
**
**
**
**•
948
474
**
**
**
**
Treatment Components
Flow (Gallons/Ton)
Applied Process
** **
** ir*
** **
** **
** **
** **
** **
** **
( [2600] [2600J
f
C
** **
** **
** **
Irk **
Discharge
**
**
**
**
**
**
**
**
[298]
**
**
**
**
Process
Treatment
**
**
**
**
** .
**
**
**
PSP
SSP
PSP.NL,
FLP.CL
PSP
PSP
PSP
Central
Treatment
**
**
**
**
**
**
**
**
CNT(l)
(UNK)SS.SL
(UNK),(FP)
Operating
Hode
**
**
**
**
**
**
**
**
[RTP 88.5J
or
RUP(IOO)
RUP(IOO)
RUP(IOO)
Discharge
Mode
**
**
**
**
**
**
**
**
Direct
Direct
Direct
Zero
Discharge
Zero
Discharge
Zero
Discharge
-------
TABLE III-3
HOT FORMING SECTION
SUMMARY TABLE
PAGE 8
Plant
Code
0288A
01
0288A
02
0288A
03
0288A
04
0288A
05
0288A
06
0288A
07
0288A
08
Products
Rings
Rings
Rings
Rings
Rings
Rings
Rolled R.R.Hheels
Rings
Steel
Types
CS20
ATS5
OS75
CS30
ATS 5,
OS65
CS30
SS2.0S68
CS20
SS1.ATS1,
OS78
CS56
SS2.ATS2,
OS40
CS50
OS 50
CS100
CS95
085
Age Production
1st yr. Capacity
of Prod. Ton/Day
1925 7.2
1939 13.8
1937 22.2
1941 11.19
1967 20.5
1960 4.0
1919 333.6
1919 36.6
Flow (Gallons/Ton)
Applied Procean nlnrhnraa
4114
2527
2359
3136
1995
7014
316
1328
4114
2527
2359
3136
1995
7014
316
1328
4114
2527
2359
3136
1995
7014
316
1328
Treatment Components
Process Central Operating Discharge
Treatment Treatment Hode Mode
PSP. OT Direct
SSP.SS
PSP,
SSP.SS
PSP,
SSP.SS
PSP,
SSP.SS
PSP
ss
PSP
SSP.SS
PSP,
SSP.SS
PSP,
SSP
OT Direct
OT Direct
OT Direct
OT Direct
OT Direct
OT Direct
OT Direct
-------
TABLE III-3
HOT FORMING SECTION
SUMMARY TABLE
PAGE 9
Plant
Code
0316
0316A
0316B
0316C
0320
01
0320
02
0320
03
0384A
01
0384A
02
0384A
03
0384A
04
0384A
05
0384A
06
0384A
07
Products
Round, Rebar
Billets ,Rebar
Round, Rebar
Round, Rebar
Billets
Steel
Types
CS100
CS100
CS100
CS100
ABS100
Age
1st yr.
of Prod.
1959
1970
1961
1976
1936
Production
Capacity
Ton/Day
446
420
423
Started
9/76
1500
Flow
Applied
9044
7543
10,383
UNK
UNK
(Gallons/Ton)
Process Discharge
9044
7543
10,383
UNK
UNK
5699
0
0
UNK
UNK
Treataent
Process
Treataent
PSP
PSP,
SSP, 88
PSP,
SSP.SL
(UNK)
PSP
PSP
Components
Central
Treataent
CHT(3)(36)
88,CT,8L
(UNK)F(04)
CNT(2)
(UHK)SCH,NC
Operating
Hade
RTP(37)
BD(63)
HUP(IOO)
RTP(IOO)
UNK
or
Discharge
Mode
Indirect
Zero
Discharge
Zero
Discharge
UNK
Direct
88,CL,8L(UHK)
Billets
ABS100
1936
1428
UNK
UNK
UNK
PSP
CNT(2)
(UNK)SCR,NC,
or
Direct
88,CL,SL(UHK)
Flat Bars
ABS100
1936
588
UNK
UNK
UNK
PSP
CNT(2)
(UNK)SCR,NC
or
Direct
8S,CL,SL(UNK)
Billets
Billets, HF
Blanks
Billets, HF,
I-Beam, Channel ,Zee
Angle ,Geuser Shoe,
Brg.Capa
Billets ,1-Beau
Channel , Angle ,
Bulb Angle, Misc
Billets, I-Beams
Channel , Zee, Bulb
Angle .Angle ,Round
Square, Hex, Flat
Bar, Miac
Billets ,Rounda
Square, Angle, Hex
Flat Bar, Rebar,
Misc.
Angles ,Round,
Square ,hex,Flat
Bar, Rebar, Miac
CS30
LAI
FMS69
CS55,
LA3,
FMS42
CS77,
LAI 9
CS56
LA21
FMS23
CS65
LA15,
Tea 5,
RAL15
CS98
LA2,
CS45,
LAI 5
TeslS,
RAL25
1967
1967
1917
1902
1925
1969
1931
2418
3420
1479
933
816
1758
879
3055
3055
3797
3860
8029
3376
3276
3055
3055
3797
3860
8029
3355
3276
3055
3055
3797
3860
8029
79
3276
PSP
SSP
PSP,
SSP
PSP
PSP
FSP
PSP,
SSP
PSP
CNT(1)(14)
SS,SL(UNK)
CNT(1)(14)
SS,SL(UNK)
CNT(1)(3.8)
SSP,8L(UNK)
CNT(1)(29)
SS,SL(iiNK)
CNT(2)(3)
SS,SL(UNK)
CNT(2)
(UNK)CL.CT,
FLL.FLA.FLP
FLW
CHT(2)(2.5)
SS,SL(UNK)
(RTP)
(RTP)
(RTP)
(RTP)
(RTP)
RUP(33)
RTP (64. 6)
BD(2.4)
(Kip)
Direct
Direct
Direct
Direct
Direct
<-
Direct
Direct
-------
TABLE III-3
HOT FORMING SECTION
SUMMARY TABLE
PAGE 10
Plant
Code
0396D
0424
01
0424
02
0424
03
0432A
0432A
02
0432A
03
0432A
04
0432B
01
0432B
02
0432J
0440A
0448A
01
0448A
02
Products
Billets
Billets, Angle
Round , Square ,Hex
Flat Bar
Angle, Round,
Square, Hex, Flat
Bar
Angle, Round,
Square, Hex, Flat
Bar
Bar, Billet
Other Shapes
HF , I-Beam , Channel
Angle, Flat Bar
Jr .Channel , Truck
. Rims
Rounds
Rod
Billets, Rounds,
Square, Hex, Rebar
Round , Square ,Hex
Flat Bar, Rebar,
Octagon
Billets
Angle, Round, Hex
Square, Flat Bar
Rebar
Billets ,WF, I-
Beara, Channel ,H-
Section, Angle,
Plate, Mine Arch
Channel , Round
Rebar, Misc.
Steel
Types
CS100
SS80
ATS 20
SS80
ATS 20
SS80
ATS20
CS80
LA20
CS60
LA40
CS70
LA30
CS100
CS95
LAS
CS95
LA4.5
SS0.5
OS 10,
SS90
SS100
CS99
LAI
CS98
AS2
Age Production
1st yr. Capacity Flow (Gallons/Ton)
o ro^ — iron/ ay -•
1959 2031
1942 44
1946 25
1920 25
1910 2709
1925 1167
1927 1503
1952 1254
1931 1179
1953 1000
1950 NA
1928 45
1944 1068
1945 583
a|i|*n.cu
0
7283
11,707
.1
10,537
UNK
[6340]
UNK
UNK
UNK
UNK
UNK
3200
UNK
UNK
rrocesa
0
7283
11,707
10,537
UNK
[6340]
UNK
UNK
UNK
UNK
UNK
3200
UNK
UNK
mscnarge
6024
10654
9588
UNK
(6340)
UNK
UNK
UNK
UNK
UNK
3200
UNK
UNK
Treatment
Process
Treatment
PSP
PSP
PSP
PSP
PSP
PSP
PSP
SSP,
CY,07
PSP
SS
PSP
SS
PSP
PSP
PSP
PSP
SSP
Components
Central
Treatment
CNT(1)(16),
SS,SSP,CT,
SL(UNK)FDS
(UNK)
CST(1)(9)
S3,SSP,CT,
SL(UNK)FDS
(UNK)
CNTQH8),
SS,SSP,CT,
SL(UNK)FDS
(UNK)
CNT(2)
(UNK)SCR,CL
FLL,VF,S8,
FLH
(FP)
(FP)
CNT(3)(18)
SSP
CNT(2)
(UNK)CL,CT,
SL(UNK)
CNT(2)
(UNK)CL,CT,
SL(UNK)
Operating
Mode
fn—n\
(RTP)
RTP(17)
BD(83)
RTP(9)
BD(91)
RTP(9)
BD(91)
(RTP)
(RTP)
(RTP)
(RTP)
or
or
or
RUP(UNK)
RTP(UNK)
RET(UNK)
BD(UNK)
RUP(UNK)
RTP (UNK)
RET(UNK)
BD(UNK)
Discharge
Mode
NA
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
POTW
POTW
Direct
Direct
-------
TABtE III-3
HOT FORHIKG SECTION
SUMMARY TABLE
PAGE 11
Plant
Code
0460A
01
0460A
02
0460B
0468B
0468F
0476A
01
0476A
02
0476A
03
0584F(2
0612
01
0612
02
0612
03
0612
04
0612
05
Products
Wire
Wire
Channel ,Angle,
Square , Hound ,Tee ,
Flat Bar
Fence Post, Flanged
Channel ,Wire ,Rebar
Wire, Rod, Rebar
Angle , Round , Square
Flat Bar , Rebar
Rounds, Rebar
Round, Square,
Flat Bar, Rebar
WF,I-Beam,Zee,
Channel ,Piling,
Flat Bar ,Angle
Billets
WF-Beam (Channel
WF-Beam (Channel
Angle
Angle, Round,
Flat Bar, Rebar
Round
Steel
Types
CS100
CS100
CS100
CS100
CS100
CS90
LA10
CS100
CS75
LA25
CS50
VGS50
CS100
CS100
CS100
CS100
CS100
Age
1st yr.
of Prod.
1920
1958
1969
1968
1976
1915
1946
1969
1930
1952
1963
1957
1951
1936
Production
Capacity
Ton/Day
897
702
441
1294
312
190
502
800
807
3162
1386
1092
948
1239
Treatment Components
Flow
Applied
4816
7744
32,686
7,811
29,465
16,719
9018
10,075
14,900
[4204]
&87QJ
[12,527]
[4204]
5462
(Gallons/Ton)
Process Discharge
4415
7385
327
7,789
29,465
16,293
•8746
282
14,900
[4204]
[9870]
[12,527]
[4204]
5462
0
0
327
89
9841
10,786
1010
282
14,900
[84]
[197]
[250]
[84]
174
Process
Treatment
PSP
SSP
PSP
S3
PSP
SSP,
SS
PSP,CT
SSP.FLP
FF(UNK)
PSP,
SSP,
SS
PSP
PSP,
SS
PSP,
SS
PSP
PSP
SSP
PSP
SSP
PSP
SSP,
PSP
SSP
Central
Treatment
CHT(2)(19)
SCR,SS,T,
SL(UNK)
CNT(2)(25)
T.SCR,
SL(UNK)
i
CNT(3)(69.5)
8S,CT,SL
(UHK)
CHT(2)(37),
SCR,FLP,NL,
CL,SS,CY,
SL(UNK)
CHT(2)
(UNK)SCR,SS
FLP,NL,CL,
CY.SL(UHK)
CNT(2)(0.4)
SCS,FLP,NL,
CL.SS.CY,
SL(UNK)
CNT(2)(5.5)
SS,01,SL
(UHK)
CHT(1)(24.5)
SCH.SR.FDS
CHT(1)(19.4)
SS,02,FDS
CHT(1)(19.4)
SS,02,FDS
CST(1)(24.5)
SS,02,FD3
PSP, SSP
SS.CT,
Operating
Mode
RTP(IOO)
RTP(IOO)
RUP(99)
BD(1)
RTP(98.9)
BD(l.l)
RTP(66.6)
BD(33.4)
RTP(33.8)
BD(66.2)
RIP (88. 8)
BDU1.2)
RUP(97.2)
BD(2.8)
OT
RTP(98)
BD(2)
RTP(98)
BD(2)
RTP(98)
BD(2)
RTP(98)
BD(2)
RTP(96.8)
BD(3.2)
Discharge
Mode
Zero
Discharge
Zero
Discharge
POTW
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
FDS(UNK)
-------
TABLE III-3
HOT FORMING SECTION
SUMMARY TABLE
PAGE 12
Plant
Code
0640
0640A
01
0640A
02
0652A
01
0652A
02
0672A
01
0672A
02
0672B
01
0672B
02
0684A
01
0684A
02
0684A
03
0684D
01
0684D
02
0684D
03
Products
Rod Mill, Round
Rebar
Round, Rebar
Channel, Angle
Round, Flat Bar
22"Structural,
I-Beam, Channel
I-Beam .Channel
Angle
I-Beam, Channel
Angle, Flat Bar
Rebar .Mini-Beams
Round, Flat Bar
Jail Bar, Guy
I -Beam .Channel
Rail, Spec. Section
I-Beam, Channel
Bulb Angle, Spec.
Bar
Billets
Automotive Parts
Scraper Blades
Billets
Billets
Billets, Round
Flat Bar
Round , Square .Hex
Flat Bar ,0ctagon
Steel
Types
CS100
OS 100
CS100
CS86
LA14
CS86
LA14
CS84
LA16
CS1QO
CS40
LA60
CS40
LA60
CS95
LAS
CS100
CS100
CS15
AS85
CS15
SS2.AS83
SS48
AS 52
Age
1st yr.
of Prod,
1953
1954
1954
1906
1907
1951
1930
1907
1918
1911
1911
1923
1918
1920
1920
Production
Capacity Flow (Gallons/Ton)
» Ton/Dsy •_—.•-_-» **. — .
903
203
507
243
345
817
328
270
462
2112
573
2052
1929
1626
51
3352
11,449
13,775
7111
6261
5418
10,967
4880
5922
1705
10,052
1493
1689
UNK
rrocesg
3352
11,449
13,775
7111
6261
5418
10,967
4747
5610
1705
10,052
DISMANTLED
1493
1689
UNK
Discharge
3352
345
331
7111
6261
563
1151
0
0
1705
10,052
1493
1689
UNK
Treatment
Process
Treatment
PSP
PSP
SSP
83
PSP,
SSP, S3
PSP,
SS.SSP
PSP,
SS.SSP
PSP.SS
SSP.SS
PSP.SS
SSP, S3
PSP
SSP
PSP
PSP,
ss
PSP
PSP
PSP
PSP
Components
Central
Treatment
CNT(2)(40)
SL(UNK)FDS
(UNK)
CNT(2)(14),
SS.SL(UNK)
FDS(UNK)
CNT(2)(44)
CHT{2)(45)
SS,T,SL(UNK)
CNT(2)(37)
SS,T,SL(UNK)
CNT(2)(33)
SS.SL(UNK)
CNT(2)
(UNK)SS.SL
(UNK)
CNT(2)
(UNK)SS.SL
(UNK)
Operating
Mode
OT
RTP(97)
BD(3)
RTP(97.6)
BD(2.4)
OT
OT
RTP(89.6)
BD(10.4)
RTP(89.5)
BD(10.5)
RTP(IOO)
RTP(IOO)
OT
OT
OT
OT
OT
Discharge
Mode
Direct
POTW
POTW
Direct
Direct
Direct
Direct
Zero
Discharge
Zero
Discharge
Direct
Direct
Direct
Direct
Direct
-------
I
TABLE III-3
HOT FORMING SECTION
SUMMARY TABLE
PAGE 13
CD
Plant
Code
0684E
01
0684E
02
0684F
01
0684F
02
0684F
03
0684G
01
0684G
02
068AG
03
0684G
04
0684H
01
0684H
02
0684H
03
0684H
04
Products
Round, Square
Round, Square
Hex, Octagon
Billets
Round, Square
Flat Bar
Round, Square
Flat Bar, Rebar
Billets
Round, Square
Flat Bar
Square, Flat Bar
Rebar, Other
Round, Square
Flat Bar, Rebar
Billets
Round, Square
Round, Square
Flat Bar
Squares
Steel
Types
CS22
SS1.AS77
CS19
SS6
AS75
CS98
IA2
CS92
LAB
CS98
LA2
CS63
ATS 37
CS81
ATS 19
CS53
ATS47
CS61
ATS39
OS 70
AS30
CS33
AS67
CS63
AS37
CS85
AS15
Age
1st yr.
of Prod.
1920
1961
1916
1927
1927
1916
1918
1918
1920
1943
1958
1943
1947
Production
Capacity
Ton/Day
1185
504
1338
765
756
900
1131
573
237
2898
1758
2898
1314
Flow
Applied
3087
8571
3767
8282
8190
2240
4774
5026
9722
[4710]
[580]
[910]
3792
(Gallons/Ton)
Process Discharge
3087
8571
3767
(INK
DDK
2240
4774
5026
9722
[4710]
[580]
[910]
3792
1440
4003
3767
UNK
UNK
2043
4774
5026
9722
[1*1
M
-
[2.8]
193
Treatment Components
Process Central Operating
Treatment Treatment Mode
PSP
PSP,
S3
PSP,
SS
SSP
PSP
S3
SSP
PSP
SS,
SSP,
SS
PSP
PSP
SS
PSP,
PSP
PSP
SSP,
SS
PSP
SSP
SS
PSP
SS
PSP
SSP
CHT(2)(45)
SS,CL,CT,FL
(UNK)SL(UNK)
CST(2)(53),
SS,CL,CT,FL
(UNK)SL(UNK)
CNT(1)(14) OT
SS,VF,FLL,FLP
FL06,SCR,CL
FDS(Ut)K)
CNT(1)(17) OT
SS,VF,FLL,FLP
FL06,SCR,CL,
FDS(UNK)
CUT(2)(8) OT
CL,VF,SCR,FLL,
FLP,FL06,FDS
(UNK)
CNT(2)(15)
NW,FLL,NL,
FL06.VF.CL
FLP,SS
CNT(1)(51)
SSP,S3
CNTUK27.2) OT
SSP.SS
CNT(l)(21.8) OT
RTP(53.3)
BD(46.7)
RTP(53.3)
BD(46.7)
REUC8.8)
BD(91.2)
OT
CNT(1)(15)
FLP,SS,FLL,
CL.T.CT
CNTUH15)
FLP,SS,FLL
CL,CT,T
CNT(1)(7)
FDS(UNK)CL
RTP(99.7)
RTP(99.7)
RTP(99.7)
CBT(1)(13) RTP(94.9)
VF,FLL,FLP, BD(5.1)
CL,T,SS,CT,
FDS(UHK)
Discharge
Mode
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
POTH
POTW
POTW
Direct
-------
TABLE III-3
HOT FORMING SECTION
SUMMARY TABLE
PAGE 14
i£.
Plant
Code
0684H
05
0684H
06
0684H
07
0776G
01
0776G
02
0776G
03
0776G
04
0776H
01
0796A
01
0796A
02
0796A
03
0796A
04
0804B
01
0804B
02
0856A
01
0856A
02
Products
Rounds ,Square,
Hex, Flat Bar
Round ,Hex,Rebar
Round ,Hex,Rebar
Billets ,Round
Square
Round, Square
Hex, Flat Bar
Square ,Hex,
Flat Bars
Combination
Hill, Rounds
Flat Bars
**
**
**
**
Seamless Rings
Seamless Rings
Flat Bar, Specials
Channel, Zee,
Bulb Angle, Angle
Steel
Types
CS68
LA2.AS30
CS82
ATS 1, AS 17
CS87
AS13
CS2.SS11
LA9,MS5
ATS73,
CS2.SS11
LA9.MS5
ATS73
CS2.SS11
LA9.MS5
ATS73
CS2.SS11
LA9.MS5
ATS73
ATS 100
**
**
**
**
CS75
HSLA25
CS60
HSLA40
CS79
LA14,AS7
CS67
LA31.AS1.8
Age
1st yr.
of Prod.
1967
1958
UNK
Pre-1950
Pre-1950
Pre-1950
Pre-1950
1902
**
4*
**
**
1890
1948
1903
1905
Productio
Capacity
Ton/Day
1707
996
432
66
17
6
25
37
**
**
**
**
150
342
471
525
n
Flow (Gallons/Ton)
Applied
[3507J
1 [3400]
*
*
*
*
2347
**
**
**
**
138
131
UNK
UNK
Process Discharge
[2468] [10]
[3400] [10]
* * .
* *
* *
* *
2347 2347
** **
** **
** **
** **
138 12.8
131 131
UNK UNK
UNK UNK
Treatment Components
Process Central Operating
Treatment Treatment UnJa
PSP
SS
PSP
SS
PSP
**
**
**
**
PSP
PSP
SS
PSP
SS
CNT(UNK) RUP44
(UNK),NA, RTP55.7
FLP,CL,CT BD0.3
COT(1)(39) [RTP99.7J
** **
** **
** **
** **
CNT(1)(19.6) RTP<90.7)
BD(9.3)
or
(CLH).(FP) (RIP)
(CLR),(FP) (RTF)
Discharge
Mnrlo
node
POTW
POTW
POTW
Direct
**
**
**
< - **
Direct
Direct
Direct
Direct
-------
TABLE III-3
HOT FORHIHO SECTIOH
SUMMARY TABLE
PAGE 15
u\
O
Plant
Code
0856A
03
0856A
04
0856F
0856F
02
0856F
m
UJ
08S6F
04
085 6F
05
085 6H
01
0856H
02
0856K
01
0856K
no
uz
0856K
0856N
01
0856H
02
Products
I -Benm, Channel
Angle
I -Beam .Channel
H-Beara,Tee,Hiac
Blooms & Skelp
Billets, Round
Skelp
Billets
Angle, Round
Flat Bar,Rebar
Rod
WF-Beam,H-Pile
I -Beam .Channel
Zee, Sheet Piling
Hisc. Shapes
Circular Sect.
Forging
Axles
Wheels
Round, Rebar
Rebar
Steel
Typen
. ,/ fc ..— i-
CS89
LA11.ATSO
CS96,
LAS. 5
AS0.3
CS100
CS100
CS100
CS100
CS100
CS86,
LA14
CS72,
LA23
CS100
CS100
CS98
AS2
CS65,
Age
1st yr.
of Prod.
1907
.2
1910
1952
1952
1952
1953
1969
1927
1926
1918
1966
1971
1970
Production
Capacity
Ton/Day
396
444
6867
6867
5232
1057
2133
1683
1338
123
255
732
3348
Flow (Gallons/Ton)
Applied
UHK
UHK
1258
952
UHK
12,238
8101
1515
1906
61
198
1770
3226
Process
UHK
UHK
1258
952
UHK
12,238
8101
1515
1906
61
198
1770
3226
Dig charge
UHK
UHK
419
476
UHK
6804
8101
1515
1906
61
198
1770
3226
ATS 17, MS 11
RAL5.BS2
CS65,
1970
1722
6272
6272
6272
ATS17.MS11
RAL5.BS2
Treatment
Process
Treatment
PSP
PSP
PSP
SS
PSP
SS
PSP
SS
PSP
SS
PSP
PSP
S3
PSP
S3
PSP
.SS
PSP
SS
PSP
SS
PSP
SS
PSP
SS
Coaponents
Central
Treatment
(CLE),(FP)
(CLR),(FP)
CHT(2)(3),
BOA1.FLP,
GF.SL(UHK)
CHT(2)(3),
BOA1 ,FLP
GF.SL(UNK)
CHT(2)(6),
BOA1,FLP,
GF,SL(UHK)
CHT(2)(8)
BQA1.FLP,
GF,SL(UHK)
CHT(2)(97)
SS.SL(UHK)
CNT(2)(25)
CHI (2) (10)
CNT(2)(4),
CL.FLP
CHT(2)(95)
CL.FLP
CHT(2)(50)
SL(UHK)
(CLR),(FP),
(CT)
CHT(2)(50)
SL(UHK)
(CLR),(FP),
(CT)
Operating
Hode
RTP
RTP
RUP(66.7)
BD(33.3)
RUP(50)
BD(50)
RUP(SO)
BD(50)
RUP(44.4)
BDC55.6)
OT
or
OT
OT
OT
OT
(RTP)
(RTP)
Discharge
Hode
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
-------
TABLE III-3
HOT FORMING SECTION
SUMMARY TABLE
PAGE 16
Plant
Code
0856P
085 6Q
01
0856T
01
0856U
01
0856U
02
0856U
03
0856U
04
0856U
05
0860B
01
0860B
02
0860B
03
0860B
04
0860B
05
0860B
06
Products
Rods
Rounds
Round, Square
Misc. Shapes
Misc. Shapes
Angle, Flat Bar,
Half Round, Other
Flat Bar and
Other Shapes
Square, Strip,
Round, Spring Steel
Flat Bar.Rebar,
Other Shapes
Billets, Round
Square, Flat Bar
I-Beam, Channel
Zee, Bulb Angle,
Angle Special
I-Beam (Channel
Tee, Bulb Angle
Square
Bar
Tee, Angle, Flat
Bar, Spec. Section
Bulb Angle
Square ,Flat ,Spec .
Steel
Types
CS99
LAI
CS60,
LA40
CS60
OS40
CS100
CS100
CS95
LAS
CS100
CS80
LA20
CS94
LAI, ASS
CS94
LAI,
* j
ASS
CS94
LAI
ASS
CS94
LAI, ASS
CS94
LAI, ASS
CS94
LAI, ASS
Age
1st yr.
of Prod.
1955
1932
1906
1925
1926
1918
1918
1931
1971
1909
1910
UNK
1911
1911
Production
Capacity
Ton/Dsy
1233
2979
1029
204
690
378
225
693
2132
536
486
1135
429
Flow (Gallons/Ton)
Appileq
5656
UNK
535
14,894
6699
5638
12,288
8125
3309
5909
6522
2663
9399
IDLE
rrocess
5656
UNK
535
14,894
6699
5638
12,288
8125
3309
5909
6522
2663
9399
Discharge
5656
UNK
535
14,894
6699
5638
12,288
8125
3309
5909
6522
2663
9399
Treatment
Process
Treatment
PSP
PSP
SSP
PSP
PSP
PSP
PSP
PSP
PSP
PSP
SS
PSP
SS
PSP
S3
PSP
PSP
Components
Central
Treatment
CNT(2)(86)
SSP.SS
CNT(2)(UNK)
SS,SL(UNK)
CNT(2)(5)
SSP.SS
CNT(2)(8)
SSP,SS
CNT(2)(3.8)
SSP,SS
CNT(2)(5)
SSP.SS
CNT(2)(10)
SSP.SS,
CNT(2)(6.7)
SS.SL(UNK),
(FP),CNT(2)
Operating
Mode
OT
OT
OT
OT
OT
OT
OT
OT
(RTP)
(RIP)
Discharge
Mode
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
(3)SS,SL(UNK)
(FP)
CNT(2)(3)
SL(UNK),SS,
(FP)
CNT(2)(3)SS,
SL(UNK),(FP)
CNT(2)
(4)SS,SL
(UNK),(FP)
(RTP)
(RTP)
(RTP)
OT
Direct
Direct
Direct
Direct
-------
TABLE III-3
HOT FORMING SECTIOH
SUMMARY TABLE
PAGE 17
to
Plant
Code
0860B
07
0860B
0860B
09
0860B
10
0860B
11
0860F
01
0860F
02
0860H
01
0860H
02
0860H
03
0864A
0864B
0864C
01
0864C
02
Products
Round, Square
Hex, Rebar, Spec.
Round, Rebar
Channel , Angle
Flat Bar, Strip
Round, Flat Bar
Rebar, Spec. Sect.
Mill, Round .Flat
Bar .Rebar
Hire Rods
Hire Rods
WF-Beam
WF-Beam,I-Beam
Chat.nel, Sheet
Piling ,Angle
Zee
Rod, Coils
Billeta,HF-
& I -Beam, Channel
Zee, Angel
Round
Billets, Channel
Angle, Round, Flat
Dar* RphflT
O3IT f ncuaL
Channel .Angle
Round, Flat Bar
Rebar
Steel
Types
a i
UHK
CS94
LSI, ASS
CS94
LSI, ASS
CS94
LAI, ASS
CS94
LAI, ASS
CS97
LA3
CS94
LA6
CS80
LA20
CS85
LAIS
CS99
ATS1
CS94
LA6
CS100
CS75
LA5.ATS20
CS75
LAS
ATS20
ARC
•»£*-
1st yr.
of Prod.
1911
1919
1927
UNK
1972
1936
1943
1931
1959
1974
UNK
1941
1916
1916
Production
Capacity
Ton/Day
IDLE
492
474
892
1464
726
1167
2616
1380
2058
2040
1161
450
360
Treatment Components
Flow
Applied
11,993
7590
12,751
6880
7934
4936
7796
[4720]
[6930]
10,729
9054
3840
10,000
(Gallons/Ton)
Process Discharge
11,993
7590
12,751
6880
7934
4936
7796
[4720]
[6930]
10,729
9054
3840
10,000
11,993
7590
12,751
6880
793
494
218
[180]
M
933
245
280
730
Process
Treatment
PSP
PSP
PSP
PSP
PSP
SS
PSP
SS
PSP
SS
PSP
SS
PSP.SSP
SS.CT,
E,FSP,
VF,T
PSP
PSP
PSP
SS
PSP
SS
Central
Treatment
CNT<2)<5.6)
SS.SL(UNK)
CNT(2)(3.4)
SS,SL(UNK)
CNT(2)(10.8)
SS,SL(UNK)
CNT(2)(9.6)
SS.SL(UNK)
CHT(2)(25)
SSP,T,VF,F,
HA.NL.CT
FDS(UNK)
CNT(2)(25)
SSP,T,VF,F
NA,HL,CT,
FDS(UNK)
CHT(2)(18.7)
SSP.SS.SCR,
FLL.FLA.VF
CL.T
CNT(2)(22.7)
SSP,SS,SCR
FLL.FLA.VF
CL.CT.T
CHT(2)(83)
SS,CL
SL(UNK)
CHT(2)(1.6)
NL,FLL,FLP
CL.NA.SS.T
CHT(2)(29)
SSP,SS,CT,
SL(UHK)
CNT(2)(61)
SSP.CT.SS
SL(UNK)
Operating
Mode
OT
OT
OT
OT
RIP (90)
BD(10)
RTP(90)
BD(10)
RTP(97.2)
BD(2.8)
RTP(96)
BD(4.0)
RTP(99)
*ir* / • \
BD(l)
RUP(78.9)
RTP(12.3)
BD(8.7)
RUP(97.3)
BD(2.7)
RTP(92.7)
BD(7.3)
RTP(92.7)
BD(7.3)
Discharge
Mode
Direct
Direct
Direct
Direct
Direct
Direct
POTW
POTW
Indirect
Direct
Direct
Direct
Direct
-------
TABLE III-3
HOT FORMING SECTION
SUMMARY TABLE
PAGE 18
Plant
Code
0868A
01
0868A
02
0868A
03
0868A
04
0868A
05
0868A
06
0920B
01
0920B
02
0946A
01
0946A
02
0946A
03
0948B
0948F
01
0948F
02
0948F
03
Products
Rails
Mill, Billets,
Blooms
I -Beam, Channel
Bulb Angle, Angle
R
-------
TABUE 1II-3
HOT FORMIHG SECTION
SUHHARY TABLE
PAGE 1?
FOOTNOTES
(1) 1977 value
(2) Mill no longer in operation.
* : Dry Operation
**: Confidential Data .
: Data listed in brackets was received in the responses to the detailed questionnaires
or during sampling visits
(): See note on Table III-2.
Steel Types
CS t Carbon Steel
LA : Low Alloy Steel
SS : Stainless Steel
CMHR: Chrome/Molybdenum Heat Resistant
OS I Other Steel Not Identified
ATS : Alloy Tool Steel
ES : Electrical Steel
AS t Alloy Steel
BS I Boron Steel
ABS: Alloy Bar Steel
FMSt Free Machining
RALt Resulphurized and Leaded
VGSt Vanadium Grade Steel
MS I Managing Steel
Additional Footnotes
01: Decant Tank
02: Inclined Plate Separator
03: Settling Basin
04: ' Continuous Cloth Filter
OS: Settling Tank
06: Flocculation w/Ferric Chloride
For a definition of other C&TT Codes, see Table VII-1.
-------
TABLE III-4
GENERAL SUMMARY TABLE
jjQT FORHIHGt FLAT-HOT STRIP AMD SHEET
Ul
in
Plant
Code
0020B
0060
0060B
0060D
0112A-03
0112-04
0112B
0112D-02
0176
0248B
Product
Plate,
Hot Strip
Hot Strip
Hot Strip
Hot Strip
Hot Strip,
Skelp
Plate, Sheet,
Hot Strip,
Skelp
Plate.Hot
Strip, Sheet
Plate,
Sheet
Hot Strip
Plate ,Hot
Strip, Slabs
Steel
Type
SS-40
ES-60
CS-95
LA-5
CS-98.4
LA-1.6
CS-5.1
SS-22.4
ES-72.5
CS-100
CS-95
LA-5
CS-99.9
LA-0.1
CS-98.6
LA- 1.4
SS+ES
100
CS-10
SS-90
Age - Production
1st Year Capacity
ui. riuu • \ions /if fly/ Applied
1953 2,550
1968 10,032
(1971)
1953 4,790
(1967)
1958 2,520
1937 6,978
(1960)
1947 7,893
1936 7,368
(1957)
1966 12,744
1953 240
I960 1,500
[5690J
8,297
UNK
7,143
4,911
5,619
UNK
[5790]
9,630
7,680
Flow (Gallon/Ton)
Process
[5690]
7,936
INK
7,143
1,405
584
UNK
[5790]
9,630
7,680
DIB char gi
J569o]
251
UNK
UHK
1,405
584
UNK
[5790]
693
92
Treatment Components
Process Central
B Treatment Treatment
PSP SSP.CL,
FDS(UNK)
PSP.SS CNT2-82.6,
FLL.FLOd),
CL,VF,CT
PSP.SSP.SS CNT2(UNK),NL,
FLPjCL,VF,CT
PSP CNT2(UNK),
FLL,FLP,FL
(01),CL,SL
(UNK).CT
PSP,CT CNT2(UNK),SS,
Scr,AE,NL,
FLA,FLP,SL
(UNK),CY,T
PSP,CT CNT2(UNK),SS
Scr,AE,NL,FLA
FLP,SL(UNK),
CY,T
PSP CNT2(UNK),SS,
FDS(UNK),T
PSP CNT2-61.3,
CL,FLP,NL,
NH,CR,SL(UNK)
PSP CNT2-13.SSP,
T,SS,CY,CL
PSP.SSP FLP,Scr,TP,
Operating
Mode
or
RUP-4.RTP-94,
BD3
RTP(UNK),RET
(UKK),ED(UHK)
RTP(UNK),
HET(UNK),
BD(UNK)
RUP-71.4,
BD-28.6
RUP-89.6,
BD-10.4
RTP((UNK),
BD(UNK)
or
RTP-92.8,
BD-7.2
RTP-98.8,
Discharge
Mode
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
-------
in
TABLE Ill-It
GENERAL SUMMARY TABLE
HOT FORMING: FLAT-HOT STRIP AND SHEET
PAGE 2
Plant
Code
0256C
0256L-03
0256L-04
0320-02
0384A-02
0384A-03
0384A-04
0396D-01
0396D-02
0424-02
0432A
Product
Hot Strip
**
**
Sheet
Hot Strip
Plate,
Strip, Sheet
Plate, Strip,
Sheet
Hot Strip
Hot Strip
Plate,
Sheet
Hot Strip,
Skelp
Steel
Type
j v
CS-86.15
SS-8.45
ES-5.4
**
**
CS-100
CS-96.2
LA-2.9
ES-0.9
CS-83.9
LA-16.1
CS-98.8
LA-1.2
CS-100
CS-100
CS-100
CS-90
LA-5
ER-X
Age -
1st Year
of Prod.
1952
(1967)
**
**
1974
1965
(1967)
1932
(1958)
1938
(1960)
1927
1960
1950
1957
Production
Capaci ty
(Tone /Day)
2,328
**
**
8,232
12,291
3,666
5,400
231
1,638
20.1
4,950
Flow (Gallon/Ton)
Appl led Process Discharge
UNK UNK UNK
******
** ** **
9,951 6,737 6,737
10,193 7,380 7,380
17,511 17,511 17,511
8,573 8,573 8,573
24,935 24,935 UNK
7,033 7,033 UNK
716 716 716
[4800J [480^ [480o]
Treatment
Process
Treatment
PSP
**
**
PSP.SS
PSP.SS
PSP
PSP
PSP
Component 8
Central
Treatment
CNT2(UNK),SL
(UNK),SS
**
**
CNT2-52.7,
NC | SC )CLt f
SL(UNK)
FLL.FLP.FLA,
FLO(1),SS,CL
CNT2-31.8,
SS.SL(UNK)
CNT2-23,
SL(UNK),SS
CNT2(UNK),
SL(UNK),SS
PSP.CT.FDSP, CNT2(UNK),SS
CL.VF SL(UNK)
-
PSP.SS
CNT2(UNK),
FDSP.SL(UNK),
CT
CNT2(UNK),
FLP.FLM.CL,
SS.Scr.VF
Operating
Mode
RTP(UNK),
BD(UNK)
**
**
RUP-32.3,
BD-67.7
RUP-UNK,
(RTP) fUNK)
BD-72.4
(RTP)
(RTP)
RTP(UNK),
BD(UNK)
RTP(UNK),
BD(UNK)
CT
»
OT
Discharge
Mode
Direct
**
**
Direct
Direct
Direct
Direct
POTW
Indirect
to POTW
Direct
Direct
0432B Plate, CS-90
Hot Strip SS^-10
1937 3,942
UNK
UNK
UNK
PSP.SS
OT
Direct
-------
TABLE III-4
GENERAL SUMMARY TABLE
HOT FORMING: FLAT-HOT STRIP AND SHEET
PAGE 3
Plant
Code Product
0432C Plate, Hot
Strip, Skelp
0448A-01 Plate,
Skelp
0448-02 Plate, Hot
Strip, Sheet
Skelp
047 6A Plate, Sheet
Hot Strip,
Skelp, Bar
t_n
-J 0492A Skelp
OS28A Hot Strip
OS84B Plate,
Hot Strip
0584C Hot Strip
Steel
Type
CS-92
SS-4
LA-4
CS-96
AS-4
CS-95
AS-5
CS-80
LA-20
CS-100
CS-94
SS-3
LA-3
CS-80
LA-20
CS-80
LA-20
Age - Production
lot Year Capacity
of Prod. (Tons/Day)
1964 10,40*.
1943 2,417
(1969)
1950 5,509
(1969)
1915 828
(1960)
1953 3,152
1955 5,549
1961 14,022
1967 9,375
Flow (Gallon/Ton)
Applied
[3500]
(INK
UNK
6,282
3,471
4,686
{4150]
3,680
Process
[3042]
UNK
UNK
6,282
3,471
4,686
[4150]
3,680
Discharge
[375]
UNK
UNK
2,525
3,471
4,686
[4150]
3,680
Treatment Components
Process Central
Treatment Treatment
CNT2-65,PSP,
SS.FLL.FLP,
A,CL,VF,CT
PSP.SS CNT2(UNK),CL
SL(UNK),CT
PSP,SS,CL, -
SL(UNK),CT
PSP CNT2-60.7,
SSP,Scr,88,
NL.FLP.CL,
SL(UNK)
PSP.SSP CNT2-9.8
SL(UNK),8S
PSP CNT2-66,ASF
CO,EB,FLP,
NL,Scr,CL,
T,SS
PSP,SSP,SS
PSP,8,SSP CNT2-48.6,
SS,SL(UNK),
FOSP,CLB,802
Operating
Mode
lRUP-13.1,"]
RTP-76.2,
BD-10.7 1
, RUP(DNK),
RTP(UNK),
RET(l)NK)
RUP(UNK),
RTP(UNK),
BD(UNK)
RTP-59.8,
BD-40.2
RET100
or
or
(RTP)
Discharge
Mode
Direct
Indirect
POTH
Direct
Indirect
Direct
Direct
Direct
dechlorination
0584F Hot Strip
CS-100
1927 8,323
(1955)
CH
[3160J
[H
PSP CNT2-40.7,
SL(UNK),S8
or
Direct
(CLR),(VF),(FP)
-------
TABLE III-4
GENERAL SUMMARY TABLE
HOT FORMING: FLAT-HOT STRIP AND SHEET
PAGE 4
Plant
Code Product
0684B Plate, Hot
Strip, Sheet,
Skelp
06B4F-02 Plate, Sheet,
Skelp
06841-01 Hot Strip
Steel
Type
* ji*~
CS-84
SS-5
LA-2
AT-1
ES-8
CS-94
SS-2
LA-4
CS-96
LA-4
Age - Production
1st Year Capacity Flow (Gallon/Ton)
of Prod. (Tons/Day) Applied Procesi Ditcharge
1961 6,396 [6660] [4063] &8?]
(1964)
1971 8,223 9,347 7,578 327
1957 3,429 5,802 5,802 5,288
(1964)
Treatment Components
Proces* Central
Treatment Treatment
PSP,SL(UHK), -
CT
PSP CNT2-56.0,
Scr,FLL,FLP,
FLO(1),CL,SS,
SL(UNK),FDS
(UNK),CT,VF
PSP CNT2-13.8,
SSP,SS,BOA1,
Operating
Mode
[RUP-39.0
RTP-47.7,
[BD-13.3 J
RUP-18.9,
RTP-77.6
BD+Losaes-
3.5
RTP-8.9,
BD-91.1
Discharge
Mode
Direct
Direct
Direct
NH,3L(UNK),SS
Ul
03 0684V-02 Sheet
0776H-02 Sheet
085 6D Hot Strip
08S6E Plate,
Sheet
0856F-01. Hot Strip
0856F-02 Skelp
SS-100
S3- 10
LA- 15
AT-75
CS-85
LA-11
ES-4
SS-100
CS-100
CS-100
1916 20.7 8,803* 8,803* 403*
1902 18 6,400 6,400 6,400
(1962)
1938 8,445 4,450 4,450 4,450
(1961)
1927 28 UNK UHK UNK
1952 9,168 5,497 4,238 4,238
1953 3,042 2,840 947 947
PSP, S3,
SL(UNK)
PSP
PSP,88,(CLR)
(FP), (CT)
-
PSP CNT2-45,
GF,SC,FLP,
BOA(1),SL
(UNK), S3
PSP CNT2-3.3.GF,
SC.FLP,
BOA(1),SL
(UNK), S3
HTP-95.4,
EET-4.6
or
(RTP)
or
SOP-22.9,
BD-77. 1
RUP-66.7,
BD33.3
Indirect
Direct
Direct
Direct
Direct
Direct
-------
TABLE III-4
GENERAL SUMMARY TABLE
HOT FORMINGS FLAT-HOT STRIP AND SHEET
PAGE 5
<£>
Plant
Code
0856P
0856U-01
0856U-02
0856U-03
0856U-04
0856U-05
0860B-01
0860B-02
0864A
0868A-02
0868A-03
Product
Hot Strip
Hot Strip,
Skelp, Bar
Hot Strip,
Specials
Hot Strip
Plate, Hot
Strip, Skelp,
Bar
Plate, Hot
Strip, Sheet,
Skelp
Hot Strip
Hot Strip
Plate, Hot
Strip, Sheet
Hot Strip
Hot Strip
Steel
Type
CS-100
CS-100
CS-100
CS-95
LA-5
CS-100
CS-85
LA- 15
CS-96.5
SS-2
LA-1.5
CS-100
CS-94.8
LA-5. 2
CS-100
CS-99
LA-1
Age - Production
lot Year Capacity Flow (Gallon
of Prod. (Tons/Day) Applied Process
1929 253 5,125 5,125
1929 558 11,277 11,277
1918 150 22,944 22,944
1920 639 6,400 6,400
1926 915 4,847 4,847
1935 2,907 11,809 11,809
1967 12,204. 8,448 7,510
1936 5,895 5,594 5,594
(1976)
1944 6,018 4,666 4,666
(1971)
1929 177 21,356 18,443
1937 4,854 2,905 2,905
(1969)
Treatment Components
/Ton) Process Central
Discharge Treatment Treatment
5,125 PSP, S3 CNT2-98,
SSP.SS
11,277 PSP CNT2-11.3,
SSP.SS
22,944 PSP CNT2-6.9,
SSP.SS
6,400 PSP CNT2-7.3,
SSP.SS
4,847 PSP CNT2-7.9,
SSP.SS
11,809 PSP CNT2-61.4,
SSP.SS
7,510 PSP.SS CNT1-79.8,
SSP.SS, FDSP,
T,VF
5,594 PSP.SS CNT1-20.2,
SSP.SS,
FDSP.T.VF
4,666 PSP CNT2-50.4,
CL.SS,
SL(UNK)
1,815 PSP CNT2-5.4,
SSP.SS,
SL(UNK)
334 PSP CNT2-23.3,
SSP.SS,
SL(UNK)
Operating
Hode
or
or
or
or
or
or
RTP-(UHK),
BD-(UHK)
(RTF)
RET-58.7,
BD-41.3
RUP-13.6,
RTP-77.9,
BD-8.5
RTP-88.5,
BD-11.5
Discharge
Hode
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
-------
TABLE III-4
GENERAL SIWHARY TABLE
HOT FORMING: FLAT-HOT STRIP AND SHEET
PAGE 6
Plant
Code
0920C
0920N
0948A
0948C
Product
Hot Strip
Hot Strip
Plate, Hot
Strip, Sheet,
Skelp
Plate, Hot
Strip, Sheet,
Skelp
Steel
Type
CS-99.5
LA-0.25
HCS-0.25
CS-96
LA-4
CS-B9
LA- 10
ES-1
CS-95
LA-5
Age -
1st Year
of Prod.
1953
(1964)
1966
1935
(1960)
1968
* : Includes flows from one plate mill.
**: Confidential data.
( ) Dates in parentheses represent years in
treatment systems
Data
which were
listed in brackets was
KEY TO C&TT
Production
Capacity
(Tons/Day)
3,300
7,992
7,584
8,724
Treatment Components
Flow (Gallon/Ton)
Applied
7,767
[8200]
6,076
6,602
Process
5,150
[5683]
6,076
6,602
which the mill went through a major
installed after January
received in
STEPS
the response
1, 1978.
Discharge
5,150
[4860J
6,076
6,602
Process Central
Treatment Treatment
PSP,
SSP,
(FP)
SS,
88
PSP, S3,
FDHP
PSP,
PSP,
SS
S3 CNT2-97.6,
FDSP.CL,
FLO(1),SS
modification. Treatment components in
to the detailed questionnaires or
during
sampling visits.
Operating
Mode
(RTP)
RUP-(UHK),
BD-(UNK)
EHJP-30.7,1
HP- 10.1
ID-59.2 J
or
RET-100
parentheses
Discharge
Mode
Direct
Direct
Direct
Indirect
represent
AS : Alloy Steel
CS : Carbon Steel
HCS: High Carbon Steel
SS : Stainless Steel
AT I Alloy Tool
ES t Electrical Steel
LA : Low Alloy
SAS: Super Alloy Steel
For definitions of C&TT codes see Table VII-1.
-------
TABLE III-5
GENERAL SUMMARY TABLE
HOI FORMING; FLAT-PLATE (CARBOH)
Plant
Code Product
0060F-01 Plate
0060F-02 Plate
OU2A-01 Plate
0112A-02 Plate
0112C-01 Plate
0112C-02 Plate
0112D-01 Plate
0384A-01 Plate
Steel
Type
CS-73
LA-16
AS-11
CS-73
LA-16
AS-11
OS-100
CS-98
TS-2
CS-82.7
AS-17.3
CS-69.7
AS-30.3
CS-70
LA-15
AS-15
CS-74.7
LA-25.3
Age - Production
1st Year Capacity
Flow (Gallon/Ton)
of Prod. (Tons/Day) AppliedProcessDischarge
1962 2,115
1950 1,410
1920 1,056
(1964)
1931 2,592
(1957)
1902 834
(1954)
1906 471
(1961)
3,976 3,976 DHK
UNK UNK
UNK UNK
UNK UNK
UNK
2,455 2,455 2,455
2,778 2,778 2,778
UNK
UNK
Treatment Componenta
.Process Central
Treatment Treatment
PSP
PSP
PSP,S3
PSP,SS
PSP
PSP
1964 .3,360 [3240] [3240] [3240] PSP,SS
CNT2(UNK),
SSP.Scr,
SL(UNK),SS
Operating
Mode
RTF(UNK),
RET (UNK),
BD(UNK)
CNT2(UNK), RTP(UHK),
SSP,SL(UNK), RET(UNK)
Scr.SS BD(UHK)
CNT2(UNK) OT
SS.Scr.AE,
NL,FLA,FLP,
SL(UNK),CY,T
CNT2(UHK), OT
Scr,AE,NL,SS,
FLA,FLP,SL
(UHK),CY,T
CNT2(UNK), OT
NC,AE,SSP,SS,
T,FDS(UNK),
CT
CNT2(UNK), OT
NC,AE,SSP,SS,
T,FOS(UNK),
CT
1913 972
(1951)
7,867 7,867 7,867
PSP.SSP,
SS
CNT2-12.2,
SS,CL,FLP,
NL,NW,CR,
SL(UNK)
CNT2-93,
SL(UNK),SS
OT
(RTP)
Discharge
Mode
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
-------
TABLE II1-5
GENERAL SUHHARY TABLE
HOT FORMING! FLAT-PLATE (CARBOH)
PAGE 2
Plant
Code Product
0496
112"/120" Plate
0496
140" Plate
06841-02 Plate
0856H-01 Plate
0856H-02 Plate
085611-03 Plate
0860B-03 Plate
0860H-01 Plate
Steel
Tvpe
Jr
Carbon
Carbon
CS-76
LA- 24
CS-72.1
LA- 27. 9
CS-87.4
LA- 12.1
AT-0.5
CS-73.5
SS-1.5
LA-13.5
AT-11.5
CS-67
AS-33
CS-50
LA-42
AT-8
Age - Production
1st Year Capacity
of Prod. (Tons/Day)
1904 1,740
(1943)
1959 1,830
(1968)
1967 1,629
1898 984
1936 3,939
1944 2,916
1962 3,162
1907 648
(1973)
Flow (Gallon/Ton)
Applied
H
[120]
7,558
117
5,473
3,652
2,550
[979CJ
Process
[870]
[120]
7,558
117
5,473
3,652
2,550
[9790]
Discharge
H
[120]
6,889
117
5,473
3,652
2,550
[360]
Treatment Components
Process Central
Treatment Treatment
PSP.SSP,
S3
PSP.SSP,
S3
PSP
PSP.SSP,
SS,(CT)
PSP,(CT)
PSP,SS,(CT)
PSP.SS
(FP)
PSP,SS,(CT)
CHTl-28,
FLP,DR,FDMG
CNT1-4,
FLP,DR,FDHG
CHT2-13.9,
SSP.SS,
BOA(1),NW,
SL(um),ss
-
.-.
-
CHT2-7.5,
SL(UNK),
S3
CNT2-5.3,
Scr,CL,CT,
T,FLL,VF,FLA
Operating
Mode
or
or
RTP-8.9,
BD-91.1
(RTP)
(RTP)
(RTP)
(RTP)
rRTP-96.3,1
[BD-3.7 J
Discharge
Mode
Direct
Direct
Direct
Direct
Direct
Direct
Direct
POTW
SSP,SS
-------
TABLE II1-5
GENERAL SUMMARY TABLE
HOT FORMING: FLAT-PLATE (CARBON)
PAGE 3 .
Plant
Code
0860H-02
0868A-01
0868B
Steel
• Product Type
Plate, CS-60
Floor Plate LA-40
Plate CS-80
LA-20
Plate CS-85
LA- 10
AT-5
Age - Production
1st Year Capacity Flow (Gallon/Ton)
Treatment Components
Process Central
of Prod. (Tons/Day) Applied Process Diachflrpe Tr»,^»nt Treatment
1931 2,886 5,489 5,489 154
1919 1,800 3,922 3,922 451
(1942)
1970 3,894 4,992 4,992 185
PSP,SS,(CT) CNT2-14.7,
Scr,SSP,SS
CL,T,CT,FLL,
VF.FLA
PSP CHT2-11.7,
SL(DNK),
SS,SSP
PSP,SS CNT2-99.3,
FLP,A,SS,
COn civ /intir \
Operating
Mode
RTP-97.2,
BD-2.8
RTP-88.5,
BD-11.5
RTP-96.3,
BD&Losses-
•»• -u
Discharge
Mode
POTW
Direct
Direct
F(UNK)(UNK)P
-------
CT>
TABLE III-6
GENERAL SUMMARY TABLE
HOT FORMING! FLAT-PLATE (SPECIALTY)
Plant
Code
0256L-01
0256L-02
0424-01
0496
U12"/
120")
0496
(140")
0496
(140"/
206")
0684 V-01
0776H--01
Steel
Product Type
CONFIDENTIAL DATA
Plate SS-78
AT- 14
TS-8
Plate S3 and
LA
Plate SS and
LA
Plate SS and
LA
Plate SS-86
AS- 14
Plate SS-10
LA- 15
AT-75
Age - Production
Treatment Components
1st Year Capacity Flow (Gallon/Ton)
of Prod. (Tons/Day) Applied
1971 450 800
1904 1,740 fe.653]
(1943)
1959 1,830 J87o]
(1968)
1918 630 206
1916 119.4 8,803*
1902 60 960
Process
800
[2,653]
H
206
8,803*
960
Discharge
800
[2,653]
H
206
403*
960
Process
Treatment
PSP.SS,
SSP
PSP.SSP,
S3
PSP.SSP,
S3
PSP.SSP,
S3
PSP.SS,
SL(UNK)
PSP
Central Operating
Treatment Mode
CHT2-14, BET-61.5
FDSP.SS, BD-38.5
SL(UHK),CT
CHT1-28, OT
FLP.DR.FDMG
CUT 1-4, OT
FLP.DR.FDHG
CHT1-24, OT
FLP,DR,
FDMG
RTP-95.4,
RET-4.6
or
Discharge
Mode
Direct
Direct
Direct
Direct
Indirect
Direct
* t Includes flow from one sheet mill.
( ) Dates in parentheses represent years in which the mill went through a major modification. Treatment components in parentheses represent
treatment systems which were installed after January 1, 1978.
Data listed in brackets was received in the responses to the detailed questionnaires or during sampling visits.
KEY TO C&TT STEPS (
AS : Alloy Steel AT : Alloy Tool
CS : Carbon Steel LA : Low Alloy
. SS : Specialty Steel SAS; Super Alloy Steel
TS : Titanium Steel
For definitions of C&TT codes see Table VII-1.
-------
TABLE III-7
GENERAL SUMMARY TABLE
HOT WORKING PIPE AMD TUBE
Plant
Code
0060C
01
0060C
02
0060F
0088A
01
-
0088A
02
0088A
03
0088C
01
0088C
02
0112A
01
Product
Seamless
Pipe
Seamless
Pipe
Butt Weld
Pipe
Seamless
Tube
Seamless
Pipe
Seamless
Tube
Seamless
Tube
Seamless
Tube
Butt Weld
Pipe
Age - Production
Steel 1st Year Capacity
Type of Prod. (Tons/Day)
CS-60
HSLA - 40 1913 906
CS-45
HSLA-55 1913 408
CS-10 1950 1044
HSLA-90
CS-14.0
SS-3.5 1914 285
HSLA-40.0
CHHR-42.5
CS-10. 5
HSLA-40.0 1917 252
CMHR-49.5
CS-7
HSLA-93 1932 171
CS-60
HSLA-40 1910 283.8
CS-60
HSLA-40 1937 268.5
CS-100 1939 366
Treatment Components
Flow (Gallon/Ton) Process Central Operating
Applied Proceaa Piacharge Treatment Treatment Mode
UHK UHK UNK PSP, S3 CUT 2(DHK), RTP(UHK),
FLP.SSP, BD(UHK)
S3
*
UHK UHK UHK PSP, S3 CNT2(UNK), HTP(UHK),
FLP.SSP, BD(UNK)
38
(Ho production in 1976) -
UNK UHK UHK PSP CHT l(UHK),
SSP.SS, (BTP)
Straw Filter
(VF)
UHK UHK UHK PSP CHT l(UHK),
SSP.SS, (BTP)
Straw Filter
2712 2712 2712 PSP - OT
3552 3552 1369 PSP.SSP, /^CNT 2-33.7, RTP-61.4,
S3 \GF,CY,(VP), BD-38.6
)(FP),(CT)
/
6436 6436 2481 PSP.SSP, /
S3 V
UHK UNK UHK PSP, S3 CHT2(UNK), OT
Scr,NL,
A,FLA,FLP,
SL(UNK),8S,
T,CY
Discharge
Mode
Direct
Direct
Direct
1
Direct
Direct
Direct
Direct
-------
TABLE III-7
GENERAL SUMMARY TABLE
HOT WORKING PIPE AND TUBE
PAGE 2
cn
Age - Production Treatment Component!
Plant
Code
0112A
02
0196A
0240B
05
0256G
•
0396E
0432A
01
0432A
02
0432A
03
Product
Butt Weld
Pipe
Seamless
Tube
Seamless
Pipe
Butt Weld
Pipe
Butt Weld
Pipe
Butt Weld
Pipe and
Welded Tube
Butt Weld
Pipe and
Welded Tube
Seamless
Pipe
Steel 1st Year Capacity Flow (Gallon/Ton) Process
Type of Prod. (Tons/Day) Applied Process Discharge Treatment
CS-100 1940 744 UNK UNK UNK PSP.SS
CS-95
1ISLA-5 1953 ** 12,794 12,794 4,572 PSP.SS
CS-34
AS-66 1925 213 [l70fl] [l70
-------
TABLE III-7
GENERAL SUMMARY TABLE
HOT WORKING PIPE AND TUBE
PAGE 3
CTi
Plant
Code . Product
0432A Seamless
04
Steel
Type
Age - Production
1st Year Capacity
Plow (Gallon/Ton)
Treatment Components
Process Central
Pipe and CS-70
Tube HSLA-30
0448A Butt Weld CS-100
Pipe
0476A Butt Weld CS-100
Pipe
0492A Seamless
05 Tube
CS-5
HSLA-95
0548 Seamless CS-90
Tube AS-10
0548A Seamless CS-70
01 Pipe LA-30
0548A Seamless CS-70
02 Pipe and LA-30
Tube
0652A Seamless CS-83
Tube HSLA-17
0684A Butt Weld
02 Pipe CS-100
of Prod. (Tons/Day) Applied Process Discharge' Treatment Treatment
1928
516
1948 456.3
1930 381.6
1975 156
1945 196.8
1960 126
1957 42
1954 363
UNK
UNK
UNK UNK
4672 887
4573 915
UNK
UNK
887
10154 10154 8237
915
8000 8000 1794
6857 6857 3429
(3672) [3672] [3672]
PSP
PSP.SS
PSP
PSP.SSP,
ss
PSP
PSP.SSP,
ss
1966
1002
4311
4311
4311
PSP.SSP,
SS
PSP.SS
CNT 2(UNK),
CL.SL(UNK),
CT
CNT2-9.9,
Scr,SS,NL,
CY,PLP,CL
CNT2-1.4,
SL(UNK),
SS
CNT2-27.1,
NL,SL(UNK),
GF,FLL,NA
CNT2-77.8,
Spray
Cooling
CNT 2-22.2,
Spray
Cooling
-Operating
Mode
OT
RUP(UNK),
RTP(UNK),
BD(UNK)
SUP-78.7,
BD-19.1,
Losses 2.2
HTP-18.9,
RET-81.1
RUP-80,
BD-20
RTP-77.6
RET-22.3
BD-0.1
RTP-50,
RET-49,
BD-1
OT
OT
Discharge
Mode
Direct
Direct
Direct
Indirect:no
discharge from
total system
Direct
Direct
Direct
Direct
Direct
-------
TABLE II1-7
GENERAL SUMMARY TABLE
HOT WORKING PIPE AHD TUBE
PAGE 4
-CD
Plant
Code
0684H
0728
0796A
01
0796A
02
0796A
03
0796B
0856C
0856F
01
0856F
02
0856N
01
Steel
Product Type
Seamless CS-50
Tube HSLA-50
Butt Held
Pipe CS-100
* *
* *
* *
* *
Seamless CS-90
Pipe HSLA-1
AS-9
Butt Weld
Pipe CS-100
Butt Held
Pipe CS-100
Seamless
Pipe CS-100
Age - Production Treatment Components
1st Year Capacity Flow (Gallon/Ton) Process Central Operating Discharge
of Prod. (Tons/Day) Applied Process Discharge Treatment Treatment Mode Mode
1953 540 L7010J C701°] I21] PSP.SS CNT2-8.9, [RTP-99.7] POTO
FDSP.VF,
FLL,FLP,
CT,CL,T
1929 240 [2560) [2560] [82J - COT 2-96.8, RTP-96.8, Indirect-
PSP,SSP, RET-3.2 Complete Re-
SL(UNK),CT cycle and Reuse
** ** * * * * *
* * * * * * * * *
** ** * * * * *
** *** * * * *
1972 36 1,667 83 83 PSP - RUP-95, Direct
BD-5
1953 663
CNT2-6.7, RUP-50 Direct
7,111 3,556 3,556 PSP GF,SSP>FLP, BD-50
BOA(l),
SL(UNK),SS
1963 957
1928 1011 3418 3418 3418 PSP CUT 2-9.4, OT Direct
SL(UNK),SS
-------
TABLE III-7
GENERAL SUMMARY TABLE
HOT WORKING PIPE AND TUBE
PAGE 5
Plant
Code
0856N
02
0856N
03
0856N
04
0856Q
01
0856Q
02
0916A
01
0920C
01
0920C
02
0920C
03
Product
Seamless
Pipe
Seamless
Pipe
Butt Weld
Pipe
Seamless
Pipe
Seamless
Pipe
Butt Weld
Pipe
Seamless
Tube
Seamless
Tube
Seamless
Tube
Steel
Type
CS-85
HSLA-15
CS-90
HSLA-10
CS-100
CS-100
CS-100
CS-100
CS-85
HSLA-15
CS-85
HSLA-15
CS-85
HSLA-15
Age - Production Treatment Components
1st Year Capacity Flow (Gallon/Ton) Process Central np«raHnB
of Prod. (Tons/Day) Applied Process Discharee Treatment Treatment vn^
1930 1500 3648 3648 3648 - CNT2-10.7, OT
SL(UNK),
S3
1949 981 3083 3083 3083 PSP CHT 2-5.9, OT
SL(UNK),
SS
I960 888 3730 3730 3730 PSP CHT 2-6.5, OT
SL(UHK),
SS
1930 927 UNK UNK UNK PSP.SSP CHT 2(UNK), OT
SL(UNK),S8
1930 1365 UNK UHK UNK PSP.SSP CHT 2 (UNK), OT
SL (UNK),
SS
1931 600 2765 2765 2765 PSP.SS, - OT
FD(UNK) P,
SL(UNK)
1934 229.5 4706 4235 4235 PSP CHT 2-19.7, (RTP)
NC.SSP,
88
1945 373.2 5788 5209 5209 PSP CNT 2-39.5, (RTP)
NC,SSP,SS
Not in Operation in 1976
t924 lH-3 HA HA NA PSP CUT J-IQ.7. fim.1
Discharge
Mode
Direct
Direct
Direct
Direct
Direct
Direct
Direct
Direct
n « v A fit-
HC,SSP,S3
-------
TABLE III-7
GENERAL SUMMARY TABLE
HOT WORKING PIPE AHD TUBE
PAGE 6
Plant
Code
0948A
01
0948A
02
0948A
03
0948C
01
0948C
02
-------
TABLE II1-8
HOT FORMING-PRIMARY
CARBON AND SPECIALTY STEELS
DATA BASE
Operations Sampled for
Original Study
Operations Sampled for
1977 Toxic Pollutant Study
Operations Sampled for 1980
Toxic Metals Survey
Total Operations Sampled
Operations Selected
for D-DCP
Operations Sampled and/or
Solicited via D-DCP
Operations Responding
to DCP
Estimated Number of Hot
Forming-Pr imary Operat ions
No. of
Operations
13
5 iricl.
1 above
9 incl.
1 above
25
9 incl.
3 above
31
111(2>
130
% of
Total No. of
Operat ions
10.0
3.9 incl.
0.8 above
6.9 incl.
0.8 above
19.2
6.9
2.3
23.8
85(3)
100
Daily Capacity '
of Operations
(Tons)
46,086
14,394 incl.
5,565 above
50,376 incl.
2,322 above
102,969
42,993
16,608
129,354
423,332
460,000
Total Daily
Capacity
10.0
3 . 1 inc 1 .
1.2 above
11.0 incl.
0.5 above
22.4
9.3
3.6
28.1
92.0
100
(1) 1976 capacity
(2) Responses were received for 114 operations, three of which were reported to be idle. Data are included in
the totals for five operations with confidential data.
(3) Responses were solicited and received from approximately 85% of all active Hot Forming - Primary operations.
-------
TABLE III-9
HOT FORMING SECTION
CARBON AND SPECIALTY STEELS
DATA BASE
Operations sampled for
original guidelines study
Operations sampled for 1977
toxic pollutant study
Operations sampled for 1980
toxic metals survey
to Total operations sampled
Operations selected for
detailed DCP
Operations sampled and/or
solicited via detailed DCP
Operations responding to
basic DCP
Estimated number of hot
forming section operations
No.
of
Operations
25
13 incl.
4 above
10 incl.
1 above
43
10 incl.
2 above
51
240(2)
282
% of
Total No.
of Operations
8.9
4.6 incl.
1.4 above
3.5 incl.
0.4 above
15.2
3.5 incl.
0.7 above
18.1
85(3)
100
Daily Capacity
of Operations
(Tons)
15,752
15,581 incl.
287 above
18,672 incl.
948 above
48,770
8942 incl.
3765 above
53,947
236,809
278,599
% of Total
Daily
Capacity
5.7
5.6 incl.
0.1 above
6.7 incl.
0.3 above
17.5
3.2 incl.
1.4 above
19.4
85
100
(1) 1976 capacities were used for the values in this column.
(2) Responses from 242 operations were received; however, two of those operations were reported
to be idle. This number includes confidential operations.
(3) It has been estimated that responses have been received from 85% of the active section operations
in the United States.
-------
TABLE 111-10
HOT FORMING FLAT
HOT STRIP AND SHEET
CARBON AND SPECIALTY STEELS
DATA BASE
Operations sampled for
original guidelines study
Operations sampled for 1977
toxic pollutant study
Operations sampled for 1980
toxic metals survey
Total operations sampled
Operations selected for
detailed DCP
Operat ions s ampled and/or
solicited via detailed DCP
Operations res pond ing t o.
basic DCP
Estimated number of hot
forming flat operations
No.
of
Operations
% of
Total No.
of Operations
10.8
3.1
Daily Capacity' '
of Operations
(Tons)
40,455
17,694
% of Total
Daily
Capacity
13.2
5.8
8 incl.
3 above
14
7 incl.
5 above
16
„(«
65
12.3 incl.
4.6 above
21.5
10.8 incl.
7.7 above
24.6
85(3)
100.0
74,635 incl.
27,498 above
105,286
48,795 incl.
35,064 above
119,017
260,324
306,264
24.4 incl.
9.0 above
34.4
15.9 incl.
11.4 above
38.9
85.0
100.0
(1) 1976 capacities were used for the values in this column.
(2) Responses from 57 operations were received, however, 2 of these operations were reported
to be idle. This number includes confidential plants.
(3) It has been estimated that responses have been received from approximately 85% of the active flat operations
in the United States.
-------
TABLE III-ll
HOT FORMING FLAT
PLATE
CARBON AND SPECIALTY STEELS
DATA BASE
Operations sampled for
original guidelines study
Operations sampled for 1977
toxic pollutant study
Operations sampled for 1980
toxic metals survey
Total operations sampled
Operations selected for
detailed DCP
Operations sampled and/or
solicited via detailed DCP
Operations responding to
basic DCP
Estimated number of hot
forming flat operations
No.
of
Operations
2
7
1 incl.
1 above
9
2
11
27
32
% of
Total No.
of Operations
6.3
.21.9
3.1 incl.
3.1 above
28.1
6.3
34.4
85(2>
100.0
Daily Capacity
of Operations
(Tons)
6810
15,948
3,360 incl.
3,360 above
22,758
2537
25,295
35,414
41,664
% of Total
Daily
Capacity
16.3
38.3
8.1 incl.
8.1 above
54.6
6.1
60.7
85.0
100.0
(1) 1976 capacities were used for the values in this column.
(2) It has been estimated that responses have been received from approximately
in the United States.
of the active flat operations
-------
TABLE 111-12
01
Operations sampled for original study
Operations sampled for 1977 toxic
pollutant study
Operations sampled for 1980 toxic
metals survey
Total number of operations sampled
Operations selected for the detailed
DCP
Operations sampled and/or solicited via
detailed DCP
Operations responding to the
basic DCP
Estimated number of hot working pipe
and tube operations
HOT WORKING PIPE AND TUBE
CARBON AND SPECIALTY STEELS
DATA BASE
Number
of
Operations
5
2
3
10
3 incl.
2 above
% of Total
Number of
Operations
8.2
3.3
4.9
16.4
4.9 incl.
3.3 above
Daily Capacit
of Operations
(Tons)
2,439
1,239
2,892
6,570
816 incl.
453 above
13 incl.
52(2)
61
21.3 incl.
7,386
100
26,202
30,826
(4)
% of Total
Daily
Capacity
7.9
4.0
9.4
21.3
2.6 incl.
1.5 above
24.0
85
100
(1) 1976 capacity
(2) Includes two operations reported as idle.
(3) It has been estimated that responses were received from 85% of the hot
working pipe and tube operations in the United States
(4) This number does not include data from the two operations reported as idle.
-------
FLAT
PRIMARY
SLABS l
r
PLATE
MILLS
PLATE
-J
CTi
CAST STEEL
INTERMEDIATE
i
II
II
HOT
STRIP
MILLS
HOT BAND (SKELP)
I »HOT ROLLED FLAT
PROOUCT-SHEET.STRIP >
P
BUTT WELD
WELD
PIPE
PIPE AND
TUBE
BLOOMS
SECTION
LARGE
Or-
SEAMLESS
PIPE MILLS
LARGE | .
STRUCTURAL PRODUCTS
SEAMLESS
PIPE PRODUCTS
BAR
MILLS
»
HOT 1
blKUlylUKML
MILLS
ROLLED BARS
L
m
i
^
SMALL
CTRIimiRAI
MILLS
^ HOT ROLLED
"1 BAR PRODUCTS
1
ETS
IPHEACP'EASL ^
ROD
MILLS
FORGING
MACHINING
ROD (INTERMEDIATE)
^F
!WISHED FORGED
PRODUCTS
U
HOT ROLLED
ROD PRODUCTS
MACHINING
FORGED S
TEEL
PRODUCTS
EXTRUSIONS
EXTRUDED
»pRODUCTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
PROCESS FLOW DIAGRAM
3wn.4/25/r(
FIGURE HI-I
-------
Hot Steel
II77°C to I343°C
(2I50T to 24508F)
4-50 ton size ingot-
_BLOOMING a SLABBING MILL PRODUCTION
(Based on ingot steel input 8 neglecting mill
production efficiency a down time)
a) Ingots to blooms or slabs-75%-85%.
b.) I ingot ton of finished product requires
1.25 ingot ton input at 80% efficiency
c.) 1-4% raw waste load as mill scale S
8 -10 % as crop ends.
d.) Scarfing will reduce production output
by an additional 2-2!/2% over(b)a(c).
High pressure descaling
jet water 1000 to 2000 psig
both sides of mill for
reversing
/—Crane ingot
•* lifting tongs
INGOT WEIGH SCALE
8 TURNTABLE
INGOT BUGGY TRANSFER
TO HOT ROLLING MILL
Soaking pit furnace
burners, gas, oil fired
Btc. 756,000 kg cal/hr
3,000,000 btu/hr)
wrners 30"40 Ions
opacity per month per sq. ft.
of floor area for heating
of ingots.—^ Removable cny«r«
/ Jx / / / / A
To storage
To plate mil I
To hot
rage yard]
lentil I U
strip mill J
SCARFER HOOD
See Fig DT-3 for
scarfer process flows
oooooooo
MILL TABLE ROLLS
SPRAY WATER COOLED
EXTERNALLY
SOAKING PITS FURNACES
STEEL INGOT REHEATING
n
Mill stand low pressure
cooling water
Slabs -
SLAB OR
BUDOM SHEAR
BLOOM OR SLAB
WEIGH SCALE '
HOT ROLLINS MILL
Single stand
Reversing
igh
4,576 l/kkg-
(1,100 gal/ton)
Two higl
Mill Scale Analyses(approxT)
FeO_-55.6%_. | '
- - . / Mill Scale N
Bali - 2-4% CaO,MgO,S, ( )± 80 kgyhwtric ton"), .
" - - -^qj (±120 Ibs/ingot ton p1"""
\± 41 kg/hietrio ton
: 100 !bs/Ingot ton
± 80 kg/tnetric ton
•Fre« Iron
9,068 l/kkg (2300 gal/ton)-
Oilt-0.20 gal/ingot ton
- Descaling water
tramp oil 8 greases
\
MOO OckXJOOOi (I)TON FINISHED
I . COOLING BEDS 8 PRODUCT
CrppTn* RUN-OUT TABLES
Blooms-
»To sleelmaking
facilities
CROP ENDS TO RECYCLED SCRAP
,±•100.2 kg/metric ton
(±200 Ibs/ingot ton)
Input to mill
To storage yard )
To billet mill /
To bar mill l —
To rod mill (^
To structural a rail mill I
To wide flange beam miHJ
SECONDARY FINISHING 8 SHAPING MILLS
SCALE
PIT
EXHAUST
STACK
HOT FORMING-PRIMARY BREAl.
BLOOMING 8 SLABBING MIL
MILLS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
PRIMARY MILLS
PROCESS FLOW DIAGRAM
Dwn.8/14/79
FIGURE m-2
-------
CD
850 to 4,814 cu. m/mtn Svstems
(30,000 to 170,000 cfm)syslems
49°C to 60°C(I20°F to I40°F)
Saturated gases with water droplets.
±0.005 Ibs submicron particles
per Ib of steel removed in scarfing.
Typical gases'
Oj,-20.3%
N -77.6%
CO -0.6%
Total-100%
Coolant water ~"
Slag removal water j
impressed purge air
Oxygen
Natural gas
Oxygen-fuel gas preheating
flames raise surface temp-
eratures to melting, pure
dry oxygen is then applied
to surfaces for removing
defects.
>20,000-100,000 scfm
Air inlet
Billet, bloom or slab
•'Az'to MB" thickness of
steel surface removed
from blooms or slabs
during scarfing.
• Scarfer table rolls control
speed of scarf ing, 50-250 FPM
2% removal In scarfing
MILL SCALE & SLAG
Approximate Composition
Metallic iron(Fe)-44%
Ferrous oxide(FeO)-33%
Ferric oxide(Fe20s)-2l%
Balance(SI02,Mn,C,
S,etc.)-2%
Total-100%
l
I
4,587 l/kkg-
;i,IOO gal/ton)
r
-4380 l/kkg
(1050 gal/ton of steel scarfing)
5 Water at 7-12 gal/IOOOft3
Saturated gases
-1668 l/kkg
(400 gal/ton)
>— 206 l/kkg
(50 gal/ton)
-^Exhaust
(30,000 to 170,000 cfm)
Saturated (140° F)60°C
Fan Stack
SCARFER SCRUBBER SYSTEM
Recycle Pumps
\tJ^J IfUVIUMf * •
Blowdown discharge water will be acidic when
scarf Ing resul-.-
furized steel*.-/
w .11
WET 60S
PRECIPITATOR
-*Exhaust
30,000 to 170,000 CFM
aturated (I40°F)60°C
SCALE
PIT
21 l/kkfl (5 gal/ton) for
" Intermittant wash
209 l/kkg (50 gal/ton) for
Continous wash
Fan Stack
WET PRECIPITATOR SYSTEM
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING-PRIMARY MILLS
AUTOMATIC HOT SCARFER
PROCESS FLOW DIAGRAM
Dwn.8/15/79
FIGURE H-3
-------
BLOOM STORAGE YARD
ROLL COOLIMG
DESCALIMS SPRAYS
CONTINUOUS
CAST BLOOMS
STRUCTURAL SECTIONS
STORAGE
». AMD
SHIPMENT
HEAVY HEXAQON5
HEAVY ROUNDS
ANGLES
TEES
BEAMS
HOT BLOOM
PROM BLOOMING'
MILL DIRECTLY
TO BILLET MILL
WATER
TRAMP OILS
MILL SCALE
MILL SCALE FINES
C~ COOLING SPRAYS
\
000000
TABLE ROLLS
©
©00S00Q
ROLL COOLING
ono ©000©
BILLET MILL
STANDS
WATER
MILL SCALE
TRAMP OILS 4 GREASES
FLYING
SHEAR
^^wmh
COILS OR ROD
STORAGE
AND
SHIPMENT
CONTINUOUS
WAfER ROD MILL
TRAMP OILS *
NARROW STRIP
CONTINUOUS
MARROW
STRIP MILL
FOR CURLING STRIP
STORAGE
AND
SHIPMENT
WATER
TRAMP OILS
MILL SCALE FINES
ENVIRONMENTAL PROTECTION! AGENCY
STEEL INDUSTRY STUDY
HOT FORMING.
SECTION MILLS
PROCESS FLOW DIAGRAM
-------
^
^
U.
VJ
•
a -i
VIKU/V/"!
STE&
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I
£
51 2
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jft
5 :
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-------
00
COKE OVEN G^S, NATUBAL
aAS OB. Ql L F-IEED~
FUP.NAC&
CONTINUOUS
C&ST1N6 MACHINE
PQODUCT
TO 1.250.100
5L&6 MILL
DlCECT TO
SECONDARY
SLABBING MILL
SEE PBOCE65 FLOW DIA&OAM FI6UBE m-2
KB.aL./mi.P&a METBI& TON
1300,000-4..500.000 B.TU/UR.
PER INGOT
CONTINUOUS SLAB
REHEAT FUB.NACS'-a
SLABS HE-ATED TO t I13E*C
(H2SO°F) 146, Hfr TO 732*8
U&ABTH AEEA.(.30'
TO ISO LB5/FT.aH£AETH
&I2EA)
t772 METRIC TONS/ME.CAP.
't aOQTONS/HB.CAPACITV)
RECYCL& COOLING WATER
fQg PUBKIACE WAT&B.
COOL.&D SU.IDS
6517 TO 12490 Jt/METBIC
TOM PRODUCT
CZPOOTO 3.000 SAL/
TON POO DUCT)
HOT STRIP MILL PRODUCTION
EFFICIENCY OF MILL BASED OM
INPUT + OUTPUT AND
MILL DOWNTIME I EFFICIENCY 1
&) SLABS TO MOT STQIP 8&%-SS%
AVEtZA&E; & RAW WASTE. LO&D AS MILL.
SCALE/TOIM PBODUCT:
t 3% Af-> SCRAP
PLYING SHE4GL FOE
CUT-TINS FLAT
SH&ETS TO L&NGTHS
SLAB STQBAGE
STRIP COOLING
SPRATS
ROLLCOOUN& WAT&g. tTYRj
DEALING WATEC
SHEAB. COOLING
BOLL COOL ING
WATEE
HISM PBES&.DESCALING
WATER (20OO Pat)
C&00-I500 PST) ITYP)
STEEL
» SHEETS
TO HOT
PILEC
SCAL&
BQEAU.EK
BROADSIDE
MILL
IF STRIP IS
ROUGHING
STANDS
4-HIGW
SCALE
BEEA^EE.
FINISHING
STANDS
a.-HIGH
DOWN
COI LEG
WIDER THAN
AVAILABLE
SLABS ARE
RECYCLED
4tlt9 AVS/H6TBIC
TOM PR&D.
(S8LB5. AVS/
TON PRODUCT)
I ME-TBlC TON
(I IN&OT TON)
FINISHED
PRODUCT
MILLSCALa (3> RNISHINS STANDS)
NOTE. MIUL e>CALE; - SO M AV&/M&TPIC. TON PPODUCT
LB&. AVG./TON PaODUCT~
MISC. E-LeMENTAir^SPrPo'uTJB
WAT&a - a°/o EVAPORATION RATE
2.7,040 ^/M&TgJC
TON PRODUCT
'~ PRODUCT)
TO COLD MILL6
Oil— .15 Kjt- -.5Ka/ METBlC TQM PRODUCT
(O.5LB&. TO 1LB7TON PBODUCT)
MOT STRIP IV1IL_L_
ENVIRONMENTAL PfiOTSCTlOA/ ACaSNC-V
INDUSTRY sruov
WOT FORMIMG
HOT STRIP MILL
PUOIV D/ASRAM
PEVI 2-21 -7fa!
m-6
-------
NON CONTACT
COOLING WATER
NON CONTACT
COOLING WATER
CRANE
oo
to
BUNDLED SKELP
CUT TO LENGTH
ROLL
LEVELER
COILED
NARROW
STRIP
UNCOILERS
FLASH
WELDER
FORMING
aWELDING
MILL
NON CONTACT
COOLING WATER
COOLING
BED
WATER
BOSH
COOLING|
BED
9 © © ©
DESCALER
a SIZING
MILL
».TO STORAGE
WATER TO SCALE PIT
OR PLANT SEWERS
SCALE
PIT
TO PLANT
SEWERS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
BUTT WELDED PIPE MILL
PROCESS FLOW DIAGRAM
Dwa 3/l3/79|
I.
FIGURE HE- 7
-------
MILL SPRAY
COOLING
WATER
NON - CONTACT
COOLING
WATER
MANDREL
COOLING
WATER
MANDREL
COOLING
COOLING
QD
U)
ROUND
BILLETS
REHEAT
FURNACE
PIERCING
MILL WATER
COOLED
MANDREL
WA
1 ^.flfl^fl]
| (o) fo)
SIZING Ml
rER
— j :
1
WA'
1
— 3E~
1
ER
^ r— i TO
^~ ' _fc "iflT1 | ^STORAGE
.^ . r^-i a SHIPMENT
TUBE
REHEAT
FURNACE
WATER COOLED
MANDREL
HEAT
TREATING
FURNACE
TUBE
COOLING
SPRAY
HDR'S
CUTTING
MILL
TO PLANT
SEWER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SEAMLESS TUBE MILL
PROCESS FLOW DIAGRAM
Own. 3/13/7:
FIGURE HE-8
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HOT FORMING SUBCATEGORY
SECTION IV
SUBCATEGORIZATION
Introduction
formin<3 into the four subcategories under the
Promulgated limitations has been changed Hot forming
operations are now grouped into one subcategory. This subcategorv if
divided into four subdivisions that are the same as the original
subcategories. These subdivisions have been segmented fu?thfr in
recognition of differences in flow among hot forming operations A
m the
Segmentation
(1976 Regulation)
Hot Forming-Primary
a. Carbon operations
w/o scarfers
b. Carbon operations
w/scarfers
c. Specialty operations
Hot Forming-Section
a. Carbon & Specialty
operations
Hot Forming-Flat
a. Hot Strip & Sheet
operations
b. Carbon Plate operations
c. Specialty Plate operations
Pipe & Tube (Hot Working)
a. Carbon & Specialty
operations
Revised
Segmentation
Hot Forming-Primary
a. Carbon & Specialty
operations w/o scarfers
b. Carbon & Specialty
operations w/scarfers
Hot Forming-Section
a. Carbon operations
b. Specialty operations
Hot Forming-Flat
a. Hot Strip & Sheet
operations
b. Carbon Plate operations
c. Specialty Plate operations
Hot Forming - Pipe & Tube
a. Carbon & Specialty
operations
Segments within the four subdivisions are based primarily upon
differences in flow rates (applied, process, and discharge) P
Although the Agency considered other factors, it found that flow rates
and mill configuration are the most important factors in the
85
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segmentation of the four basic hot forming . f ub2^isions . The Agency
of these elements is discussed in greater detail below.
Factors Considered in Subcateqorization
Manufacturing Process and Equipment
If
I
forming operations are discussed in greater detail later in tnis
section.
existed which would make further subdivision
lence? higher limitations and standards have been
for those primary mills with machine scarfing equipment.
Final Products
the data for
?he seamentation of that subdivision.. For this reason,
each type Sf ho? fo?ming operation were analyzed f^,v^ne
final product considerations. The Agency found that only the
Sr standards in the other hot forming subdivisions. Additional
discussion of this factor is presented below.
86
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Primary Mills
In primary operations, two basic final products are processed from the
not steel ingots: slabs and blooms. Most mills (58%) produce either
blooms or slabs; however, approximately 35% of the primary mills
produce both blooms and slabs. The remaining primary mills (7%)
plate06 Pr°ducts Other than slabs or blooms, such as bars or heavy
The data for all primary mills indicate that no significant
differences exist among the product types. Water use rates are
t- f fct?e A^ency found no difference in the technical
ity of achieving the limitations and standards. For these
reasons, the Agency concluded that further subdivision of primary
operations based upon product type is not appropriate.
Section Mills
In section hot forming operations, a wide variety of products are
produced, ranging from angles to railroad wheels to billets The
responses to the DCPs show that more than 40 different products are
produced in the section mills in the United States. At about 30% of
the mills, a single product is produced. However, at the remaining
™i Jj'x. more /nan one product is processed, with some mills producing
«f ?hoSn ?5° d"Ctf- *h^s diversity complicated the Agency's analysis
of the effect of final products on subcategorization. However, flow
data for mills producing different products indicate there are no
discret flow rates applicable to different products. Thus, the Agency
did not subdivide section mills into segments by product type.
To determine if flow variations exist between the different products,
the flow data for the mills were separated into eight product
£j;ShiflCati°nS- F5r *xamPle' al* types of beam mills wire put into.
the beam category and all the different types of bar mills were
riSSi1^? /?>, ^ mulls' This 9rouPin9 of similar product types
consolidated the data base and simplified the flow analysis The
Agency then conducted statistical analyses on these groupings to
compare the applied and discharge flow rates on a gallon/ton CIsis
The Agency concluded that the data for all mills are within the same
statistical population. The Agency did not find any significant
variations which would indicate that any one type of section mlu
requires more (or less) water or that wastewaters from any one type
could not be treated and recycled to the degree necessary to achieve
^m^m^ionf- For these reasons, the Agency concluded that further
segmentation of the section mill subdivision based upon final product
considerations is not appropriate.
Flat Mills
The three types of flat mills operating in the United States today are
*MOH g and. sheet mills (HSM), plate mills, and combination mills
which produce both plate and hot strip. Of the 80 flat mills, 29 are
hot strip mills, 25 are plate mills, and the remaining 26 are
87
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combination mills. For this analysis, strip mills, sheet mills, and
skelp mills were grouped together under the strip mill designation
because of similarities in mill configurations and flow rates.
As with other hot forming operations, different types of flat mills
produce effluents of similar volume and quality. More information on
wastewater characteristics is provided later in this section.
When the Agency analyzed flow rates for flat operations, it found
significant variations which affect the segmentation of the flat
subdivision. Hot strip and sheet mills and combination mills were
compared, but it was found that both types of mills have similar
applied flows and wastewaters from these mills can be reduced to
similar levels. Therefore, combinations mills were combined with hot
strip and sheet mills for the purpose of developing effluent
limitations and standards. However, the Agency found significant
differences between plate and hot strip mills, with hot strip mills
using up to 4900 gallons/ton more applied flow than some plate mills.
This wide variation led the Agency to further segment the flat
subdivision into plate and hot strip mills.
Pipe and Tube Mills
As noted above, the two hot working pipe and tube products are butt
welded pipe and seamless tube. The Agency compared data for these two
tvpes of pipe and tube mills and found no significant differences in
the final product which would affect segmentation. Wastewater quality
and quantities are similar for both types of mills and the Agency
found the limitations and standards are being achieved at each.
Hence, no segmentation of the pipe and tube subdivision is
appropriate.
Raw Materials
Raw materials for hot forming operations include steels of various
material specifications. A basic split was made between carbon steel
and specialty steel mills. For purposes of this report any mill
rolling less than 50% carbon steel is called a "specialty steel
operation. Of the 485 hot forming operations for which DCP responses
were received, 96 (19.8%) are specialty steel operations. While the
sampling data do not show a significant difference in treated
wastewater quality between carbon and specialty operations, the Agency
found significant differences in flow rates in some hot forming
subdivisions. The differences between the carbon and specialty mills
in each hot forming subdivision are examined below.
Primary Mills
Data for primary mills show that raw materials affect only model plant
size There are no significant differences in the wastewater
characteristics between the two types of mills. In addition, the
Agency found no significant differences in flow between carbon and
specialty operations. The average applied flow for carbon mills
88
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S?^fers,JS 2"° gallons/ton, and for specialty mills without
scarfers, 2625 gallons/ton. A model applied flow of 2300 gallons/ton
was selected for primary operations. The achievability of this model
now is demonstrated by both carbon and specialty operations.
The average production capacity of carbon operations is about 6620
tons/day while that of the specialty operations is about 1440
tons/day. Because of this difference, the Agency prepared separate
cost estimates for the carbon and specialty treatment models.
Section Mills
The Agency analyzed carbon and specialty section mills in the same
,t?™°n a£Lthe Primarv operations. It found differences in flow rates
,™S 2al/t°n Ys 320° gal/ton) and average sizes (3050 tons/day vs
1200 tons/day) between, carbon and specialty operations which led to
further segmentation and separate costing. It did not find any
significant differences in wastewater characteristics of the section
mills using different raw materials.
Flat Mills
For flat operations, the raw material analysis led to the
determination that separate limitations are appropriate for carbon and
specialty plate operations due to differences in flow rates (applied
and discharge). The Agency found no difference between the carbon and
specialty hot strip operations. Also, as for primary and section
operations, separate costing was completed for carbon and specialty
plate operations. ^a^uy
Carbon plate mills use 1900 gallons/ton more applied flow than the
specialty mills (3400 gal/ton vs 1500 gal/ton). For this reason, the
Agency has promulgated separate limitations and standards for the two
types of plate mills.
Flow _rates for carbon and specialty hot strip and sheet mills are not
significantly different (6380 gal/ton vs 6710 gal/ton). The Agency
selected an applied flow basis of 6400 gallons/ton for developing the
limitations and standards for the hot strip and sheet millsT This
oera ratS 1S wel1 demonstrated at both carbon and specialty
As with the primary and section operations, a difference in the sizes
of specialty and carbon plate mills required separate cost
development. For the plate mills, the average size of carbon mills is
3480 tons/day and for specialty mills, 1060 tons/day. For hot strip
mills, there is no significant difference in size between carbon and
specialty operations. In fact, both carbon and specialty products are
often rolled on the same mill. For these reasons, all hot strip
operations were costed together. v
89
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Pipe & Tube Mills
The only significant difference between
tube operations is in size. Wastewater
similar. Carbon operations have an
gallons/ton and the specialty operations
of 5790 gallons/ton. A flow basis of
develop the limitations and standards for
operations. This flow is demonstrated at
carbon and specialty pipe and
quality and quantity are
average applied flow of 5490
have an average applied flow
5520 gallons/ton was used to
the carbon and specialty
both types of mills.
Production rates are more than twice as great for carbon mills as for
specialty mills (970 tons/day versus 480 tons/day). This significant
difference in size led to separate costing of the treatment systems.
Wastewater Characteristics and Treatability
The wastewater characteristics of the hot forming operations depend
upon scale formation and oil usage within the mill. Although there
are differences in pollutant concentrations generated by different hot
forming operations, the Agency concluded that it is not appropriate to
subdivide the hot forming subdivisions on this basis as described
below.
Suspended solids and oil and grease are the conventional pollutants
found in hot forming operation wastewaters. Toxic metal pollutants
are also present in lesser concentrations due to the use of alloying
elements in the steel and contamination from other sources. From
scale generation rates, the Agency estimates that raw wastewater
concentrations of suspended solids vary from 390 mg/1 for specialty
plate operations to 7,590 mg/1 for carbon primary operations with
scarfers. Also, based upon oil usage rates data, the Agency has
estimated that the oil concentrations in hot forming operation
wastewaters range from 15 to 160 mg/1. The Agency estimated the raw
waste concentrations for suspended solids and oils because consistent
and reliable samples of raw wastewaters are difficult to obtain from
most hot forming operations because of the danger involved in
obtaining such samples. At most mills, the Agency sampled the primary
scale pit effluent and based its scale pit effluent estimates on those
data.
As noted above, there is a significant variation in raw wastewater
concentrations from hot forming operations. However, these
differences are reduced to a fairly narrow range after primary scale
pit treatment as shown below:
Concentration Range of Pollutants(mg/1)
Discharge from Primary
Raw Wastewaters Scale Pits
Total Susp. Solids
Oil & Grease
390-7,590
15-160
48-91
15-42
90
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Agency concluded that it -is not necessary to
r»»n i-ho *-,,r«^ ~f v,~4. * ,__ operations because of
Possible variations in wastewater quality between carbon and specialty
were f^n/ereWh ?° a^ly^ed' H°Wever' no significant variations
were found. While discharges from some of the specialty mills had
higher levels of toxic metal pollutants than carbon mills, some carbon
?iii S K had comparably high levels. In any event, toxic metals
5f?h t.h° carb.on and specialty mills can be reduced to similar levels
with the_same • type. of treatment. On this basis, the Agency concluded
that no further subcategorization is warranted. t.iuaea
Similar treatment components are used at all mills and a consistent
°L i^hnt^hllHy. ^S demonstrated. Wastewaters from most
™ ? fh of the hot forming subdivisions are treated in central
treatment systems (combining different hot forming wastewaters prior
clar?f?rS??nn ' ^l^l • treatment components include sedimentation,
™ii S '' filtration systems, often in combination. Extensive
recycle systems are also installed at many plant sites. Flocculation'
wi£h^rTV°r °«her flocculant aid ^ often used in conjunction
with sedimentation. Because of the similarities in treatability of
hot forming wastewaters, no further subdivision based upon this factor
is appropriate.
Size and Age \
The Agency also analyzed possible correlations relating the effects of
a?e and fize upon wastewater flow, wastewater characteristics and the
2™oiy *? retrofit treatment equipment to existing facilities.
However, it found no relationships which warranted further division.
fLdisf"?fJd ?arlj,eT £" this section, size has an impact on costing of
the treatment models. .for specialty and carbon hot forming operations.
fPa-rnt-impaCt that Size has on the h°t forSiSi
Hot forming operations vary greatly in physical size,
n Pr0dUCVi2e: However' a" analysis of those factors
?? s^"lflca"t relationships between process water usage,
fl°whrates, effluent quality, or any other pertinent factor
-1 through IV-8 show there are no relationships between
flow (gal/ton) and size (tons/day). Since millS a?e
on™
Figures
discharge
generally operated in a similar manner, the resulting wastewater
ar. similar regardless of size. The sampling dltf do
ln ™*ew.ter characteristics
The Agency also^ found that the size of a particular hot forming
operation does- not affect the ability to install adequate treatment
Xnro^m^arg?H ^ SmaU mills have foment systems that are
approximately the same age and which have similar treatment
theP°c^ts' toA1?S;, I!6 ,C°S^ da.ta su^lied by the industry show that
the costs to install treatment (on a $/ton basis) are more
significantly affected by the type of treatment installed than by thl
91
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size or age of the mill. It was found that the costs on a $/ton basis
vary slightly based on the size of the mill. However, the" Agency
accounted for these variations by developing costs for average sized,
model mills within each subdivision and by developing costs separately
for carbon and specialty plants, where warranted.
The relationship between wastewater flow and age was analyzed in the
same fashion. The plots of discharge flow (gallons/ton) versus age
(first year of operation) are shown in Figures IV-1 through IV-8. As
with the flow versus size plots, no relationship between flow and age
is evident. Therefore, the Agency has concluded that the age of a
mill has no significant effect on discharge flow.
The Agency also analyzed the effect of age on the ability, ease, and
cost of installing or retrofitting pollution control equipment. Table
IV-1 lists older hot forming operations that have been retrofitted
with pollution control equipment. The numerous examples demonstrate
that pollution control equipment has been retrofitted at many older
mills.
The Agency also demonstrated that treatment systems could be
retrofitted on older mills at about the same costs as for newer mills.
The responses to the D-DCPs and past cost studies were used in this
demonstration. Almost all D-DCP responses indicate no retrofit costs
were associated with the installation of treatment systems, or, that
retrofit costs could not be distinguished from treatment costs.
Retrofit costs, typically less than 5% of the total installation cost
were reported for some mills. Retrofit costs were also analyzed by
comparing detailed cost estimates completed for retrofitted plants
(with no consideration for age) with the actual cost of installation
for these systems. This analysis also showed that no significant
additional costs are associated with the installation of treatment
facilities onto "older" plants. Hence, the Agency concluded that
about the same costs for pollution control are necessary for older
and "newer" plants.
The sampling data collected during this study were analyzed to
determine if age has a significant effect on wastewater
characteristics or effluent quality. The ages (first year of
production) of the operations sampled varied from 1904 to 1974. No
significant differences were noted in effluent quality from older
mills versus newer mills. In fact, the mill that was built in 1904
has one of the newer and more sophisticated treatment systems. In any
event, comparable levels of discharge are achieved at mills of all
ages where adequate treatment is installed.
Based upon the above, the Agency finds that both old and newer
production facilities generate similar raw wastewater pollutant
loadings; that pollution control facilities can be and have been
retrofitted to both old and newer production facilities without
substantial retrofit costs; that these pollution control facilities
can and are achieving the same effluent quality; and, that further
92
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subcategorization or further segmentation within this subcategory on
the basis of age or size is not appropriate.
Geographic Location
The .Agency examined the raw waste characteristics, process water
application rates, discharge rates, effluent quality and other factors
pertaining to plant location and found no general relationship or
pattern. Hot forming operations are located in 22 states across the
country. Most of these operations are located in the major steel
producing areas of Indiana, Illinois, Pennsylvania and Ohio. Table
IV-2 summarizes the location of hot forming operations for which DCPs
were received.
About 12% of the mills are located in what could be considered "arid"
or semi-arid regions. The Agency analyzed water consumption for hot
terming operations and determined the amount to be small. For this
reason, subdivision is not necessary because of water consumption or
geographic location considerations. Additional details on this issue
are presented in Section VIII.
Process Water Usage
As discussed earlier, the Agency found significant variations in both
the applied and discharge flows of the various hot forming
subdivisions. This factor, in combination with those described
previously, led the Agency to revise the segmentation of the hot
forming subcategory from that contained in the 1976 regulation.
To analyze the flow data, applied flow rates were developed for each
subdivision and each potential segment of that subdivision
Production weighted average flows were used for this analysis. These
flow value derivations are shown in Section IX for each hot forming
subdivision. Statistical analyses were completed on these applied
flows to verify previous segmentation and to develop new segments
where necessary. v ymcuue>
After applied flow rates were developed, the Agency determined recycle
rates for each category. These recycle rates were 'used with the
applied flow to calculate the appropriate discharge flows used to
develop the BPT, BCT and NSPS, limitations and standards. A summary
of the hot forming model applied flows, recycle rates and resultant
discharge flows is shown below:
93
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Applied
Flow
(gal/ton) BPT/BCT
Recycle Rates (%)
Discharge
(gal/ton)
NSPS BPT/BCT NSPS
2300
3400
5100
3200
6400
3400
1500
5520
61
61
96
96
897
90
1326 140
PRIMARY
a. Carbon &
Spec.
wo/scarf.
b. Carbon &
Spec.
w/scarf.
SECTION
a. Carbon
b. Specialty
FLAT
a. Hot Strip
b. Garb.Plate
c. Spec.Plate
PIPE & TUBE
a. Carbon &
Spec.
Additional details on these flow rates and recycle rates are presented
in Sections IX, X, and XII.
58
58
60
60
60
77
96
96
96
96
96
96
2142
1344
2560
1360
600
200
130
260
140
60
1270 220
94
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TABLE IV-1
Subdivision
A. Primary
B. Section
C. Flat
1 - Plate
EXAMPLES OF PLANTS WITH
RETROFITTED
POLLUTION CONTROL EQUIPMENT
HOT FORMING SUBCATEGORY
Plant
Reference
Code
0020B
0060D
00601
0088D
0112
0112A
0112B
0176
0188A
0188B
0248C
0320
0060C
0060F
00601
0060K
0088D
0112
0112A
0112F
0136B
0316
0112C
0424
0448A
0496
0860B
Plant Age
(year) ,
1948
1910
1941
1959
1907
1930
1928
1917
1959
1940
1962
1936
1913
1942
1956
1920
1962
1907
1937
1922
1908
1959
1902
1970
1943
1918
1936
Treatment Age
(year)
1971
1959
1958
1971
1979
1970
1970
1965
1970
1946
1975
1952
1920-1975
1965
1958
1955
1971
1943-1979
1971-1978
1947-1978
1959-1969
1966
1964
1971-1978
1948
1948-1977
1967
95
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TABLE IV-1
EXAMPLES OF PLANTS WITH
RETROFITTED
POLLUTION CONTROL EQUIPMENT
HOT FORMING SUBCATEGORY
PAGE 2
Subdivision
2 - Hot Strip
& Sheet
D. Pipe & Tube
Plant
Reference
Code
0020B
0396P
0432A
047 6A
0684F
0856D
0856P
0060C
0060F
0060R
043 2A
0476A
0548A
0728
0856N
0856Q
0916A
0920C
0948A
Plant Age
(year)
1953
1960
1957
1915
1937
1938
1929
1913
1950
1930
1957
1930
1945
1929
1930
1930
1931
1934
1926
Treatment Age
(year)
1971
1970
' 1974
1977
1969
1980
1966
1948
1971
1961
1974
1977
1969
1952
1961
1963
1971
1970
1966
96
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TABLE IV-2
GEOGRAPHIC LOCATION OF HOT FORMING OPERATIONS
State
Pennsy Ivania
Ohio
Illinois
Ind iana
Texas
California
Alabama
New York
Maryland
Co lorado
Michigan
West Virginia
Georgia
Kentucky
Utah
Missouri
Washington
Florida
Oklahoma
N. Carolina
S. Carolina
Connecticut
Primary
Mills
32
17
11
13
4
5
3
4
4
1
4
2
0
3
2
0
1
0
0
0
0
0
Section
Mills
79
29
30
19
6
9
9
10
5
11
3
3
6
0
1
0
2
3
1
1
1
1
Flat
Mills
27
15
6
10
4
2
5
1
3
0
2
1
0
1
1
4
0
0
0
0
0
0
Pipe & Tube
Mills
20
14
11
11
6
1
0
0
2
1
0
0
0
1
0
0
0
0
0
0
0
0
Total
Z of
Total
158
75
58
53
20
19
17
15
14
12
9
6
6
5
4
4
3
3
1
1
1
1
32.6
15.5
12.0
10.9
4.1
3.9
3.5
3.1
2.9
2.5
2.0
1.2
1.2
1.0
0.8
0.8
0.6
0.6
0.2
0.2
0.2
0.2
# of States = 22
485
100
97
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FIGURE IV-1
HOT FORMING SUBCATEGORY
PRIMARY - WITHOUT SCARFERS
GO
DISCHflRGC FLOW VS PRODUCTION CflPflCm
era
TOO-
"o SOT
n
o wo
[L
£ S00'
0)
H
Q an
BPT MODLL FLOW = 897 GPT
A A
A AA
A. A A A
4-
i — i -
FROOUCIIOtl CfFflCITY lions/dog)
DISCHRRGE FLOW VS flSC
0000
TUB-
„ IB-
o wo-
VD-
a am
BPT MODEL FLOW = 897 GPT
4 A A A
A3 » A JL^
1^ AaA,A^,
OGE (flrsl gear of prodnoUai)
-------
ID
HOT
FIGURE IV-2
FORMING SUBCATEGORY
PRIMARY - WITH SCARFERS
DISCHfWE FLOW VS PRODUCTION
moo
A
KB A
SOB
4>
I
m A A
3 A
h.
U Sm' BPT MODEL FLOW *
t A
s
S™ /A A A A
A A A
A "
ran A A
A/ A A A AA
o mo coo "BJU eooo jora ran
PRODUCTION CffflCin llons/doj)
CfPflCITI DISCHflRSE FLOW VS flGE
noo
am
*%
0
0)
~ on-
1326 6PT M JtDJ-
) I
/ Zm
1
ton-
A
A
A A
A
BPT MODEL FLOW * 1326 6PT
A \
A A A AA I
. --A~2s ^
A A
A AA. AA
A A A A ^
.__. 0 | , 1 1 pfl , Of ,
iw an m m w m m m w
(«E (first jetr of production!
-------
O
O
FIGURE IV-3
HOT FORMING SUBCATEGORY
SECTION - CARBON
DISCHflRGE FLOW VS PRODUCTION CflPflCITY DISCHflRGE FLOW VS flGE
lam-i
HUB-
-.nan-
0
TO ran
(9
O 000'
tL
ft; QQ)<
m
ZED
0
mo-
A A
IBB-
A |
V -1"
Ai A a on-
A i
$ A ^ BD'
A A «
A A . BPT MODEL FLOW= 2142 GPT
A AAA AA A *
A A
•f
A
i »
A A A
A
AA A A * A
A.A A° A A
A A AA
&
A A A A A A
A . BPT MODEL FLOW = 2142 GPT
A A? A AA
^ A\M A A A fc
^ AA^ AA A AA AlflAAAAAAn A,
r^^KnT" "m in VD SBD 80) • TIB BBBBIWlBB.IBIHillHlfiBJDOT
nMWCIIOH CBWin Itaw/dag) UK Iflrsl gw of prodnctiml
-------
o
H
FIGURE IV-4
HOT FORMING SUBCATEGORY
SECTION - SPECIALTY
DISCHflRGE FLOW VS PRODUCTION CflPflCin
DISCHflRGE FLOW VS
14P.W
HUD
*•»
I.
0
0)
3 .
gas,.
tu
U
Q
•C CIV)*
o ***
H
Q
am
0'
TOD
A
irao
A
x sm
D
S
A a ma-
il.
QI
O
A A i on-
A «
^ -A A 3
&
80}*
A ^ A ^ BPT MODEL FLOW =1344 GPT
A A
. - - A " I . A fl • ,.,., .
A
A
A
A A
A
AA A A
A AA.
/\£ A BPT MODEL FLOW = 1344 GPT
. A V Am> .
o ao tin isbo an an JHD IBO no ira iwo BSD IOT JOT
fBODUCIIOH CflPOCIIY (tons/dag) (fit (flM gear of produclwn)
-------
o
to
FIGURE IV-5
HOT FORMING SUBCATEGORY
FLAT - HOT STRIP & SHEET
DISCtffiBE FLOH VS PRODUCTION CflPflCm DISCHflRSE FLOW VS fl6E
25000'
230001
j
a
at am-
^
DISOHflROE FIX
§ i
0
25DOO*
A
20009'
1
D
3
A A u.
a 10000
A i
a
4 2
A A A A Q
" •* »i V 4
A A A
•A A BPT MODEL FLOWs 2560 GPT
fl
A A
^ ^ A A* AA 0
A
A
A A
A
AA
A A 4, A A'
T^ 4 A
A A BPT MODEL FLOW =2560 GPT
A
A A
A A AAA A^
5 Hm «oo eooo em IODOO GDOO IOD 16000 UODISIOISOIHIIIMJISDBBOIOTJIJB
FRDOUCIIOH CfFflCm Itons/daj) .HE (f irsl goor of prodwiion)
-------
H
O
U!
FIGURE IV-6
HOT FORMING SUBCATEGORY
FLAT - PLATE - CARBON
DISCHflRGE FLON VS PRODUCTION CffflCIlY
DISCHflRGE FLOH VS flGE
ean
TOD
^
a am
a
DISCHRROE FLOW
ill
WOO
0-
A 8003
A JaD-
A 0
A <
a sm
a
a SB
A E!
AM
0
A * * I
Q 20BJ-
BPT MODEL FLOW =1360 GPT
A MB-
A A 1 A A
fRDDUCIIOH (HWm Itws/dagJ
A
A
A
A
A
A
A *
BPT MODEL FLOW = 1360 GPT
A
A A
A A A A
i i i i i i i T 1 ' I ~
D6E (first ge
-------
FIGURE IV-7
HOT FORMING SUBCATEGORY
FLAT - PLATE - SPECIALTY
DISdWE FLOH VS PRODUCTION CflPflCm
DISCHflRGE FLOH VS flGC
0
a
ISO
SCHRROE
§
s
BPT MODEL FLOW - 600 GPT
FRODUCIIDH CffflCm llons/dos)
m^
SO-
0
a
isn
SD
BPT MODEL FLOW= GOO 6PT
-i 1 1 1 1 1 1 1 r
OGE (first gear of prodiicllcnl
-------
o
in
FIGURE IV-8
HOT FORMING SUBCATEGORY
RPE & TUBE
DISCHfM FLOW VS PRODUCTION CflPflCm
DISCHRRGE FLOW VS flSE
ausi
2DOOD
*•» •
|
D
roism
3
u
O HUD'
to
H
Q
5000'
0-
A
ma
1
_j
D
2
Q 10000
A A g
to
A n
A
fl SID-
A . .A
A A . * , A A
A A A **
A BPT MODEL FLOW= 1370 GPT
A" A .
A
A A
.
A A
A
A A A
^ A A A
.BPT MODEL FLOW =1370 GPT A
A A A
. > . A .
e m to ea so m m> in isn m mwwmwmmw
PRODUCTION CflPflCITY (tons/daj) (jg£ (first near of produdlonl
-------
-------
HOT FORMING SUBCATEGORY
SECTION V
WATER USE AND WASTEWATER CHARACTERIZATION
Introduction
This section describes the water systems in use in the hot forming
subcategory and the types of wastewaters originating from each of the
rolling mill processes. The description of the water systems is
limited to those water systems which come into contact with pollutants
generated by the processes, and excludes noncontact cooling water
systems. Wastewater characterization for hot forming mills is based
upon monitoring data obtained during field sampling surveys, and data
supplied directly by the industry.
General Discussion
Water Use
Hot forming wastewaters are comprised of direct contact cooling and
descaling waters. Roll cooling water is used to cool the work rolls
of the mill stands to prevent surface cracking of the steel rolls due
to sudden temperature changes. When not rolling the hot steel, the
rolls are kept turning to prevent uneven cooling within the steel
rolls. Approximately 4% of the water sprayed on the hot steel
evaporates and the balance is discharged beneath the rolling mill to
trenches called flumes.
When the hot steel product is being rolled, iron oxide scale (called
mill scale) forms on the surface of the hot steel. The scale is
removed by direct contact high pressure (1,000-2,000 psig) sprays
which release water before each roll pass of the product. Low
pressure spray cooling water is also used to keep the mill stand rolls
and the table rolls cool as the hot steel passes over or in between
them.
Wastewaters from descaling, roll cooling, hot shear equipment cooling,
roll tables, and flume flushing, are generally discharged through
flumes or trenches to inground concrete settling chambers called scale
pits where the heavier solid particles settle out. Scale pits often
contain underflow weirs with launders to trap oils and greases picked
up by the process waters. The waste oils are removed from the water
surfaces by belts, ropes, or other types of floating oil skimmers, and
then discharged to waste oil storage tanks. Contract haulers
periodically remove the accumulated oils. The scale is cleaned by
clam shell buckets or scale pit drag link conveyors. Waste oils are
generated at an average rate of 0.1 to 0.2 gallons per ton of steel
produced at the various rolling mill operations (i.e., primary
section). Major sources of oils at many mills are the oil cellars
107
-------
where recirculated oils are conditioned (i.e. separated from entrained
water). The discharge from the cellars often contains high quantities
of oil and is usually directed to the scale pits. Other major sources
of oil include leaks from lubricating and hydraulic systems. The
primary scale pit overflows are generally not directly discharged, but
are usually routed to wastewater treatment plants for additional
treatment. Many rolling mills recycle part of the scale pit effluent
back to the rolling mill for use in flume flushing.
Wastewater Characterization
Scale and oil and grease are the conventional pollutants discharged
from rolling mill operations. As the hot steel is being rolled in the
mill stands, the steel surface oxidizes and is continuously scaling
and flaking off. The scale particles range in size from submicron to
several millimeters. The particles are 70-75% iron and consist of
ferrous oxide (FeO), and ferric oxide (Fe203). Overhead cranes
equipped with clam buckets are generally used to clean the scale pits.
Scale pit.effluents are discharged to plant sewers or are partially
recycled back to the mills. The suspended solids content in scale pit
overflows can be as high as 300 mg/1. These wastewaters can be
further treated by clarification, filtration, and recycle. Oils from
the scale pit effluents are generally in the range of 15 to 45 mg/1.
Oils are found in rolling mill wastewaters as a result of oil
conditioning, oil spills, line ruptures, and excessive dripping of
lubricants. Also, appreciable quantities of spent oils and greases
are contributed to the wastewaters when equipment is washed down.
Wastewater concentrations as high as 150 mg/1 may be reached during
line ruptures.
The discharges from the different types of hot forming operations are
similar with respect to suspended solids, oil and grease, and pH.
However, the quantity of suspended solids generated and applied water
rates vary among rolling mills.
Toxic metal pollutants are found in the wastewaters from the rolling
mills. The appearance of toxic metals such as chromium, copper, lead,
nickel, and zinc . result from the use of these metals in steelmaking
and alloying and possibly in lubricants used at certain mills.
Relatively few toxic organic pollutants were detected in wastewaters
from the hot forming mills sampled. This subject is discussed in
Section VI.
Water Use
1. Primary Rolling Mills
Blooming or slabbing rolling mills generally have
contact water systems.
six principal
108
-------
a.
b.
c.
d.
e.
f.
High pressure descaling spray water
Work roll and roll table spray cooling water
Hot shear spray cooling water
Flume flushing
Hot scarfer spray flushing and cooling system
Hot scarfer wet gas cleaning system
The first, four sources are common.to all hot forming operations
and were briefly discussed above. Hot scarfer water systems and
hot scarfer gas scrubber systems are described below.
Automatic Hot Scarfers
Automatic hot scarfing machines for surface finishing generate
fumes, smoke, and slag. The scarfing operation continuously
produces molten slag just ahead of the reaction zone. This slag
is directed to a slag pit or trench beneath the scarfer machine
where high pressure water (150 psig) is used to break up and
flush the slag. Exposed equipment in the vicinity of the
scarfing reaction is also sprayed to protect it from heat and
flying slag particles.
Wastewaters from the automatic scarfer spray water systems are
generally routed to a scale pit where the heavy slag particles
settle out. The scale pit overflow is discharged to plant
sewers. Often these spray waters are discharged into the same
primary scale pit as the mill equipment cooling and descalinq
waters. ^
The high pressure spray water granulates the slag and protects
the scarfer pinch rolls from slag splatter. The slag produced
weighs approximately 180 Ibs/ft^ dry and 198 Ibs/ft* wet The
slag particles vary in size from smaller than 100 mesh to less
than 1/2 inch in size with most (75%) in the 40 to 60 mesh range
The chemical composition of slag is approximately:
Metallic Iron (Fe)
Ferrous Oxide (FeO)
Ferric Oxide (Fe203)
Balance (Si02, Mn, C, etc.)
100%
The total iron content in scarfer slag is about 84%.
The quantity of slag produced by the scarfing process ranges from
2t to 4-6 of the tonnage scarfed whereas, the quantity of mill
scale produced by the primary mills ranges from 1-1/2 to 3% of
the tonnage rolled by the mill.
As noted earlier, -the hot scarfing process results in appreciable
quantities of fume and smoke. Additional wastewater results when
wet air cleaning systems are used to clean the exhaust gases from
109
-------
the scarfer. Dry collectors are not normally used because the
exhaust gases are saturated with water vapor. Discharge waters
may be acidic if resulphurized steels are being scarfed. The
discharge rate varies with the type of gas cleaning system used.
The high energy Venturi requires 1500-2000 gpm, while wet
continuous precipitators use about 200 gpm, and intermittent
spray wash precipitators use about 300 gpm for a 30 second spray
every half hour.
2. Section Rolling Mills
Section rolling mills generally have four main contact water
systems:
a.
b.
c.
d.
High pressure descaling spray water
Mill stand roll and roll table .spray cooling water
Hot shear spray cooling water
Flume flushing
Scarfing is also practiced at a few section mills. The combined
discharge from these sources is the wastewater source regulated
by the limitations and standards.
3. Flat Mills
Plate Mills
Plate rolling
systems:
mi
ills have three principal contact water
(1) Descaling water sprays
(2) Mill stand roll and roll table water sprays
(3) Flume flushing
The combined discharge from these sources is the wastewater
source regulated by the limitations and standards.
Hot Strip and Sheet Mills
Hot strip rolling mills generally have six principal contact
water systems:
(1) Flume flushing water
(2) High pressure descaling water
(3) Low pressure roll coolant water
(4) Table roll and shear cooling waters
(5) Product cooling including runout tables
(6) Coiler cooling water
Large quantities of cooling waters are applied to cool the
strip on the runout table after it has been rolled on the
final mill finishing stands. This water is relatively clean
and is often recycled because of its large volume.
no
-------
Approximately 8% of the strip cooling waters evaporate and
the balance is either recycled or further treated with the
other wastewaters.
The mill scale from the finishing roll stands is much finer
and is retained on a 325 mesh screen. Hot strip and
combination mills require greater cooling water rates due to
cooling tables and laminar water spray cooling. Laminar
flow is a method of non-turbulent water flow applied over
the entire surface of the strip to effect uniform surface
cooling and prevent strip distortion.
The combined discharge from the sources mentioned above is
the wastewater source regulated by the limitations and
standards.
4. Pipe and Tube (Hot Working)
Wastewaters are generated in the hot working operation as a
result of the large amounts of direct contact cooling and
descaling waters required by the hot steel and the piercing, pluq
and reeler mill equipment.
types of contact
The butt welded pipe mills generally have two
wastewater systems.
a. Roll cooling spray waters
b. Pipe cooling bed water bosh
The pipe cooling bed water bosh is sometimes used to provide
adequate cooling capacity without the use of excessively long
pipe cooling beds. These wastewaters provide direct contact
cooling and are generally discharged to the roll coolinq
wastewater system.
The seamless tube mills generally use two types of contact water
systems:
a.
b.
Roll spray coolant waters
Spray, water quench
Several pipe mills also have ancillary contact or process
wastewaters for hydrostatic pipe testing and other miscellaneous
uses. The spray quench water system is used to produce higher
strength pipe and tube than that achievable by only hot working
the pipe and tube. The product is quenched, reheated, and
quenched again by means of water sprays. These wastewaters are
handled in a manner similar to that of the roll coolina
wastewaters. - . .
111
-------
Recycle Water Rates
To reduce the large volumes of wastewater discharged from hot forming
operations, recycle systems are installed at most mills. These
systems recirculate either treated or partially treated process water
back to the mill which reduces service (makeup) water requirements and
discharge flow.
The degree of recycle that can be practiced at hot forming operations
is controlled primarily by product .quality and temperature
requirements of the process water. The water must be fairly cool
since one of the principal uses of process water is to cool the
rolling stands. For this study, recirculation of hot forming wastes
is considered to be recycled if the water is recirculated to a hot
forming operation. If the water is recirculated to a process other
than hot forming, {i.e., EOF, Blast Furnace) it is considered to be
reused and is considered part of the discharge flow from the hot
forming mill.
Based upon these determinations, the Agency analyzed the recycle rates
in hot forming operations. Recycle of scale pit process water and
recycle of treated process water were considered separately. > A
detailed listing of recycle percentages is given in Section IX and a
summary of the average recycle rates is provided below:
Average Recycle
Rate of Scale Pit
Process Water*(%)
Primary Operations .
Section Operations
Flat Operations
Pipe and Tube Operations
61 .4
57.9
5.9.6
77.0
Average Overall
Process Water
Recycle Rate**(%)
74.4
84.6
71. 2
73.5
* Average recycle rate of water from primary scale pits for flume
flush-ing or similar process uses, for mills with recycle systems.
** Overall recycle equals the total recycle practiced at mills with
recycle systems. As noted above, many mills have higher recycle
rates.
Overall process water recycle rates for the better treatment systems
exceed 96% for each hot forming subdivision. Zero discharge has been
reported for several mills.
Wastewater Characteristics
Tables V-l through V-15 present the raw wastewater concentrations of
pollutants discharged from hot forming operations sampled for this
study. Data are divided into those obtained during the original
guidelines study and those obtained during the toxic pollutant study
because of the diverse nature of the sampling conducted during the two
studies. For the original study, only metals and limited pollutants
112
-------
were analyzed. However, for the toxic pollutant study, toxic metals
and toxic organic pollutants were studied in addition to the
previously limited pollutants.
In order to accurately characterize the raw wastewaters of hot forming
operations it was necessary to isolate the contribution of these
operations. The wastewater quality data in Tables V-l through V-15
present such data.
Concentrations were calculated by subtracting all "background" amounts
of each pollutant from the individual total pollutant amounts present
in the wastewaters. This included pollutants in intake waters and
pollutants in recycle loops, if any recycle was practiced. Only those
pollutants which were present at levels equal to or greater than 0.010
mg/l in the averages of all the plants were used to characterize the
raw wastewaters. These data show that toxic metals as well as some
toxic organic compounds are found in wastewaters from both carbon and
specialty operations. Toxic organic pollutants, however, are present
at only low concentrations or are not truly representative of hot
forming operations and were therefore not included in the final list
of selected pollutants. Discussion concerning the final selection of
wastewater pollutants is presented in Section VI.
After reviewing the net and gross concentration values of those
pollutants considered for limitation in the hot forming subcategory,
the Agency determined that the impact of small pollutant loadings in
make-up water on effluent quality is not significant. Consequently,
*5f-^- V6^ limitations and standards are based upon gross values.
Additional discussion concerning the impact of make-up water quality
is presented in Section VII. .^u«xj.uy
113
-------
TABLE V-l
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
ORIGINAL GUIDELINES SURVEY
HOI FORHIHC-PRIHARY ;
Net Concentration of Pollutants in Raw Haatewaters
Reference Code:
Plant Code :
Sample Points :
Flow (gal/ton):
Suspended Solids
Oil & Grease
pH (Units)
Chromium
Copper
Lead
Mercury
Nickel
Zinc
01128-01,02
A-2
4_(3+lV''
890C '
78
12
7.6
NA
NA
NA
•
NA
NA
0112B-03
B-2
3-3n,.
510
56
150
8.0-8.3
NA
NA
NA
0.0003
NA
NA
068411
C-2
21
1.5
7.9-8.1
NA
NA
NA
0
NA
NA
0946A
D-2
U+2)-(6t7)
700
37
14.2
7.8-8.2
NA
NA
NA
0.0010
NA
NA
0060
15
8
7.6-8.1
NA
NA
NA
0
NA
NA
0248B
78
49
2.5-6.4
NA
NA
NA
NA
NA
NA
0020B
E
6-10
2740
80
26 •
7.0-7.2
_
0.0
0.0
NA
0.19
-
0248A
K
9"14(3)
2480"'
127
1.0
6.3
0.0
0.0
0.0
NA
0.0
-------
TABLE V-2
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING-PRIMARY
TOXIC POLLUTANT SURVEY
h-1
H
Ln
Net Concentration of Pollutants in Raw Wastewaters^1*
Reference Code: 0496
Plant Code : 082-140"
Sample Points : (G
Flow (gal/ ton):
Suspended Solids
Oil & Grease .
pH (Units) 7
Cadmium
Chromium
Copper
Cyanide
Lead
Nickel
Silver
Zinc
Chloroform
Methylene Chloride
Bis-(2-ethyl hexyl) phthalate
Di-n-butyl phthalate
Di-n-octyl phthalate
Tetrachloroethylene
1+V-A
2
170(2)
81
63
.7-7.9
0.0
0.04
0.15
0.40
0.51
0,0
0.04
ND
0.12
0.13
ND
ND
• 0496
OS2-140"/206"
(VV-A
2
460<2>
52
2.6-8.9
0.0
0.06
0.20
0.12
0.32
0.0
0.06
ND
0.17
ND
ND
0860H
083
E-(A+B)
320
235
25
7.0-7.1
0.0
0.49
0.04
0.10
0.0
0.033
0.005
ND
0.026
0684H(2)
088
(B+C
+
1700(3)
20
0.5
7.9
0.0
0.02
0.21
0.002
0.30
0.12
0.0
0.020
"it
ND
0.012
ND
(1) All values are in mg/1 unless otherwise noted.
(2) Visited earlier as Plant C-2.
(3) Includes flow from machine scarfing
operation.
: Calculation yielded negative result
* : Net concentration is less than 0.
0 : Zero value (included in averages)
ND , : Not detected
010 mg/1
0176
081
B-D
760
15
157
7.9-8.1
0.0
0.09
0.44
0.002
0.71
0.21
0.0
0.06
ND
0.003
ND
ND
ND
680
81
50
2.6-8.9
0.0
0.04
0.30
*
0.31
0.25
0.0
0.04
*
0.024
0.061
*
*
Note: Negative values (-) are counted as zero in calculating averages.
-------
TABLE V-3
Reference Code: 0088D
Plant Code: 282A
Sample Points: B-A
Flow (gal/ton): 5050
Suspended Solids NA
Oil and Grease NA
pH (units) NA
Chromium 1.47
Copper 2.41
Lead 0.088
Nickel 1.10
Zinc 0.39
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING: PRIMARY
TOXIC METALS SURVEY
m
Net Concentration of Pollutants in Raw Wastewaters%"
0240A(2)
285A
B-A
2320
43.7
NA
7.9 - 8.1
0.15
0.22
0.18
0.38
_
0432C
286A
C-K-A
2190
NA
NA
NA
0.030
0.13
0.12
0.013
2.81
0584F
288A
B-A
820
51.3
NA
NA
ND
0.057
0.011
ND
0.013
0684B
289A
B-A
1050
NA
NA
NA
NA
NA
NA
NA
NA
0856R
290A
B-A
6400
27.0
NA
7.5 - 7.7
0.027
0.040
0.0
0.0
0.003
0856B
291
A-B-C
2340
113
NA
7.0 - 7.3
0.0
0.075
0.12
0.071
0.023
0856N
293A
B-A
2250
37.3
NA
NA
0.024
0.021
0.099
0.038
-
0920N
294A
C-A-D Average
4310 2970
54.1
NA
7.1
0.0
0.051
0.0
0.0
0.027
54.4
NA
7.0 - 8.1
0.21
0.38
0.077
0.20
0.41
(1) All values are in mg/1 unless otherwise noted.
(2) Visited earlier as Plant R.
- : Calculation yielded negative result. Result is counted as zero in calculating averages.
NA: Not Analyzed
ND: Not Detected
Note: All plants perform scarfing except Plant 289A.
-------
TABLE V-4
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
HOT FORMING-SECTION
ORIGINAL GUIDELINES STUDY
NET CONCENTRATION OF POLLUTANTS IN RAW WASTEWATERS(1}
Reference Code:
Plant Code :
Sample Points :
Flow (gal/ton):
Suspended Solids
Oil & Grease
pH (Units)
Chromium
Copper
Nickel
Zinc
0240A
R
4-1
7960
25
3.3
7.1
0.0
0.0
0.06
0.02
0176
0
(3)
NA
NA
NA
NA
NA
NA
NA
NA
0684D
Q
8-10
1780_
30
1.2
7.5
0.01
ND
0.04
0432J
6-9
670
53.6
9.7
6.5
0.07
0.0
0.11
0424
8-5
5260
36.8
1.0
5.1
0.0
0.0
0.11
0.011
0284A&B
H
13-14
4210
44
7.8
6.2
0.0
Q.O
0.0
0.0
0256
K
10-7
1470
63
3.5
7.2
0.0
0.05
0176(2)
0
1-2
4970
3.4
8.4
0.0
0.0
0112B
A-2
4-3
600
86.3
13.9
7.6
NA
NA
NA
NA
-------
03
TABLE V-4
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
HOT FORMING-SECTION
ORIGINAL GUIDELINES STUDY (
NET CONCENTRATION OF POLLUTANTS IN RAW WASTEWATERS
9
Reference Code:
Plant Code :
Sample Points :
Suspended Solids
Oil & Grease
pH (Units)
Chromium
Copper
Nickel
Zinc
0291C
D-2 No. 5
5-6-7
9560
25.8
15.0
8.0-8.1
NA
NA
NA
NA
0291C
Bar D-2 No. 2 Bar
4-6-7
9740
38.3
9.8
8.0-8.1
NA
NA
NA
NA
0291C 0196A
D-2 No. 6 Bar E-2 Rod
(4) 2-4-6
8400 8820
NA
NA
NA
NA
NA
NA
NA
67.2
U1
• I
8.2-8.3
NA
NA
NA
NA
0196A
E-2 Bar
3-4
3170
27
8.2-8.3
NA
NA
NA
NA
0384A
F-2*
(2-3)
1910
12.7
7.7
NA
NA
NA
NA
(1) All values are in tng/1 unless otherwise noted.
2 The data for Plant 0 is not included in the averages since it was later revisited as
later visit is more representative of current plant operations and is therefore used
(3) A separate sample of the section mill could not be obtained.
(4) There is insufficient information available to allow a net calculation.
0640A
G-2
l-(2+4)
14.020
22.2
0.5
7.7
NA
NA
NA
NA
Plant 081.
instead.
0432A
H-2
(3-1)
6950
33
13.8
6.6
NA
NA
NA
NA
08560
1-2
(2-6)
5010
124
1.4
7.6
NA
NA
NA
NA
The data from
Average
5600
46
6.1
5.1-8.3
0.012
0.01
0.047
0.012
this
- : Calculations yielded negative result
* : Includes scarfing flow
NA : Not analyzed or not available
ND s Not detected
NOTES: a. Negative values counted as zero in average calculations. nnftratinna
b. Because of the difficulty in sampling the raw wastes directly from the opera ions,
the sampling results shown above are all based on the mills' discharge from the
primary scale pits.
-------
TABLE V-5
Reference Code:
Plant Code :
Sample Points :
Flow (gal/ton):
Suspended Solids
Oil & Grease
pH (Units)
Cadmium
Copper
Nickel
Zinc
Methylene Chloride
Naphthalene
2,4 Dinitrophenol
Bis(2-Ethylhexyl)phthalate
Butyl Benzyl Phthalate
Dimethyl Phthalate
Pyrene
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
TOXIC POLLUTANT STUD.Y
HOT FORMING-SECTION
NET CONCENTRATION OF POLLUTANTS IN RAW HASIEHATERS(1)
0176(2>
081-1&2
(C-D)
3570
0
4
7.9
0.0
0.16
ND
0.015
0.014
ND
0.0
0860H
083 34"
(G-B-A)
4690
26
37
6.9
0.0
0.051
0.0
0.013
ND
0.012
ND
ND
0860H
083 Rod
(K-B-R-A)
6930
199
8
7.4
0.0
0.070
0.070
0.029
ND
ND
0.0
0432A
087-14"
(D-B)
6340
23
1
7.3
0.0
0.024
0.0
0.076
0.0
ND
ND
0.027
ND
ND
ND
0684H
088-10"/H"
(T-V)
3400
34
10
7.5
0.0
0.01
0.01
0.19
0.19
0.0
0.014
1.28
0.0
ND
0684H
088-34"
(F-Q)
580
20
7.7
0.0
0.08
0.08
0.02
0.003
0.0
0.013
ND
ND
ND
088-36"Billet
(D+E-Q)
4710
18
7.9
0.0
0.13
0.04
0.01
0.10
0.0
ND
ND
0.0
ND
0684H
088-32"
(G-Q)
930
27
7
7.8
0.0
0.08
0.05
0.02
0.0065
ND
ND
0.37
ND
0.0
ND
0684H
088-14*
4800
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
0684H
081-#4Hot
(F-A)(4) Average
8229 4290
84
251
7.2
0.0
0.12
0.82
0.06
ND
ND
0.16
ND
ND
•ND
47.8
35.3
6.9-7.
0.0
0.063
0.14
0.05
0.033
0.0
*
0.21
*
0.0
0.0
(1) All values are in mg/1 unless otherwise noted.
(2) Visited earlier as Plant 0.
(3) Insufficient samples to allow calculation of the net concentrations.
W Some company supplied analytical data was used for net concentration calculation.
ND
NA
NOTE:
Average is less than 0.010 mg/1
Calculation yielded negative results
Not Detected
Not Available
ause of the difficulty in sampling the raw wastes- directly from the operations, the
ipling results shown above are all based on the mills' discharge from their primary scale pit.
-------
Reference Code:
Plant Code:
Sample Points:
Flow (gal/ton)
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
TABLE V-6
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING: SECTION
TOXIC METALS SURVEY
Net Concentration of Pollutants in Raw Waatewaters
0088D 0112
282B 283
B-A B-A
6450 1850
NA NA
NA ' NA
NA NA
0.11 0.006
0.068 0.070
0.027 0.035
0.068 0.033
0.036 0.027
(1)
0240A
285B
C-A
2600
19.6
NA
8.0 - 8.1
0.036
0.029
0.019
0.21
0856R
290B
C-D-A
950
3.2
NA
8.6 - 8.7
0.027
0.11
0.053
0.040
0856N
293B
C-A
2990
28.3
NA
NA
0.010
—
—
0.012
Average
2970
17.0
NA
8.0 - 8.7
0.038
0.055
0.027
0.073
0.013
to
o
(1) All values are in mg/1 unless otherwise noted.
* : Net concentration is less than 0.010 mg/1
- : Calculation yielded negative result. Result is counted as zero in calculating averages.
NA: Not Analyzed
-------
TABLE V-7
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
ORIGINAL GUIDELINES STUDY
HOT FORMING: HOT STRIP & SHEET
NET CONCENTRATION OF POLLUTANTS IN RAH HASTEHATERS(1)
Reference Code
Plant Code
Sample Points
Flow (gal/ton)
Suspended Solids
Oil & Grease
PH
Chromium
Copper
Mercury
Nickel
Zinc
0248B
D
(6-1)
3310
31
16.4
6.3
.0
NA
0.13
0020B,}
(7-10)
4520
23
13.6
5.9-6.1
-
NA
0.0
0176
NA
NA
NA
NA
NA
NA
NA
NA
NA
0860H)
(1+3+4) -6
7850
6.6
0.6
7.3-8.3
NA
NA
0.0
NA
NA
0060
L-2
(1-2)
4520
11
4.2
7.6-8.1
NA
NA
0.0
NA
NA
0384A
M-2
(2+3)-5
8440
11
1.7
8.4
NA
NA
0.0
NA
NA
0396D
N-2
(6-7)
7270
15
0.0
7.3-7.5
NA
NA
0.0
NA
NA
Average
5890
16.3
6.1
6.3-8.4
0.00
0.0
0.065
0.00
(1)
(2)
(3)
(4)
All values are in mg/1 unless otherwise noted.
da^a JrL'JS' ? ? "°- ^^ *" ^ "7"ra8M 8ince " W3S later ^visited as Plant 281.
nstead? ^ " m°re "P"3*'"^ of current plant operations and is therefore
A separate sample of the strip mill could not be obtained.
SP Hi!,13 f°r PJa"t f"2 1S "°' included in the averages since it was later revisited as Plant 292
utd instep '" ^ " more reP"86ntative of current plant operations and is therefore
NA : Not Analyzed or Not Available
-------
TABLE V-8
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
TOXIC POLLUTANT SURVEY
HOT FORMING: FLAT-HOT STRIP AND SHEET ,.,
NET CONCENTRATIONS OF POLLUTANTS IN RAW WASTEHATERV
to
to
Reference Code
Plant Code
Sample Points
Flow (gal/ton)
Suspended Solids
Oil and Grease
pH (Units)
Beryllium
Cadmium
Chromium
Copper
Lead
Nickel
Silver
Zinc
Phenolic Compounds
Chloroform
Methylene Chloride
2,4-Dinitrophenol
Bis-(2-ethyl hexyl) phthalate
Butyl benzyl phthalate
Di-n-butyl phthalate
0112D ( j
086(80" Milir '
(B-A)
5720
41
6
8.0-8.1
NA
0.0
0.0
0.0
0.01
0.0
0.02
0.028
ND
0.013
0.028
0.28
0.024
0.006
0432A
087 (44" Mill)
(C-B)
4670
18
3
7.4-7.6
0.0
0.0
0.01
0.0
0.0
0.0
-
0.0
0.018
' -
ND
'
ND
0.027
Average
4670
18
4
7.4-7.6
0.0
0.0
0.01
0.0
0.0
0.0
0.0
0.0
0.014
0.009
*
0.014
0.14
0.012
0.016
(1) All values are expressed in mg/1 unless otherwise noted.
(2) The data for Plant 086 (with the exception of the organic data) is not included in the averages
since it was later revisited as Plant 284A. The data from this later visit is more representative
of current plant operations and therefore is used instead.
ND; Not Detected
NA: Not Analyzed .
- : Calculations yielded a negative value
* : Less than 0.010 mg/1
-------
TABLE V-9
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING! FLAT - HOT STRIP AND SHEET
K)
CO
Net Concentration of
Reference Code:
Plant Code:
Sample Points:
Flow (gal /ton):
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
(1) All values are
(2) Visited earlier
(3) Visited earlier
(4) Visited earlier
•£«>.
B-A
5690
109
NA
6.7 - 7.1
0.60
0.083
0.0
0.61
0.068
in mg/1 unless
as Plant E.
as Plant 086.
as Plant J-2.
(5) Insufficient flow information
0112D
OOA A ^ -* '
B-A-D
6110
60.4
NA
NA
0.003
0.022
0.0
0.0015
043 2C
286B
(D+E)-
(A+K)
3500
NA
NA
NA
0.56
0.027
0.020
0.26
0.0039
Pollutants in Raw Wastewaters
0584B
287
B-A
4150
41.7
NA
NA
0.039
0.006
0.0
0.0
0.007
0584F
288B
C+D-A
3160
52.7
NA
NA
0.0063
0.0069
0.0
0.0
0.00042
0684B
289B
D-E
6660
24.6
NA
7.5 - 7.8
0.005
0.003
0.006
0.030
0860B
292 '
-------
TABLE V-10
Reference Code
Plant Code
Sample Points
Flow (gal/ton)
Suspended Solids
Oil & Grease
pH (units)
Chromium
Copper
Mercury
Nickel
Zinc
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
ORIGINAL GUIDELINES STUDY
HOT FORMING - PLATE
NET CONCENTRATION OF POLLUTANTS IN RAW WASTEWATERS
(1)
0856H
F
(7-9)
4290
85
50.9
6.3-6.7
0.01
0.0
NA
0.48
0.02
0868B
K-2
(1-2)
3,690
56
4.6
6.9-7.1
NA
NA
0.0
NA
NA
Average
3990
71
27.8
6.3-7.1
*
0.00
0.00
0.24
0.01
(1): All values are in mg/1 unless otherwise noted.
NA: Not Analyzed
* : Less than 0.010 mg/1
NOTE: Because of the difficulty in sampling the raw wastes directyly from the operations,
the sampling results shown above are all based on the mills' discharge from the primary scale pit.
-------
TABLE V-ll
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
TOXIC POLLUTANT SURVEY
HOT FORMING: FLAT-PLATE , .
NET CONCENTRATIONS OF POLLUTANTS IN RAW WASTEWATERSC1)
Reference Code
Plane Code
Sample Points
Flow (gal/ton)
Suspended Solids
Oil and Grease
pH (Units)
Chromium
Copper
Lead
Nickel
Silver
Zinc
Benzene
2,4-Dimethylphenol
Methylene Chloride
4-Nitrophenol
Pentachlorophenol
Bis-(2-ethyl hexyl) phthalate
Di-n-butyl phthalate
Diethyl phthalate
0496
082-H2"/120"
D-A
870
22
8
7.2
0.0
0.18
0.04
o.n
0.0
0.05
0.012
0.014
NO
0.012
0.60
ND
0496
082-112"/120"
C-A
2,650
31
6
7.5
0.12
0.15
0.0
0.28
0.0
0.04
NO
0.017
ND
0.59
~*
ND
0496
082-140"
H-A
120
65
34
7.7-8.9
0.04
0.11
0.26
0.33
0.0
0.03
ND
0.024
ND
ND
0.15
—
ND
0496
082-140"
G-A
140
109
60
7.8
0.07
0.18
0.47
0.94
0.0
0.05
ND
0.14
ND
ND
-
—
ND
0496
082-140"/206"
J-A
210
25
4
7.4
0.04
0.20
0.02
0.13
0.0
0.05
ND
0.013
ND
ND
0.012
—
ND
0860H
083-30"
I-(B+A)
9,820
12
10
7.2-7.3
0.06
0.0
0.02
0.0
0.04
ND
ND
-
ND
-
0112D
086-160" .
H-A
3,220
30
13
8.0-8.2
0.0
0.04
0.0
0.06
0.0
0.03
ND
ND
ND
0.007
ND
0.82
ND
ND
Average
2 300
44
20
7.2-8.9
0.04
0.15
0.13
0.30
0.0
0.04
*
*
0.025
*
*
0.31
b.o
0.0
(1) All values are in mg/1 unless otherwise noted.
(2) The data for Plant 086 (with the exception of the organic data) is not included in the averages
since « was later revisited as Plant 284B. The data from this later visit is more representative
of current plant operations and therefore is used instead.
*: Less than 0.010 mg/1
-: Calculations yielded a negative value
NA: Not Analyzed
ND: Not Detected
-------
TABLE V-12
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING: FLAT-PLATE
TOXIC METALS SURVEY
Net Concentration of Pollutants in Raw Wastewaters
(1)
Reference Code:
Plant Code:
Sample Points:
Flow (gal/ton):
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
112D
284B
C-A-D
8830
(2)
40.1
NA
NA
0.013
0.031
0.0
(1) All values are in mg/1 unless otherwise noted.
(2) Visited earlier as Plant 086. ^_
* : Net concentration is less than 0.010 mg/1. .
- : Calculation yielded negative result. Result is counted as zero in calculating averages,
NA: Not Analyzed
126
-------
TABLE V-13
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
HOT WORKING PIPE AND TUBE
ORIGINAL GUIDELINES SURVEY
-J
Reference Code
Plant Code
Sample Points
Flow (gal/ton)
Suspended Solids
Oil and Grease
pH (Units)
Beryllium
Cadmium
Chromium
Copper
Lead
Nickel
Silver
Zinc
Phenolic -Compounds
Net Concentrations of Pollutants in Raw Wastewater
OL96A
E-2
(1-6)
12,800
27
13.4
8.2-8.7
NA
NA
NA
NA
NA
NA
NA
NA
NA
0240B
GG-2
(1-4)
1,700
40
7.3
7.0-7.8
NA
NA
NA
NA
NA
NA
NA
NA
NA
0916A
II-2
(1-5)
2,760
224
2.2
7.0
NA
NA
NA
NA
NA
NA
NA
NA
NA
0728
JJ-2
2,290
102
6.7
6.8-6.9
NA
NA
NA
NA
NA
NA
NA
NA
NA
0256G
KK-2
(1-3)
520
61
6.8-7.1
NA
NA
NA
NA
NA
NA
NA
NA
NA
Average
4,010
91
5.9
6.8-8.7
NA
NA
NA
NA
NA
NA
NA
NA
NA
-: Calculations yielded a negative value
NA: Not Analyzed
-------
TABLE V-14
SUMMARY OF ANALYTICAL DATA OF SAMPLED PLANTS
HOT WORKING PIPE AND TUBE
TOXIC POLLUTANT SURVEY
Net Concentrations of Pollutants in Raw Wastewaters
(1)
Reference Code
Plant Code
Sample Points
Flow (gal/ton)
Suspended Solids
Oil and Grease
pH (Units)
Beryllium
Cadmium
Chromium
Copper
Lead
Nickel
Silver
Zinc
Phenolic Compounds
0432A
087
(E-B)
8,080
27
2
7.1-7.4
0.0
0.0
0.0
0.009
0.25
0.0
0.0
0684H
088
(I+J+K+L)-Q
7,010
8
31
1.9
.2-7
NA
0.0
0.004
0.071
0.028
0.080
0.0
0.027
0.0
Average
7,540
29
2
7.1-7.8
0.0
0.0
*
0.040
0.014
0.16
0.0
0.014
0.0
(1) All values are expressed in mg/1 unless otherwise noted
* : Less than 0.010 mg/1
NA: Not analyzed
ND: Not detected
128
-------
TABLE V-15
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING: PIPE AND TUBE
_ TOXIC METALS SURVEY _ '
Net Concentration of Pollutants in Raw Wastewaters
^
Reference Code:
Plant Code:
Sample Points
Flow (gal/ton)
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
0856N
293C
D-A
2140
NA
KA
094 8A
295
B-A
5620
121
NA
7.2 - 7.5
0.060
0.18
0.091
0.020
Average
3880
61
NA
7.2 - 7.5
0.030
0.090
0.046
0.010
0.0
(1) All values are in mg/1 unless otherwise noted.
* : Net concentration is less than 0.010 mg/1
- : Calculation yielded negative result. Result is counted as zero in calculating averages
NA: Not Analyzed .
129
-------
-------
HOT FORMING SUBCATEGORY
SECTION VI
WASTEWATER POLLUTANTS
Introduction
This section describes the selection, rationale for selection, and the
process sources of those pollutants characteristic of hot forming
operations. As a first step in the selection procedure, the Agency
developed a list of pollutants considered to be most representative or
characteristic of hot forming processes. This initial list of
pollutants was confirmed and augmented with data collected from
extensive field sampling programs which included analysis for toxic
pollutants.. A review of the monitoring data from all of the field
sampling programs formed the basis for the final selection of
pollutants for hot forming operations. On the basis of the expected
and observed similarities among hot forming operations, a common list
of selected pollutants was developed for the four hot forming
subdivisions.
Conventional Pollutants
Suspended solids, oil and grease, and pH were the three.pollutants
limited by the BPT limitations promulgated in 1976. Suspended solids
was chosen as a limited pollutant based upon the large quantities of
scale generated by the hot forming processes. As noted in Section V,
these scale particles enter the process wastewaters as a result of the
application of water on the steel product and roll stands. Suspended
solids also indicate the degree of process wastewater contamination
and can be used as a measure of treatment performance. Various other
pollutants, including the toxic metals, are often entrained within the
suspended particulate matter; thus, suspended solids removal results
in the removal of other pollutants as well.
The Agency selected oil and grease since many lubricants are used in
hot forming processes. Oils and greases are present in hot forming
wastewaters as a result of oil conditioning, oil spills, line breaks,
leaks, excessive application of lubricants, and equipment washdown.
Finally, pH, a measure of the acidity or alkalinity of a wastewater,
was chosen due to the environmentally detrimental effects which can
result from extremes in pH. In addition, extremes in pH can cause
problems, such as corrosion and scaling, to process and wastewater
treatment equipment and facilities. The pH of hot forming process
wastewaters typically falls within the range of 6.0 to 9.0 without
control.
131
-------
Toxic Pollutants
This study also considered the discharge of toxic pollutants.
Initially, all pollutants classified as "known to be present" were
included. This classification was made on the basis of industry
responses to the DCPs, and analyses performed during the screening
phase of this project. Table VI-1 lists toxic pollutants selected on
the basis of the above considerations.
Upon completion of the analyses of the hot forming wastewaters for the
various pollutants, the Agency determined those pollutants which were
found at 0.010 mg/1 or greater in the raw wastewaters. As discussed
in Section V, net concentrations of these pollutants were calculated
by subtracting concentrations found in "background" waters. Table
VI-2 presents average net concentrations for all pollutants analyzed
in Section V for the major hot forming subdivisions. The final toxic
pollutant list was developed by including only those pollutants
(except the toxic organics discussed below) in Table VI-2 which
appeared at average net concentrations of 0.010 mg/1 or greater.
Table VI-3 shows this final list of toxic pollutants as well as
original BPT limited pollutants. The Agency believes that these
pollutants are considered to be most representative and indicative of
hot forming operations and are addressed accordingly throughout this
report.
The toxic metal pollutants enter the hot forming process wastewaters
from the product scale and potentially from other sources. The five
toxic metal pollutants (refer to Table IV-3) are used to characterize
all hot forming wastewaters. These toxic metals are found above
treatability levels in the process wastewaters of all hot forming
subdivisions.
The list of selected pollutants does not include toxic organic
pollutants. Although several toxic organic pollutants were detected
at levels greater than 0.010 mg/1 in some of the hot forming
subdivisions, various factors mitigated against the selection of these
pollutants. In the case of methylene chloride and the phthalates,
these pollutants are considered to be artifacts (i.e., resulting from
sampling or laboratory procedures) and are not believed to be
contributed by hot forming operations. The remaining toxic organic
pollutants (e.g., phenol, 2,4-dinitr,ophenol) were not included in the
final list because of their presence at such low levels which indicate
that, aside from recycle, specific treatment for organic pollutant
removal is generally not feasible. The Agency believes that those
pollutants do not tend to concentrate in recycle'systems. Although
the concentrations of those pollutants in recycle system blowdowns
will be approximately the same as the discharge from once-through
systems, the mass loadings of those pollutants will generally be
reduced proportionately to the degree of recycle.
132
-------
TABLE VI-1
PRIORITY POLLUTANTS KNOWN TO BE PRESENT
BPT FORMING SUBCATEGORY
Priority Pollutant
Numeric Designation
65
66
85
118
119
120
121
122
123
124
125
126
127
128
Pollutant Parameter
Phenol
Bis(2-ethyIhexyl)Phthalate
Te trachloroethylene
Cadmium
Chromium
Copper
Cyanide
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
133
-------
TABLE VI-2
SUMMARY OF NET PRIMARY SCALE PIT EFFLUENT CONCENTRATIONS
HOT FORMING SUBCATEGORY
(1)
H
W
Parameter
Flow(gal/ton)
Total Suspended Solids
Oil & Grease
pH (units)
Beryllium
Cadmium
Chromium
Copper
Cyanides
Lead
Mercury
Nickel
Silver
Zinc
Benzene
Chloroform
2,4 Dimethylphenol
Methylene Chloride
Napthalene
2,4 Dinitrophenol
4 - Nitrophenol
Pentachlorophenol
Phenolic Compounds
Bis-(2 ethyl hexyl) phthalate
Butyl benzyl phthalate
Di-n-butyl phthalare
Di-n-octyl phthalate
Diethyl phthalate
Dimethyl phthalate
Te t rachloroe thylene
Pyrene
Primary
2170
66
40
2.5 - 8.9
0.0
0.0
0.16
0.28
*
0.14
*
0.19
0.0
0.22
0.0
*
0.0
0.024
0.0
0.0
0.0
0.0
0.0
0.061
0.0
*
*
0.0
0.0
*
0.0
Section
4750
43
20
5.1 - 8.7
0.0
0.0
0.024
0.045
0.0
0.027
0.0
0.094
0.0
0.028
0.0
0.0
0.0
0.033
0.0
*
0.0
0.0
0.0
0.21
*
0.0
0.0
0.0
0.0
0.0
0.0
Hot Strip & Sheet
5300
36
5.2
6.3 - 8.4
0.0
0.0
0.14
0.017
0.0
*
0.0
0.11
0.0
0.014
0.0
0.009
0.0
*
0.0
0.014
0.0
0.0
0.014
0.14
0.012
0.016
0.0
0.0
0.0
0.0
0.0
Plate
3400
49
22
6.3 - 8.9
0.0
0.0
0.037
0.11
0.0
0.11
0.0
0.29
0.0
0.035
0.0
*
0.025
0.0
0.0
*
*
0.0
0.31
0.0
0.0
0.0
0.0
0.0
0.0
0.0
Pipe S Tube
4770
79
4.8
6.8 - 8.7
0.0
0.0
0.016
0.065
0.0
0.030
0.0
0.088
0.0
0.0068
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
(1) All values are in mg/1 unless otherwise noted.
* Less than 0.010 mg/1
Note: Averages for each subdivision include only those plants which were included in the individual averages, on the preceding tables.
-------
TABLE VI-3
SELECTED POLLUTANTS
HOT FORMING SUBCATEGORY
Suspended Solids
Oil and Grease
PH
119 Chromium
120 Copper
122 Lead
124 Nickel
128 Zinc
135
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HOT FORMING SUBCATEGORY
SECTION VII
CONTROL AND TREATMENT TECHNOLOGY
Introduction ,
A review of the control and treatment technologies currently in use or
available for use in the hot forming subcategory provided the basis
for the development of the BPT, BAT, BCT, NSPS, PSES, and PSNS
alternative treatment systems. This review involved summarizing
questionnaire and plant visit data to identify those treatment
components and systems in use at hot forming operations.
Capabilities, either demonstrated or based on treatment of similar
wastewaters, were used in evaluating those advanced treatment
technologies for toxic metal pollutant removal. The above
considerations were then used to determine which treatment components
and systems are most appropriate for the various levels of treatment.
This section presents a summary of the treatment practices currently
in use or available for use for the treatment of hot forming process
wastewaters.
This section also presents raw wastewater and treated effluent data
for the plants sampled, as well as the methods used to determine
wastewater loads and actual raw wastewater quality. As noted
previously, raw wastewater samples could only be obtained following
primary scale pits at most plants. The analytical data, from the
toxic pollutant surveys along with long-term effluent monitoring data
obtained from the industry, were used to establish treatment system
capabilities. Also included in this section are descriptions of the
treatment systems at each of the sampled plants.
Summary of. Treatment Practices Currently Employed
As noted previously, wastewaters generated in the various hot forming
processes are similar in character, and as a result, the treatment
technologies in use at these operations are basically the same. A
survey of the treatment components in use indicates that the following
basic treatment units are prevalent: primary sedimentation, surface
oil removal, secondary settling or filtration, and recycle. Over
ninety-six percent of all hot forming operations have primary scale
pits to collect and recover the heavier suspended particulate matter
and to allow the tramp oils to float to the surface. These pits are
cleaned either frequently or continuously in order to prevent excess
solids accumulation. Slotted tube, rope, or belt-type oil skimmers
are the principal devices in use for surface oil removal. The
efficiency of scale pits is dependent upon design. At many mills a
portion of the scale pit discharge is recycled to the process for
flume flushing. The scale pit discharges which are not recycled,
137
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typically undergo physical/chemical treatment prior to discharge or
recycle to the process.
Referring to Tables III-2 through III-7, the following treatment
technologies are in use at many hot forming operations:
B.
E.
F.
Scale Pit or similar type settling basin
Intended to provide primary sedimentation
wastewaters and oil separation.
Surface Skimming
of the raw process
The various tramp oils inherent .in mill operations are removed
from the surface of the wastewater (generally during primary
settling).
Clarifiers or Thickeners
These components provide additional suspended solids removal.
Settling lagoons and secondary scale pits are also capable of
providing the same degree of treatment as clarifiers or
thickeners.
Vacuum Filters
These filters are used to dewater the sludges removed from
various sedimentation operations, principally clarifiers and
thickeners.
Filters
These components can provide a higher degree of suspended
removal than attainable with sedimentation facilities.
solids
Recycle
A portion of the effluent from one or more
system components is recycled to the process.
of the treatment
Hot forming wastewaters are often treated in central treatment
facilities in which wastewaters from several hot forming mills (or, in
many instances, wastewaters from other subcategories) are combined for
treatment. With this type of facility, advantage can be taken of the
economies of scale and the ease of centralized process control.
Control and Treatment
Technologies Considered for BAT,
BCT, NSPS, PSES, and PSNS
In order to achieve high wastewater recycle rates (greater than 90
percent) for hot forming operations, an evaporative cooling tower is
normally used to reduce the temperature of the recycled water. It
should be noted that cooling towers are used at many hot forming
138
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operations as major components in high recycle rate systems. Heat
load reduction is necessary to ensure sufficient roll cooling
capability and to minimize fog formation in the mill. Treatment at
some mills includes a high degree of recycle without cooling towers.
Because of the presence of toxic organic and toxic metal pollutants in
hot forming process wastewaters, the Agency considered advanced levels
of treatment in the BAT, NSPS, PSES, and PSNS alternative treatment
systems in addition to recycle. Each of the technologies considered
are -reviewed below.
Evaporation
Vapor compression distillation, in which a wastewater with a high
dissolved solids level (the treatment system blowdown) is concentrated
to a slurry consistency, was considered as an alternate means of
attaining zero discharge in the hot forming subcategory. The
resulting slurry would be dried by various means while the distillate
quality effluent would be recycled to the process. However, this
technology was not seriously considered because of high enerqv
requirements and attendant high costs. Zero discharge is reported to
be achieved by the industry at many hot forming operations without
evaporative technology. However, the Agency believes that zero
discharge cannot be achieved on an industry-wide basis for hot forming
operations without the use of evaporative technologies.
Summary of Monitoring Data
Raw wastewater and effluent data for the hot forming operations which
were visited are presented by subdivision in Tables VII-2 through
yii-9. ^Table VII-l provides a legend for the various control and
treatment technology abbreviations used on the above tables and in
other tables throughout this report. The concentration values
presented represent, except where footnoted, averages of measured
values. In some cases these data were obtained from central treatment
systems.
In several instances, the effluent waste loads (lbs/1000 Ibs) for
certain central treatment operations indicated on the analytical data
tables, represent apportioned loads. In these central treatment
systems, the Agency determined the percentage contribution of an
individual operation to the total treatment system influent load and
subsequently applied this contribution to the total effluent load
This procedure was repeated for each pollutant. By using this
procedure, the Agency assessed the effects of treatment on the waste
loads of an individual process which discharges to a central treatment
facility.
As a supplement to the sampled plant analytical data, long-term
effluent analytical data from D-DCPs are presented on Table VII-l0
These data are presented as a means of demonstrating treatment
capabilities and consistency over an extended period.
139
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As mentioned previously, nearly all raw wastewater samples were
obtained from primary scale pit effluents. Therefore, other methods
were needed to determine raw process wastewater characteristics. Data
provided by the D-DCP respondents served as the basis for establishing
the levels of raw wastewater suspended solids and oil and grease.
Since suspended solids in hot forming wastewaters are almost entirely
due to scale generation in the hot forming process, a determination of
the quantities of scale generated provides a reasonable estimate of
suspended solids levels present in process wastewaters. As a result
of similar scale generation rates and wastewater characteristics, the
Agency averaged mill scale generation data from all D-DCP respondents
to derive a single scale generation rate for application to all hot
forming operations. These data are presented in Table VII-11. The
average product loss of approximately 2.1% represents a scale
generation rate and resulting suspended solids loading of 42 Ibs of
solids per ton of production. This solids loading was then applied to
the various treatment model sizes and raw wastewater flow rates to
determine raw wastewater suspended solids levels for each treatment
system. It must 'be noted that the above rate applies only to mills
without machine scarfer operations. A review of available information
indicates that primary mills with scarfing operations generate about
twice as much suspended solids than those systems without scarfing.
Raw wastewater oil and grease levels were also established on the
basis of data provided in the D-DCP responses. Virtually all of the
oils and greases present in hot forming wastewaters are present as a
result of leakages or spills of oils (i.e., lubricants) which are"
immiscible in water. Based on the data received from the D-DCP
respondents, the Agency determined an average oil and grease
generation rate of 0.23 gallons/ton (Table VII-11). This volume is
equivalent to a mass generation rate of 1.6 Ibs/ton. This rate was
applied to each treatment system as discussed above for suspended
solids. Oil generation rates much greater than this value are
considered to be the result of inadequate maintenance and operational
control.
Plant Visits
Brief descriptions of the visited plants are presented below.
Treatment system flow schematics are provided at the end of this
section.
Plant C (0424) - Figure VII-1 (Section)
The wastewaters from the specialty bar mills at Plant C empty into a
cooling reservoir which receives wastewaters from other processes as
well. A portion of the reservoir overflow is discharged to a
receiving stream, while the remaining overflow is recycled to the
process.
140
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Plant D (0248B) - Figure VII-2 (Primary)
Universal mill (specialty) Wastewaters Discharge to a scale pit
equipped with oil removal facilities. The scale pit effluent of this
once-through system is discharged to a receiving stream.
Plant D (0248B) - Figure VII-3 (Flat)
This plant provides once-through treatment for specialty hot strip
mill wastewater. Wastewater is pumped to primary scale pits and then
discharged to a receiving stream after mixing with wastewater from the
universal mill mentioned above.
Plant E (0020B) - Figure VII-4 (Primary)
Specialty steel hot strip, blooming and universal mills are treated in
nifl fhi treatment system. After first passing through primary scale
pits, the wastewaters then discharge to a main collection sump which
discharges to two clarifiers. The clarifier overflow is pumped
Thf°^i^ £ b!d fj^ers and then discharged to a receiving stream.
The filter backwash is .returned to the clarifiers.
Plant F (0856H) - Figure VII-5 (Flat)
Plant F has a once-through process wastewater system for a specialty
mill. Wastewaters flow through a primary scale pit and then are
w»^r- afe« ^ 3 rfceiving stream. Reheat furnace noncontact cooling
water also flows through the primary scale pit.
Plant H (0248A) - Figure VII-6 (Primary)
Plant H practices once-through treatment of its specialty steel
blooming mill wastewaters. Scarfer' wastewater, reheat furnace cooling
=a5S5- u bl°oming mill wastewater all empty into the same scale pit
and discharge to a receiving stream. .
Plant H (0248A) - Figure VII-7 (Section)
Merchant mill wastewaters are pumped to a scale pit and discharged to
a receiving stream by this specialty mill. No recycle is employed at
tn j. s in x x J. *
Plant K (0256K) - Figure VII-8 (Primary)
™, treatment facility for this specialty blooming mill incoporates a
recycle system with a blowdown to a receiving stream. Treatment
includes a primary scale pit with oil removal facilities.
Plant K (0256K) - Figure VII-9 (Section)
process effluent discharges to a scale pit
streanK No recycle is
141
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Plant M (0432J) - Figure VII-10 (Primary)
This specialty steel plant's wastewater treatment system serves
primary and section rolling mills (blooming mill, billet mill, and bar
mill).
The primary mill wastewaters, including hot scarfer wastewater, are
discharged to a primary scale pit. The scale pit effluent is recycled
to the mills and hot scarfer with a blowdown going to a sump pit which
receives section mill wastewaters. Overflow from this sump pit is
discharged to a spray pond and to a POTW. Water is recycled from the
spray ponds to the mills after the addition of cooling water makeup.
Plant M (0432J) - Figure VII-11 (Section)
The wastewater treatment system for this specialty plant serves
several mills including a billet bar mill, a blooming mill and a bar
mill Bar mill wastewater is pumped to a sump pit along with other
mill wastewaters. A portion of the sump pit effluent is discharged
while the remainder is pumped to a spray pond and is subsequently
recycled.
Plant 0 (0176) - Figure VII-12 (Section and Flat)
The wastewater treatment system for these specialty mills is a
combined system serving both rod and strip mills. Wastewaters are
discharged to a scale pit, then recycled to these mills. A blowdown
is discharged to a central wastewater treatment facility.
Plant Q (0684D) - Figure VII-13 (Primary)
This specialty blooming mill employs a once-through system which uses
a scale pit and oil skimming equipment to treat process wastewaters.
Other plant process wastewaters discharge to the scale pit as well.
The scale pit overflow is discharged to a receiving stream.
Plant Q (0684D) - Figure VII-14 (Section)
The wastewaters from the specialty bar mills at Plant Q are delivered
to a scale pit equipped with oil removal facilities. All process
wastewaters are discharged on a once-through basis from the scale pit
to a receiving stream.
Plant R (0240A) - Figure VII-15 (Section)
Wastewaters from the two specialty bar mills at this plant are
discharged to two separate scale pits which in turn discharge to a
common scale pit. Wastewaters from this scale pit are pumped to a
settling lagoon, then discharged to a receiving stream. No recycle is
employed.
142
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Plant k-2_ (0112B) - Figure VII-16 (Primary and Section)
ho? fSrmTnn1'^!^6?^?^.573^111 for this plant serves a combination of
hot forming mills (billet and rail mills). The wastewaters from each
?nt-« » o iS Pas? thr.?u9h Primary scale pits and are then discharged
into a secondary clarification device called a settling cone. The
!?fti 9 f0"6 ^-S eievated to all°" for gravity flow to the deep bed
filters. A portion of the settling cone overflow is recycled to the
hot forming mills with the balance going to the deep bed filters
HlUHr e5fiueefc is discharged to a lake. Filter backwash is
discharged back into the primary scale pits. oacKwasn is
1^2 (0112B) - Figure VII-17 (Primary)
identical to that of Plant A~2 except that no
This treatment facility is a combination system serving both blooming
f"CtUr;1 mi?1S' althou9h the structural mill was not operating
time °f sampling. Wastewater passes through primary scale pits
*? dlS??argSd t0 a settlin9 cone. The settling cone is
elevated to allow for gravity flow to the deep bed filters. The
nitern9eS?n,nfflUent,.HS dijcha^ed to the deep bed filters and thS
filter effluent is then discharged to a lake. Filter backwash is
discharged back into the primary scale pits. oacKwasn is
Plant ^2 (0946A) - Figure VII-18 (Primary and Section)
The wastewater treatment system for Plant D-2 serves several hot
h«rmi"?im iS including a blooming mill, two merchant bar mills, and a
=a=i millU ThS wastewaters from each of the mills pass through- primary
scale pits and then discharge to the thickener. The bar mill
IKo^nnfAf^H1^' is r?c£cled t0 the P^cess. prior to the thickener!
Also, one of the merchant bar mills' wastewater bypasses the thickener
and combines with the thickener overflow. The thicken!? underflow is
discharged to a blast furnace thickener. The rolling mill"s thi?ken«
overflow is discharged to a central scale pit equipped with oil
Si ? t?" faCil^ieS: The ^stewaters are then dischargll To deep
bed filters. The blast furnace thickener overflow is processed
cya"ide.destruction system and then filtered in the SJme
m *. fllte^in9 system. The filter effluent is. then pumped to a
main plant recycle pumping station where river makeup is added and the
?nt!raelf?nan? ^ recyclfed to the hot forming mills. The regaining
then diSchargSl ^ 0nC°ntaCt blast furnace cooling and
Plant E
- Figure V1I-19 (Section and Pipe and Tube)
Rod mill, bar mill, and seamless tube mill wastewaters are treated by
this combination system. Wastewaters discharge to a primary settlina
3S f ° WhC th
S1X
are
pumped to a clarifier. Clarfer verf l
I*** San* filters- Filter backwash and
taken to settling pits and a lagoon which
143
-------
empties into the main reservoir. The filter effluent is recycled to
only the rod and bar mills after first passing through a cooling
tower. Makeup to the system is provided by a main reservoir which
also accepts any blowdown from the system. The reservoir overflow is
discharged to a receiving stream.
Plant F-2 (0384A) - Figure VII-20 (Section)
Section mill wastewaters first pass through a series of primary and
secondary scale pits which are equipped with oil removal facilities.
Scale pit effluent is pumped to clarifiers for quiescent settling.
Oil skimming is also practiced at the clarifiers. The clarifler
overflow is recycled to the process after first passing through a
two-cell cooling tower. Clarifier underflow is dewatered using vacuum
filters and the filtrate is returned to the clarifiers. The cold well
of the cooling tower provides the point of treatment system blowdown.
Plant G-2 (0640A) - Figure VII-21 (Section)
Wastewaters from the 10" and 12" bar mills first pass through scale
pits. Scale pit effluents are pumped to two settling basins equipped
with waste ejectors and oil skimmers. Overflow from the settling
bisinslTpumped to three wastewater strainers Strai"e*
water is conveyed to a dirty water sump which follows the scale
Strainer effluent is recycled to the process after .first Posing
through a cooling tower. Makeup water from the river is added to the
inlet sump. There is no discharge from this system.
Plant H-2 (0432A) - Figure VII-22 (Section)
Rod mill wastewaters are discharged to a scale pit. The effluent from
the scale pit is pumped to five cyclones which discharge to a
receiving stream. This system is once-through with no recycle.
Plant 1-2 (08560) - Figure VII-23 (Section)
The wastewater treatment system for this plant is a combination system
treating both section mill and pickling wastewaters. Rod mill
wastewater is first sent to a scale pit. The scale pit effluent is
then discharged to a terminal settling lagoon which receives pickling
wastewater as well. All process effluent is discharged to a receiving
stream.
Plant K-2 (0868B) - Figure VII-24 (Flat)
The wastewater treatment system for this operation serves a carbon
steel 160" plate mill. Wastewaters from the 160" plate mill pass
through primary scale pits and are discharged into two secondary scale
pits. The primary scale pits are baffled and have oil removal and
collection facilities. The sludge from the secondary scale pits is
discharged to a thickener and the thickener overflow is returned to
the secondary scale pits. The effluent from these scale pits is
pumped through high rate media filters and then recycled to the plate
144
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mill after first passing through a cooling tower The treatm^nh
system blowdown is discharged to a receiving stream treatment
Plant L^ (0060) -Figure VII-25 (Primary and Flat)
flat Prod"ct rolling mill wastewaters are treated by this
in turn discharge to flocculating clarifiers. The c lar if ier overflow
the filtrate being returned to the flocculator tanks.
Plant ^2 (0384A) - Figure VII-26 (Flat)
with
K«« for this operation treats wastewaters from an 80"
carbon steel combination hot strip and sheet mill. Wastewaters from
to
Plant 1^2 (0396D) - Figure VII-27 (Flat)
as
recycled after first passing through a cooling tower A blowdown frlm
the cooling tower is delivered to the filters. Filtered water is
recycled to the mill roughing and finishing stands A clarifie?
receives the filter backwash. The clarifie? overflS; is returned ?o
fill-^i r/KieVhlle ^ Clarif ier underflow is dewatered by vlcuum
filters. A blowdown is discharged to a POTW.
Plant GG-2 (0240B) - Figure VII-28 (Pipe and Tube)
This plant is a seamless pipe mill producing specialty steel seamier
m reheated filets. This pipe mill practices 100% ?ecyc?e 23
if
pla"t I.I-2 (091 6A) - Figure VI 1-29 (Pipe and Tube)
ni- 111 Producing carbon steel pipe from
butt welded pipe mill mixes noncontact and contact cooling
145
-------
waters and discharges its wastewaters on a once-through basis to a
double compartment scale pit which is equipped with oil skimming
facilities. The scale pit effluent is then pumped to radial, media
type pressure filters. The filtered water is discharged to a final
settling lagoon. The filter backwash is discharged to a clarification
tank where neutralization is provided along with polymer addition.
The clarification tank then discharges back into the scale pits. Tne
filtered effluent is discharged to a receiving stream.
Plant JJ-2 (0728) - Figure VII-30 (Pipe and Tube)
This plant is a butt welded pipe mill producing carbon steel pipe from
skelp. The pipe mill mixes pickling rinse wastewaters with Primary
scale pit effluent and discharges the mixed wastewaters to a settling
lagoon. The lagoon overflow is pumped to a storage tank which
recycles all of the wastewaters to the butt welded pipe mill. Service
makeup water and lime are added to the recycled water. Solids from
the scale pit and lagoon' are landfilled.
Plant KK-2 (0256G) - Figure VII-31 (Pipe and Tube)
This plant is a butt welded pipe mill producing carbon and low alloy
pipe from skelp. This pipe mill provides once-through treatment with
primary and secondary scale pits. The primary scale pit has oil
Skimming facilities and is also equipped for the addition of polymer.
The secondary scale pit discharges to a receiving stream.
Plant Q81 (0176) - Figures VII-32 and VII-33 (Primary and Section)
The wastewater treatment system for this plant provides treatment for
a combination of hot forming mill (primary and section rolling mills),
combination acid pickling, salt bath descaling, wire pickling and
coating, and continuous alkaline cleaning wastewaters.
The wastewaters from the primary and section rolling .mills are
discharged to • an inclined plate separator after passing through
primary scale pits. The overflow from the separator is recycled to
the primary and section rolling mills. The blowdown from the
separator is discharged to a central wastewater treatment system which
also treats the wastewaters described above, Makeup water is added to
the inclined plate separator and section mills as required. It should
be noted that the effluent analytical data presented in this section s
tables represent only the discharge from the separator. These data
thus depict hot forming wastewater treatment only.
Plant 082 (0496) - Figure VII-34 (Primary and Flat)
The wastewater treatment system for this plant serves a combination of
carbon and specialty steel primary (slab) mills and flat
-------
? ? ftock to a 12°" Plate mill which provides a further
or «iinh P ^e KSiZe* , A 14°" P^imary "ill can also roll eithJr
206" plate Sill? * P ^ WhiCh' in tUrn' iS the feed stock for
Wastewaters from the 112" mill and the 120" plate mill pass throuah
Plt? a?d arf dischar9ed into a common senary s?al£
wastewaters from the 140" and the 206" plate mills
scale nit Pr^2r?mSCaJe P^ and subsec*uently to a combined secondary
scale pit. Overflows from the .secondary scale pits are discharaed to
three parallel settling basi-ns. The effluent from the set?ling9
is diSrE »™ iT6* t0 a-Set °f 9ravitV Alters. The filtered •
a ba?kwJ5h dJ?M-reC6iVing St^ea?' Filter ^ckwash is delivered to
Settling basinJ9 °h dischar9es to the three parallel
Plant 083 (0860H) - Figure VII-35 (Primary, Section, and Flat)
The wastewater treatment system for Plant 083 is a central facility
Ti'e !o7eSle?treral ^ f°rfng mills and steelmaking facU it es
U.e., EOF, electric arc furnace). The hot forming mills include
primary section, and plate rolling mills, (blooming- mill structural
a?-drod»1J1>: The blooming milT wast4wIterS "Ire
^^
treatment system and discharges only a blowdown to the
5SiSSnt ^he^comb'n^ milj- -afewate?s discharge to the
station. The combined wastewaters undergo treatment in
clarifie^ effluent is blowndown to a POTW. The
p U"derflow1 is P"mPed to a thickener which, in turn
discharges to a sludge decant tank. After decanting, the sludge is
Plant 087 (0432A), - Figure VII-36 (Section, Flat, and Pipe and Tube)
mill
•
by
K treatment Astern which serves a merchant
milii bloomin9 mill, hot scarfer, and a hot strip
from the various sources first pass through their
^** ^ JquiPPed with ba«l^ and Sil rem^al
it srsss -s~ 2
Plaint 088 (0684A) - Figures VII-37 and VII-38 (Primary
Pipe and Tube)
Section, and
147
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The wastewater treatment system for Plant 088 serves a combination of
hot forming mills and steelmaking facilities (i.e., vacuum degassing,
electric arc furnace). The hot forming mills include P«jary,
section, and seamless pipe and tube operations (blooming mills, three
bar mills, and a rod mill).
The wastewaters from the 32" and 34" bar, blooming, billet, and pipe
and tube mills are pumped to a collection sump after passing through
primary scale pits equipped with oil collection f aeries The
wastewaters are then pumped to deep bed pressure filters. The f liter
effluent is discharged to a pump station from where all of the
wastewaters are recycled to the mills. The steelmaking, vacuum
dlgaSsing, and otherwastewaters are directed to the same pump station
for reuse throughout the plant. Filter backwash is conveyed to
clarifiers after passing through backwash storage and rapid mix tanks.
Other rod mill, bar mill, and seamless tube. finishing mill wastewaters
are also pumped to the filter backwash clarifiers. The clarifier
overflow is conveyed to the recycle pump station for return to the
processes. The clarifier underflow is delivered to a thickener for
further settling. The thickener underflow is dewatered by vacuum
filtration while the thickener effluent is returned to the clarifiers.
Makeup river water is added at the recycle pump house.
Wastewaters from. the 10" rod and 11" bar mills are ^discharged to a
common scale pit and then, to a drag link conveyor. A large Portion of
the drag link conveyor effluent is recycled to the process after first
paSsing through a retention basin. The rest of the drag link conveyor
effluent is pumped to the filter backwash rapid mix tank and
clarifiers. The clarifier overflow is recycled to the various mills.
Clarifier underflow is conveyed to a thickener and is further
dewatered by a vacuum filter. The two systems noted above blow down a
small amount of wastewater (0.5%) to the 14" bar mill water system
described below.
wastewaters from the hot saws, shears, stands, pull rods, and bar
rotators and then recycles these wastewaters .to the Process. The
second set of scale pits accepts bar mill stands effluent and skip
cooling water. A partial recycle is taken from the scale pits back to
the process. The remainder of the scale pit effluent is pumped to a
mix tank which then discharges to a clarifier. A large Potion of the
clarifier effluent is recycled to this bar mill. The remaining
clarifier effluent is discharged to a POTW system. The clarifier
underflow is discharged to a sludge pond.
Plant 281 (0020B) - Figure VII-39 (Flat)
Wastewaters from specialty steel hot strip, blooming and universal
mills are treated in a central treatment system. After first passing
through primary scale pits, the wastewaters are sent to a main
collection sump which discharges into two clarifiers. The clarifier
overflow is pumped to deep bed filters and the filter effluent is
148
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discharged to a receiving stream.
the clarifiers.
The filter backwash is returned to
Plant 282A (0088D) - Figure VII-40 (Primary)
Dimro bloomin9 mil1 at this plant are discharged to a
primary scale pit from which 99 percent is recycled to the mill The
discharge from the scale pit is treated in a central treatment
facility which also treats bar mill wastes and pickle rinse watlrs
Plant 282B (0088D) - Figure VII-41 (Section)
Wastewater from the 22" bar mill are first treated in primarv and
r1?vcledy from* ft*5' ^oximately 99 percent of the was?ewa?e? ?f
recycled from the secondary scale pit to the 22" bar mill The
remaining wastewater is treated in a central treatment facility with
the blooming mill wastes and pickle rinse waters. mity witn
Plant 281 .(0112) - Figure VI 1-42 (Primary and Section)
drha™ millS' (the 18"' 32"' 42"' 48" and combination
discharge to a common secondary scale pit after first oassina
v ^n^duaj Primary scale P^s associated with each Sill
(except the 42" mill). The effluent from the secondary scale pit is
pumped to a deep bed f iltration. system and then discharged^ thS
plant 284 A & B (0112D) - Figure VII-43 (Flat)
and
a
f°r these mills (an 80" hot strip
sving
n H the 80" hot strip mill primary and secondary roughing
stands pass through a primary scale pit. The effluent from the
primary scale pit is recycled to the roughing mill flumes ThI
n?t9 ?L flU s?ale. P^ ^so has an overflow to the finishing scale
pit. The two scale pits are separated by a concrete wall and ar^
equipped with oil baffles and collectors. The overflow ?rom Ihe
finishing scale pit is discharged to the central treatment clarifiers? .
hr.h1-miJ1 wastewaters pass through a primary scale pit,
which also discharges to the clarifiers. Some of the scale pit
mn?y^ed H° the ?late mil1 stands for flume flushing! The
mill also has in-line plate heat treatment facilities in
which reheated plates pass through a quenching st at ion Some of the
quench pit -overflow- is delivered to the central treatment facTlitJ viJ
two sump pump stations on either end of the quench pits. t-lllty via
The central treatment clarifier overflow is discharged to two
twenty-five million gallon terminal lagoons. About 25 percent of the
lagoon effluent is recycled for reuse throughout the plant ThI
remainder of the treated effluent is discharged to a receiving stream
149
-------
Plant 285 A and B (0240A) - Figure VII-44 (Primary and Section)
Wastewaters from the blooming mill and scarfer and the 21"bar mill,
pass through separate primary scale pit systems and then to a central
treatment system which receives wastewater from other mill .sources.
ThTscIle pit system consists of two primary scale pits operating in
ser^Ss which receive wastewater directly from the mill. The effluent
Horn Ihis second pit is pumped along with other "astewaters, to a
Aeries of three lagoons. Twelve percent of the final lagoon ernuent
II diScharged ?o the river and the remainder is recycled for reuse
throughout the plant.
Plant 286A and B (0432C) - Figure VII-45 (Primary and Flat)
The wastewater treatment facility at this plant consists primarily of
mix tanks for the addition of a neutralizing lime slurry, three
ciariKers operating in parallel and recycle. The treatment system
receives wastewaters from the universal slabbing mill, 80 hot strip
receives waste electric are furnace, basic oxygen furnace
furnace reheat and the finishing mill. The universal slabbing mill
discharges wastewater to a scale pit out of which a Portion is
recycled to the mill. The remainder of the scale pit effluent flows
to the mix tanks and clarifiers for further treatment. The 80 hot
strip mill has a similar arrangement.
Plant 287 (0584B) - Figure VII-46 (Flat)
Wastewaters from the 80" hot strip mill are treated in a two celled
roughing pit followed by several lagoons operating in parallel.
Plant 288A and B (0584F) - Figure VII-47 (Primary and Flat)
Wastewaters from the blooming mill at this plant discharge to a scale
nit and then flow to a central hot forming treatment facility. This
?rea?ment system consists of settling basins equipped with oil removal
facilities followed by filters. The discharge from the filter
combines with wastewaters from other operations and then flows to a
lagoon. Associated with the filters are a backwash water basin oil
removal facilities and a thickener which concentrates the sludge
recovered from the backwash basin.
Wastewater from the 54" hot strip mill also discharges to this central
treatment system after first passing through a roughing end and a
finishing end scale pit. Some of the effluent from the finishing end
scale oit is pumped to a hot well which receives indirect cooling
wa?e? as well A portion of the hot well wastewater flows directly to
the lagoons. The remainder is discharged to a sluice way and then to
the roughing end scale pit. This scale pit discharges to the central
treatment system.
150
-------
Plant 289A and B (0684B) - Figure VII-48 (Primary and Flat)
Wastewaters from the 36" blooming mill discharge to primary and
secondary scale pits equipped with oil removal facilities. The
discharge from the secondary scale pit is discharged to a river.
The treatment system for the 56" hot strip mill consists of two
settling basins operating in parallel, followed by a cooling tower and
lagoon. A portion of the effluent from the lagoon is recycled and the
remainder is discharged.
plant 290A §M I (0856R) - Figure VII-49 (Primary and Section)
The wastewater (including surface wastewater) from the primary rolling
mill at this plant is discharged to three scale pits equipped with oil
skimmers. Effluents from the scale pits flow into the river.
The treatment system for the No. 5 bar mill consists of a scale pit
tollowed by a clarif ier and a polymer addition step. Recycle is
provided after the scale pit to provide water for flume flushing. The
flume flush water is then returned to the scale pit. Recycle of the
clarif ier effluent to the bar mill is also practiced.
Plant 291 (0856B) - Figure VII-50 (Primary)
Slab mill wastewaters, including flume' flush and scarfer wastewaters
discharge to a common scale pit and then to a main sump. From the
mai"sumP'., tne wastewater flows to a rapid mix tank where polymer is
added and then to a clarif ier for settling. A portion of the treated
wastewater is recycled from the clarif ier to the flume and scarfer
The remainder passes through pressure filters and a cooling tower
recycling to the slab mi-U.. A small blowdown discharges to the
Plant 292 (0860B) - Figure VII-51 (Flat)
Wastewater from the 84" hot strip mill discharge to three separate
scale pits. Over half the mill effluent flows through the roughing
mill scale pit which empties to the river. The remainder of the mill
effluent passes to the finishing mill scale pit and another scale pit.
A portion of the waste stream which flows to this latter pit is
recycled to the mill. The remainder overflows to the finishing mill
frfj6 Plfc- Effluent from the finishing mill scale pit is pumped to a
filtration plant and is then discharged to the river. A thickener
treats the backwash from the filtration plant.
Plant 293 A^
Pipe and Tube)
and C (0865N) - Figure VII-52 (Primary, Section and
Wastewaters from a primary rolling mill, bar mills, and seamless tube
mills are treated in a central lagoon system. Each of the mills first
discharges to a scale pit before the wastewater proceeds to the
151
-------
central treatment lagoon. Approximately half of the primary mill
scale pit effluent is recycled to the sluicing operation.
Plant 294 A and B (0920N) - Figure VII-53 (Primary and Flat)
Wastewaters from a blooming mill and a hot strip mill are treated by
two separate treatment systems at this plant. The 44" blooming mill
wastes pass through primary scale pits and a secondary scale pit.
Over 90 percent is recycled to the mill and the remainder is filtered
prior to discharge. The 80" hot strip mill uses three scale pits to
treat its wastewaters. One pit is a recirculant pit which returns
most of the wastewater it receives to the mill for further use.
Approximately 25 percent is discharged as a blowdown. The effluent
from the scale pit designated as pit no. 2 is filtered prior to
discharge. Wastewater from scale pit no. 1 is discharged directly.
Plant 295 (0942A) - Figure VII-54 (Pipe and Tube)
Wastewaters from the No. 1 and No. 2 seamless mills at this plant
discharge to a primary scale pit which empties to the river.
Impact of Intake Water Quality
Where the mass loading of a limited pollutant in the make-up water to
a process is small in relation to the raw waste loading of these
pollutants, the impact of make-up water quality on wastewater
treatment system performance is not significant, and, in many cases,
is not measurable. In these instances, the Agency has determined that
the respective effluent limitations and standards should be developed
and applied on a gross basis.
Tables VII-12 through VII-15 presents the results of the Agency's
analysis of the impact of make-up water quality on hot forming raw
wastewaters. The data demonstrate that the impact of make-up water
quality is not significant. Accordingly, the Agency developed the
limitations and standards on a gross basis and has determined they
should be applied on a gross basis. However, the Agency is aware that
plants located on inland streams take in high loadings of river silt
and sediment during periods of high surface water runoff. Some of
this river silt and sediment can pass through properly designed and
operated treatment systems. The Agency believes that allowances for
these situations should be made in accordance with 40 CFR 122.63(h).
The Agency does not believe that the occurrence of such conditions can
or should be used as a reason to defer or cancel the installation of
the model wastewater treatment facilities, or equivalent, necessary to
achieve the applicable limitations and standards.
152
-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
Symbols
A.
B.
Operating Modes
1. OT
2. Rt,s,n
P
F
S
FC
BC
VS
FH
REt,n
Once-Through
Recycle, where t » type waste
s * stream recycled
n » Z recycled
t: U "Untreated
T » Treated
n
4.
BDn
Process Wastewater Z of raw waste flow
Flume Only Z of raw waste flow
Flume and Sprays % of raw waste flow
Final Cooler Z of FC flow
Barometric Cond. Z of BC flow
Abs. Vent Scrub. % of VS flow
Fume Hood Scrub. Z of FH flow
Reuse, where t » type
n m Z of raw waste flow
t: U « before treatment
T - after treatment
Slowdown, where n.» discharge as Z of
raw waste flow
Control Technology
10. DI Deionization
11.. SR
12. CC
13. DR
Disposal Methods
20. H
21. DW
Spray/Fog Rinse
Countercurrent Rinse
Drag-out Recovery
Haul Off-Site
Deep Well Injection
153
-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 2
Disposal Methods (eont.)
22. Qt,d
Coke Quenching, where t « type
d « discharge as %
of makeup
t: DW • Dirty Water
CW • Clean Water
23. EME Evaporation, Multiple Effect
24. ES Evaporation on Slag
25. EVC Evaporation, Vapor Compression Distillation
Treatment Technology
30. SC Segregated Collection
31. E Equalization/Blending
32. Scr Screening
33. OB Oil Collecting Baffle
34. SS Surface Skimming (oil, etc.)
35. PSP Primary Scale Pit
36. SSP Secondary Scale Pit
37. EB Emulsion Breaking
38. A Acidification
39. AO Air Oxidation
40. GF Gas Flotation
41. M Mixing
42. Nt Neutralization, where t - type
t: L m Lime
C ™ Caustic
A ™ Acid
W * Wastes
0 m Other, footnote
154
-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 3
D.
Treatment Technology (eont.)
43. FLt
44. CY
44a. DT
45. CL
46. T
47. TP
48. SLn
49. BL
50. VF
51. Ft,m,h
Flocculation, where t * type
t: L « Lime
A « Alum
P « Polymer
M • Magnetic
0 « Other, footnote
Cyclone/Centrifuge/Classifier
Drag Tank
Clarifier
Thickener
Tube/Plate Settler
Settling Lagoon, where n « days of retention
time
Bottom Liner
Vacuum Filtration (of e.g., CL, T> or TP
underflows)
Filtration, where t * type
m = media
h » head
m h
D » Deep Bed
F - Flat Bed
52. CLt
53. CO
S - Sand G « Gravity
0 = Other, P « Pressure
footnote
Chlorination, where t • type
t: A - Alkaline
B «• Breakpoint
Chemical Oxidation (other than CLA or CLB)
155
-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 4
D.
Treatment Technology (eont.)
54. BOt
55. CR
56. DP
57. ASt
58. APt
59. DSt
60. CT
61. AR
62. AU
63. ACt
64. IX
65. RO
66. D
Biological Oxidation, where t » type
t: An « Activated Sludge
n "No. of Stages
T " Trickling Filter
B » Biodisc
0 ° Other, footnote
Chemical Reduction (e.g., chromium)
Dephenolizer
Ammonia Stripping, where t - type
t: F « Free
L * Lime
C * Caustic
Ammonia Product, where t « type
t: S " Sulfate
N - Nitric Acid
A » Anhydrous
P • Phosphate
H » Hydroxide
0 • Other, footnote
Desulfurization, where t - type
t: Q « Qualifying
N m Nonqualifying
Cooling Tower
Acid Regeneration
Acid Recovery and Reuse
Activated Carbon, where t * type
t: P
G
Powdered
Granular
Ion Exchange
Reverse Osmosis
Distillation
156
-------
TABLE VII-1
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 5
D.
Treatment Technology (cont.)
67. AA1
68. OZ
69. UV
70. CNTt,n
71. On
72. SB
73. AE
74. PS
Activated Alumina
Osonation
. Ultraviolet Radiation
Central Treatment, where t « type
n • process flow as
% of total flow
t: 1 » Same Subcats.
2 » Similar Subcats.
3 » Synergistic Subcats.
4 - Cooling Water
5 * Incompatible Subcats,
Other, where n « Footnote number
Settling Basin
Aeration
Precipitation with Sulfide
157
-------
TABLE VII-2
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORHIHG; PRIMARY HO/SCARFIHG
CD
Raw Hastewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ton):
0020B
E
6
2740
mB/1 lbs/1000 Ibs
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ton):
C&TT
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
110
28
7.0 -
*
*
ND
0.19
0.04
1.26
0.32
7.5
0.00
0.00
ND
0.0022
0.00046
0020B
(•
E
— )5
2740
PSP,
mg/1
— V.? i , , ,
13.0
2.0
5.8
*
*
ND
*
0.03
CL,FP,OT
lbs/1000 Ibs
0.16
0.017
- 6.6
0.00
0.00
ND
0.00
0.00034
(1) Data not available
(2) Sample includes wastewater from
* : Concentration
is <0.
**: Less than 0.0000005
NA: Not Available
ND: Not Detected
- : Insufficient
010 mg/1
lbs/1000 Ibs
(1)
0256KU;0
K
12
5600
•E/l lbs/1000 Ibs
NA
NA
NA
NA
•NA
NA
NA
NA
0256K
K
12
800
PSP,SS,RUP 85.7
mg/1 lbs/1000 Ibs
NA
NA
NA
NA
NA
NA
NA
NA
684D 0176
*«»
3420
mg/1
48
12.8
7.0
0.54
*
ND
0.17
0.08
lbs/1000 Ibs
0.68
0.18
- 7.6
0.0077
0.00
ND
0.0024
0.0011
0684D
Q
5(2)
3420
PSP,SS,OT
mg/1
29
4.0
7.
*
0.02
ND
0.63
0.07
lbs/1000 Ibs
0.41
0.057
2 - 7.6
0.00
0.00028
ND
0.0090
0.0010
0860H
081
B
760
mg/1 lbs/1000 Ibs
21
165
7.9
0.13
0.97
0.81
0;55
0.14
0.067
0.52
- 8.1
0.00041
0.0031
0.0026
0.0017
0.00044
0176
PSP
mg/1
18
10
7.8
0.08
0.76
0.32
0.48
0.10
081
E
51
,TP,RTP 93
lbs/1000 Ibs
0.0038
0.0021
- 8.1
0.000020
0.00016
0.00007
0.00010
0.00002
06S4B
083
E
320
mg/1
244
35
7.
0.12
0.53
0.04
0.09
0.1
lbs/1000 Ibs
0.33
0.047
0 - 7.1
0.00016
0.00071
0.000053
0.00012
0.00013
OttbUH
(-
PSP,
mg/1
9
10
7.
0.13
0.04
<0.02
0.07
hot forming operations other than primary. Data is therefore not
083
;) B
12
CL,CT,RTP 96
lbs/1000 Ibs
0.00039
0.00076
1 - 7.6
0.0000011
0.0000056
**
<0. 0000015
**
289A
- Average
1050 2320
mg/1 lbs/1000 Ibs mg/1 lbs/1000 Ibs
NA - 106
NA - 60
NA 7.0 -
NA - 0.20
NA - 0.38
NA - 0.21
NA - 0.25
NA , - 0.09
0684B
289A
B
1050
PSP,SSP,SS,OT
mg/1 lbs/1000 Ibs
31 0.136
NA - .
7.5 - 8.0
0.004 0.000018
0.036 0.000158
0.17 0.000744
ND ND
0.31 0.00136
0.58
0.27
8.1
0.00021
0.00095
0.00066
0.0016
0.00053
included in the average.
or Not Analyzed
data
-------
TABLE VII-3
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING! PRIMARY W/SCARFING
Raw Wastewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ton):
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal /ton):
C&TT
mg/1
100
52
NA
NA
NA
NA
NA
0248B
D
9
535
lbs/1000 Ibs
0.22
0.12
6.4
-
-
-
-
—
0248B
D
9
535
PSP,SS,OT
°248A °*3?Ji 0112B(01&02)
H (1) M"} A-?
2480 4490
rag/1 lbs/1000 Ibs rae/1 lbs/1000 Ibs me/1
158 1.63 - - 100
1.7 0.018 17
5.8 - 6.2
ND ND - - NA
0.01 0.00010 - - NA
ND ND - NA
ND ND - NA
0.03 0.00031 - - NA
4
890
lbs/1000 Ibs
7.6
_
_
_
_
-
0248A 0432J 0112B(01&02)
H M"> A-2
9(3) y
2479 110
2(2)
520
PSP, OT PSP,SSP,ROP 98 PSP, Settling Cone,
rag/1
61
150
NA
NA
NA
NA
NA
01128(03)
B-2
3
510
lbs/1000 Ibs
0.13
0.32
8.0 - 8.3
_
_.
_
-
01128(03)
B-2
PSP,
FP,RT?41.6
2
510
Settling Cone
FP.OT
rag/1
49
19
7.
NA
NA
NA
NA
NA
0946A
H— t
11 Z
700
lbs/1000 Ibs
0.14
0.055
8 - 8.2
-
0060
(Z)
1
610
me/1 Ibs /1 000 Ihs
16
12
NA
NA
NA
NA
0946A
D-2
1+2
\e.
7.6 - 8.1
-
0060
L-2
,(2)
* 1+2+4+5'"
210
, PSP.T,
RET
FD,RTP 30,
70
10.3
PSP.FLL,
FLP.CL,
CT,RTP98.3
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
rag/1
100
52
NA
NA
NA
NA
NA
lbs/1000 Ibs
0.22
0.12
6.4
-
-
-
-
-
rag/1 lbs/1000 Ibs ne/1 lbs/1000 Ibs me/1
35 - 1.6
27 - 1.7
5.8 - 6.3 7.
0.24 - NA
0.04 - NA
NA - NA
0.15 - NA
0.02 - NA
lbs/1000 Ibs
6 - 8.0
_
_
- _
-
rag/1
3.0
2.2
NA
NA
NA
NA
NA
lbs/1000 Iba
0.0064
0.0047
7.7 - 7.8
_
_
_
-
rag/1
23
8.3
8
NA
NA
NA
NA
NA
lbs/1000 Ibs
0.27
0.046
.0 - 8.2
-
RET 1.1
mg/1 Iba/!0n0 Iha
4.9
7.9
NA
NA
NA
NA
NA
8.6 - 8.7
_
-------
TABLE VII-3
SUMMARY OF AHALYTICAL DATA FROM SAMPLED PLAHTS
HOT FORMING: PRIHARY W/SCARFIHG
PAGE 2
CTi
O
Raw Wastewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
C&TT
Suspended Solids
Oil and Grease
pll ( un i ts )
Chromium
Copper
Lead
Nickel
Zinc
rag/1
81
63
0.04
0.14
0.4
0.51
0.04
0496
082(140")
Gl + "l .
2
170
lbs/1000 Ibs
0.057
0.045
7.7 - 8.9
0.000028
0.000099
0.00028
0.00036
0.000028
.,
0496
082(140")
1 1 - A
2
170
PSP.SSP, Settling
mg/1
1
12
ND
0.04
ND
0.05
0.03
Basin, FG,OT
lbs/1000 Ibs
0.00071
0.0085
7.4 - 7.5
ND
0.00003
ND
0.00004
0.00002
f «
0496 0684H^'
082(140", 206") 088
H2 + J2
2 A
460
mg/1
62
3.5
7.
.0.06
0.2
0.12
0.32
0.055
lba/1000 Ibs mg/1
0.12 24
0.0067 6.0
7-8.9 7
0.00012 0.02
0.00038 0.21
0.0023 0.3
0.00061 0.12
0.00011 0.05
0496
082 (140", 206")
P,
Z
460
o f u
1700
lbs/1000 Ibs
0.17
0.043
.9
0.00014
0.0015
0.0021
0.00085
0.00035
0684H
088
(B+C/H)P
5
PSP.SSP, Settling PSP.FP, RTF 99.7
mg/1
1
9
0.04
0.04
ND
ND
ND
Basin, FG,OT
lbs/1000 Ibs mg/1
0.0019 2
0.017 4
7.4 7.
0.00008 ND
0.00008 ND
ND ND
ND 0.01
ND 0.01
Ibs /1 000 Ibs
0.000038
0.00018
6 - 7.8
ND
ND
ND
**
**
mg/1
NA
NA
0088D
282A
B
5050
lbs/1000 Ibs
_
-
ng/1
54
NA
NA
1.5
2.4
0.088
1.1
0.4
PSP
mg/1
85
NA
0.27
0.46
0.007
0.19
0.12
0.032
0.051
0.0019
0.023
0.0084
0088D
282A
C
25
,SSP,RUP 99.5
Ibs/ 1000 Ibs
0.00886
-
NA
0.000028
0.000048
0.000001
0.000020
0.000012
0.16
0.26
0.29
0.44
0.15
(6)
0240Avt"
285A
2320
lbs/1000 Ibs
0.53
-
7.9 - 8.1
0.0016
0.0025
0.0028
0.0043
0.0015
0240A
285A
D
266
PSP,SSP,SS,SL,
mg/1
13
NA
7.
0.012
0.043
0.14
0.073
0.16
RTF 88.5
lbs/1000 Ibs
0.014
-
8 - 8.0
0.000013
0.000048
0.00016
0.000081
0.00018
0432C
286A
2190
mg/1
NA
NA
0.094
0.26
0.12
0.065
5.6
\j-t-
PSP,
lbs/1000 Ibs
_
-
NA
0.00086
0.0024
0.0011
0.00059
0.051
0432C
286A
c )K
D+E+H+I+J+A
301
SS,FLL,FLP,NW,
CL,VF,CT,R1JP 47.7,
mg/1
NA
NA
0.005
0.031
ND
0.007
0.56
RTF 38.6
lbs/1000 Ibs
_
-
NA
0.000006
0.000039
ND
0.000009
0.00070
-------
cr>
TABLE VII-3
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING: PRIMARY W/SCAHFING
PAGE 3
Raw Wasteuaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
C&TT
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
mg/1
62
NA
ND
0584F
2 88 A
B
820
lbs/1000 Ibs
0.21
-
NA
ND
0.072 0.00025
0.011
ND
0.17
PSP
mg/1
2.6
NA
ND
ND
ND
ND
0.046
0.000038
ND
0.00058
0584F
288A
( B )E
820
,SSP,SS,FG
T,OT
lbs/1000 Ibs
0.0089
-
7.3 - 7.4
ND
ND
ND
ND
0.00016
0856R
290A
B
6400
mg/1 lbs/1000 Ibs
55
NA
1.47
NA
7.5 - 7.7
0.027
0.04
ND
ND
0.065
0.00072
0.0011
ND
ND
0.0017
mg/l
160
NA
7.
ND
0.13
0.30
0.11
0.06
0856R
290A
B
6400
PSP,SS,OT
mg/1 Ibs/ 1000 Ibs
55
NA
1.47
-
7.5 - 7.7
0.027
0.04
ND
ND
0.065
0.00072
0.0011
ND
ND
0.0017
0856B
291
A
2340
lbs/1000 Ibs
1.56
-
0 - 7.3
ND
0.0013
0.0029
0.0011
0.00059
0856B
291
C-D
24
PSP.CL.FP.CT,
mg/1
8.5
NA
7.
ND
ND
ND
0.045
0.018
lbs/1000 Ibs
0.00085
_•
3 - 7.4
ND
ND
ND
0.000004
0.000002
mg/1
68
NA
0.032
0.041
0.12
0.079
0.074
PSP
mg/1
13
NA
0.001
0.008
0.009
0.035
0.15
0856N
293A
B
2250
Ibs /I 000 Ibs
0.64
NA
0.00030
0.00038
0.0011
0.00074
0.00069
0856N
293A
E<2)
1040
, SS,SL,RUP
53.8
lbs/1000 Ibs
0.056
NA'
0.000004
0.000035
0.000039
0.00015
0.00065
mg/1
94
NA
ND
0.13
ND
ND
0.072
0920N
294A
C
4310
Ibs/ 1000 Ibs
1.69
7.1
ND
0.0023
ND
ND
0.0013
0920N
294A
E
510
Average
2300
mg/1 lbs/1000 Ibs
71 0.66
42 0.087
5.8-8.9
0.16 0.0030
0.32 0.0053
0.15 0.0010
0.23 0.0027
0.56 0.0055
PSP.SSP.FP.RTP 88
mg/1
7.0
NA
ND
ND
ND
ND
0.03
lbs/1000 Iba
0.015
7.1
ND
ND
ND
ND
0.000064
-------
TABLE Vll-3
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING: PRIMARY H/SCARFINC
PAGE 4
(1) Represents mill effluent rather than primary scale pit effluent.
(2) Includes wasteuatera from iron and steel operations other than primary.
Data therefore, is not included in the average.
(3) Sample contains non contact cooling water and thus ia not a representative
sample of the contact water process.
(A) The lbs/1000 Ibs value cannot be derived directly from the concentrations
and flow rate shown. See the Section VII text for further explanation.
(5) Visited earlier as Plant C-2, which is not shown here.
(6) Visited earlier as Plant R, which is not shown here
NA: Not Available
HD: Not Detectable
- : Insufficient data
**: Less than 0.0000005 lbs/1000 Ibs
CTi
to
-------
TABLE VII-4
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING; SECTION - CARBON
Raw Wastewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
£J Flow (gal/ton):
CO C&TT
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
0112B
A4?»
600
mg/1 lbs/1000 Ibs
100
17
7.6
NA
NA
NA
NA
NA
0112B
A-2
2(1)
350
PSP, Settling Cone,
FP.RTP 41.6
mg/1 lbs/1000 Ibs
1.6
1.7 ' -
7.5 - 8.0
NA
NA
NA
NA
NA
mg
37
20
NA
NA
NA
NA
NA
0291C
D-2(No. 5 Bar)
5
9560
11 lbs/1000 Ibs
1.48
0.80
8.0 - 8.1
_
-
-
- •
0291C
D-2(No. 5 Bar)
6+7
8040
PSP,T,SSP,SS,FP,
m&
23
RTF 15.9
11 lbs/1000 Ibs
0.38
8.3 0.15
8.0 - 8.2
NA
NA
NA
NA
NA
„
-
-
-
-
mg/1
50
17
8.
NA
NA
NA
NA
NA
0291C
D-2(No. 2
4
9740
lbs/1000 Ibs
2.03
0.69
0 - 8.1
„
-
_
-
-
0291C
D-2(No. 2 Bar)
PSP
mg/1
23
8.3
8.
NA
NA
NA
NA
NA
6+7
8190
,SSP,SS,FP,
RTP 15.9
lbs/1000 Ibs
0.39
0.16
0 - 8.2
_
_
_
.
- • -
Bar)
mg/1
45
18
NA
NA
NA
NA
NA
0291C
0196A
D-2(No. 6 Bar) E-2 (Rod)
3 •>
8400
lbs/1000 Ibs
1.58
0.63
8.0 - 8.1
_
_
„
_
-
0291C
D-2(No. 6 Bar)
PSP
mg/1
~
NA
NA
NA
NA
NA
(3)
\ J t
0
,RUP 100
lbs/1000 Ibs
0.0
0.0
0.0
0.0
0.0
0.0
0.0
8820
mg/1 lbs/1000 Ibs
73 2.68
21 0.77
8.2 - 8.3
NA
NA
NA
NA
NA
0196A
E-2(Rod)
/ 2
3150
PSP,CL,FS,CT,RTP 64.3
mg/1 Ibs /I OOP Ibs
4.9 0.090
10.5 0.35
8.3
NA
NA
NA
NA
NA
mg/1
34
4.5
8.2
NA
NA
NA
NA
NA
PSP
mg/1
— °?
4.9
10.5
NA
NA
NA
NA
NA
0196A
E-2(Bar)
3
3170
lbs/1000 Ibs
0.45
0.06
- 8.3
"
-
0196A
E-2(Bar)
3
1130
,CL,FS,CT,RTP 64.4
lbs/1000 Ibs
0.030
0.027
8.3
_
_
-------
TABLE VII-4
SUMMARY OF ANALYTICAL DATA FROH SAMPLED PLANTS
HOT FORMING: SECTION - CARBON
PAGE 2
Raw Hastewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ton):
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ton):
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
0384A(06)
F-2
2
1910
mg/1 lbs/1000 Ibs
41 0.33
5.9 0.047
7.7
HA
NA
NA
NA
NA
0384A(06)
F-2
3
140
C&TTPSP,SSP,SS,CL,
FLL,FLP,NW,VF,
CT,RTP 92
mg/1 lbs/1000 Ibs
29 0.017
8.3 0.0048
7.8 - 8.5
NA
NA
NA
NA
NA
0640A(01,02)
mg/1
68
2.7
7
NA
NA
NA
NA
NA
G-2
1
14,020
lbs/1000 Ibs
3.98
0.16
.4 - 8.0
_
-
-
-
., . -.
0640A(01,02)
G-2
2
0
0432A(04)
H-2
3
6590
mg/1 lbs/1000 Ibs
96 2.64
19 0.52
6.6 - 6.8
NA
NA
NA
NA
NA
0432A(04)
H-2
2
6590
PSP,SS,SL,FD,CT, PSP,CY,OT
mg/1
47
2.3 .
7
NA
NA
NA
NA
NA
RTF 100
lbs/1000 Ibs
0.00
0.00
.4 - 8.1
0.00
0.00
0.00
0,00 .
0.00
mg/1 lbs/1000 Ibs
71 1.95
17.8 0.49
6.8 - 7.0
NA
NA
NA
NA
NA
0860H(02)
083(34")
G
4720
mg/1 lbs/1000 Ibs
35 0.69
47 0.93
6.9
0.11 0.022
0.09 0.018
<0.05 <0. 00098
<0.02 <0. 00039
0.08 0.0016
0860H(02)
083(34")
(G/0)B
Q180
PSP,CL,CT,T,RTP 96
mg/1 lbs/1000 Ibs
9 0.00082
10 0.015
7.1 - 7.6
0.13 0.000015
0.04 0.000016
<0.05 <0. 0000032
<0.02 <0. 0000049
0.07 0.000021
0860H(03)
083(Rod)
K
6930
mg/1 lbs/1000 Ibs
259 7.48
38 1.10
7.3 - 7.5
0.04 0.0013
0.14 0.0040
ND ND
0.07 0.0020
0.08 0.0023
0860H(03)
083 Rod
R
90
PSP,CL,RTP 99
mg/1 lbs/1000 Ibs
62 0.023
30 0.011
7.4
<0.03 <0. 000011
0.07 0.000026
<0.05 ^0.000019
<0.02 <0. 0000075
0.06 0.000023
-------
TABLE VII-4
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING: SECTION - CARBON
PAGE 3
(Ti
(J\
Raw Wastewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ton):
0112
283
B
1850
mg/1 lbs/1000 Ibs
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ton):
C&TT
NA
NA
NA
0.006
0.078
0.035
0.033
0.30
0112
in
1850
-
0.000046
0.00060
0.00027
0.00025
0.0023
)
PSP.SSP.SS,
mg/1 Ibs/lOOO Ibs
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
85
NA
NA
0.27
0.46
0.007
0.19
0.12
0.66
0.0021
0.0035
0.000054
0.0015
0.00093
-
0856R
290B
C
950
mg/1
15
NA
8.
0.027
0.23
0.067
0.040
0.018
lbs/1000 Ibs
0.059
6 - 8.7
0.00011
0.00091
0.00027
0.00016
0.000071
0856R
290B
D
190
0856N
293B
C
2980
mg/1
59
NA
0.018
0.012
0.004
0.050
0.11
lbs/1000 Ibs
0.73
NA
0.00022
0.00015
0.000050
0..00062
0.0014
0856N
2980
0684H(06,07)
T
3400
mg/1
lbs/1000 Ibs
52 0.74
33 0.47
7.3 - 7.7
ND
0.07
ND
0.09
0.78
ND
0.00099
ND
0.0013
0.011
0684H(02)
088(34")
F
580
ng/1
24
4
7.
ND
0.08
ND
0.08
0.06
0684H(06,07)
S
10.2
PSP,SS,FLP,CL.,. PSP,SS,SL,OT
RTP&RUP 79.8, FPW
mg/1
7.7
NA
8.
ND
0.15
0.017
ND
0.012
lbs/1000 Ibs
0.0061
9 - 9.1
ND
0.00012
0.000014
ND
0.000010
mg/1 lbs/1000 Ibs
13 0.
NA
NA
0.001
0.008
0.009
0.035
0.15
0.
0.
0.
0.
0.
16
000012
00010
00011
00044
0019
PSP
VF,
mg/1
19
16
8
ND
ND
ND
0.02
0.05
,SSP,SB,CL,T,
FLP.RTP 99.7
lbs/1000 Ibs
0.00081
0.00068
.5 - 9.5
ND
ND
ND
**
**
PSP,
mg/1
2
4
7.
ND
ND
ND
0.01
0.01
Ibs/lOOO Ibs
0.058
0.097
.6 - 7.9
ND
0.00019
ND
0.00019
0.00015
0684H(02)
088(34")
(F/M)P
1.7
FD,CL,T,VF, .
RTP 99.7
lbs/1000 lbs(
0.000012
0.000033
6 - 7.8
ND
ND
ND
**
**
-------
CTi
CTi
TABLE VII-4
SUMMARY OF AHALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING: SECTION - CARBON
PACE 4
Raw Wastewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ton):
Suspended Solids
Oil and Grease
pll (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
C&TT
Suspended Solids
Oil and Grease
pll (units)
Chromium
Copper
Lead
Nickel
Zinc
068411(01)
088(36")
D+E
4710
nR/l lbs/1000 Iba
22 0.43
2 0.039
7.9 - 8.0
ND ND
0.13 0.0026
ND ND
0.05 0.00098
0.04 0.00079
0684 H( 01)
088(36")
(D+E/M)P
14
PSP,FD,CL,T,VF,
RTP 99.7
me/1 lbs/1000 Ibs
2 0.000090
4 0.00016
7.6 - 7.8
ND ND
ND ND
ND ND
0.01 **
0.01 **
068411(03)
088(32")
G
950
me/1 lbs/1000 Iba
30 0.12
12 0.048
7.7 - 7.9
ND ND
0.08 0.00032
ND ND
0.06 0.00024
0.06 0.00024
0684H(03)
088(32")
(G/M)P
2.8
PSP,FD,CL,T,VF,
RTP 99.7
mg/1 lbs/1000 Ibs
2 0.000025
4 0.00018
7.6 - 7.8
ND ND
ND ND
ND ND
0.01 **
0.01 **
0684H(05)
088(14")
X+Z.
35lO
UK/1 Ibs /I 000 Ibs
47 0.69
25 0.37
7.0 - 7.4
0.009 0.00013
0.08 0.0012
0.06 0.00088
0.016 0.0023
0.99 0.014
0684H(05)
088( 14")
AC
10
PSP,CT,CL,RUP 44,
RTP 55.7
mc/1 Ibs /I 000 Ibs
87 0.0036
15 0.000011
7.5
0.12 0.000005
0.27 0.000011
0.09 0.000004
0.47 0.000020
2.2 0.000092
Average
5160
me/1 lbs/1000 Ibs
58 1.54
18 0.45
6.6 - 8.7
0.021 0.0024
0.099 0.0029
0.017 0.00015
0.063 0.00080
0.25 0.0034
-------
TABLE VI1-4
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING: SECTION - CARBON
PAGE 5
(ill £?nt?Kn1,!!a!!teMater £r°m iron and "eel operations other than section. .Data therefore is not included in the average.
(2) The lbs/1000 Ibs value cannot be derived directly from the concentrations and flowrate shown. See the Section VII
text for further explanation.
(3) No sample of the scale pit effluent could be obtained.
(4) This component was not on stream during the sampling program.
- : Insufficient data
NA: Not Available "
ND: Not Detected
**: Less than 0.0000005 lbs/1000 Ibs
-------
TABLE VII-5
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING: SECTION - SPECIALTY
00
Raw Waatewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
C&TT
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
HB/l
3.3
1.9
*
*
ND
0.14
0.02
0424(01-03)
5260
lbs/1000 Ibs
0.072
0.042
7.0
0.00
0.00
ND
0.0031
0.00044
0424(01-03)
C
(g^g)!
910
Cooling Reservoir,
ng/l
45
6.1
0.04
0.02
ND
0.03
0.02
RET 82.7
lbs/1000 Ibs
0.0038
0.045
6.1 - 6.2
0.00
0.00
ND
0.000025
0.000038
0248 A&B
H
13
4210
•g/l
54
9.2
6
*
*
ND
*
0.02
lbs/1000 Ibs
0.95
0.16
.0 - 6.3
0.00
0.00
ND
0.00
0.00035
0248 A&B
H
13
4210
PSP.OT
mg/l
54
9.2
Ibs /1 000 Ibs
0.95
0.16
0256K
K
10
1470
0432J
H
6
670
»g/l lbs/1000 Ibs
93
4.7
7.2 -
*
0.05
ND
0.82
0.02
0256K
K
10
1470
PSP.OT
0.57
0.029
7.5
0.00
0.00031
ND
.0050
0.00012
mg/1 lbs/1000 Ibs
93
4.7
6.0 - 6.3 7.2 -
*
*
ND
*
0.02
0.00
0.00
ND
0.00
0.00035
*
0.05
ND
0.82
0.02
0.57
0.029
7.5
0.00
0.00031
ND
0.0050
0.00012
HB/l
54
9.9
0.07
0.04
NA
0.11
0.012
PSP,
mg/l
35
27
0.24
0.04
NA
0.15
0.02
lbs/1000 Ibs
0.15
0.028
6.3 - 6.5
0.00020
0.00011
NA
0.00031
0.000034
0432J
H
?(3)
99
SSP.RUP 85.2
lbs/1000 Ibs
_
—
5.8 - 6.3
-
-
-
-
-
08560
1-2
2
5010
mg/l lbs/1000 Ibs
170 3.55
7.4 0.15
7.6 - 7.7
NA
NA
NA
NA
NA
08560
1-2
(z!^5^
5010
PSP.SL.OT
mg/l lbs/1000 Ibs
39
14
6.7
NA
NA
NA
NA
NA
-------
TABLE VII-5
SUMMARY OF AUALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING! SECTION - SPECIALTY
PAGE 2
Raw Wastewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
Suspended Solids
Oil and Grease
pll (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
C&TT
Suspended Solids
Oil and Grease
pH (units)
Chromium
Coppe r
Lead
Nickel
Zinc
0176(01-03)
mg/1
14
12
0.02
0.60
0.22
0.50
0.04
081
C
3570
lbs/1000 Ibs
0.21
0.18
7.8 - 8.1
0.00030
0.0089
0.0033
0.0074
0.00060
0176(01-03)
081
(B/B+OE
250
SSP,SS,TP,
mg/1
18
10
0.080
0.76
0.32
0.48
0.10
RTP 93
lbs/1000 Ibs'
0.014
0.0024
7.8 - 8.1
0.000048
0.00064
0.00020
0.00047
0.000062
0432A(02)
087(14"Mill)
me/1
62
4
ND
0.03
0.49
ND
0.14
D
6340
lbs/1000 Ibs
1.64
0.11
I.I - 7.4
ND
0.00079
0.013
ND
0.0037
mg/1
NA
NA
0.12
0.085
ND
0.088
0.036
0432A(02)
087(14"Mill)
(
D
D+C+EJF
6340
CT,CL,FLL,VF,SS,
mg/1
38
4
7
0.014
0.004
ND
ND
0.12
FLM.OT
lbs/1000 Ibs
1.05
0.079
.4 - 7.6
0.00037
0.00011
ND
ND
0.0032
-g/i
85
NA
0088D
282B
B
6450
lbs/1000 Ibs
NA
0.0032
0.0023
ND
0.0024
0.00097
0088D
282B
C
48
PSP,SSP,SS,
RUP 99.3
lbs/1000 Ibs
0.017
NA
0.27
0.46
0.007
0.19
0.12
0.000054
0.000092
0.000001
0.000038
0.000024
mg/1
30
NA
8
0.046
0.068
0.13
0.26
0.13
0240A
285B
C
2600
lbs/1000 Ibs
0.33
.0 - 8.1
0.00050
0.00074
0.0014
0.0028
0.0014
0240A
285B
D
inn
Average
3950
rag/1 lbs/1000 Ibs
60 0.93
7.0 0.10
6.0 - 8.1
0.0036 0.00053
0.11 0.0016
0.12 0.0025
0.24 0.0026
0.052 0.00095
PSP,SSP,SS,SL,
RTP 88.5
mg/1
13
NA
7.
0.012
0.043
0.14
0.073
0.16
lbs/1000 Ibs
0.016
,8 - 8.0
0.000015
0.000053
0.00017
0.000091
0.00020
-------
TABLE VII-5
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORHIHG! SECTIOH - SPECIALTY
PACE 3
(1) Represents mill effluent rather than a primary scale pit effluent. Data is not included in the average.
(2) The lbs/1000 Ibu values cannot be directly derived fron the flow rate and concentrations shown.
Refer to Section VII text for further explanation.
(3) Insufficient data to allow calculation of a proportioned lbs/1000 Ibs.
- : Insufficient data
* : Less than 0.010 rag/1
NA: Not Available
ND: Not Detected . • .
-J
O
-------
TABLE VII-6
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PUNTS
HOT FORMING; FLAT - HOT STRIP AHD SHEET
Raw Wastewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
Suspended Solids
Oil and Grease
pll (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
C&TT
Suspended Solids
Oil and Grease
pll (units)
Chromium
Copper
Lead
Nickel
Zinc
024 8B
D
6-9
3310
Bg/1 Ibs /I OOP Ibs
4.9 0.68
14 0.19
6.3
NA
NA
NA
NA
NA
0248B
D
6-9
3310
or
mg/1 lbs/1000 Ibs
49 0.68
14 0.19
6.3
NA
NA
NA
NA
NA
0176
,j(l)
12,800
mg/1 lbs/1000 Ibs mf>/l
35 1.87 16
0.7 0.037 12
7.6 - 8.1 7
0.003 0.00016 NA
0.01 0.00053 NA
ND ND NA
0.32 0.017 NA
0.02 0.0011 NA
0176
11
12,800
PSP, RUP 98 PSP,
: VF,
mg/1 Ibs /I OOP Ibs mgA
35 1.87 5
0.7 0.037 7.9
7.6 - 8.1 8.
0.003 0.00016 NA
0.01 0.00053 NA
ND ND NA
0.32 0.017 NA
0.02 0.0011 NA
0060
L-2
1
4520
lbs/1000 Ibs
0.30
0.23
.6 - 8.1
-
0060
76
FLL,FL01,CL,
CT,RTP 97,
RET 1
Ibs /I OOP Ibs
0.0016
0.0025
6 - 8.7
-
BE/1
25
6.4
NA
NA
NA
NA
NA
0384A
M-2
2+3
8440
lbs/1000 Ibs
0.88
0.23
8.4
-
0384
M-2
n
8,440
PSP,CL,VF,OT
mg/1
16
6.9
8
NA
NA
NA
NA
NA
Ibs /I OOP Ibs
0.56
0.24
.4 - 8.5
-
mg/ 1
54
31
7.
NA
NA
NA
NA
NA
0396D
N-2
6
7270
lbs/1000 Ibs
1.64
0.94
3 - 7.5
-
A0396D
PSP
FS
ng/1
39
61
7,
NA
NA
NA
NA
NA
N-2
7
0
,CT,VF,CL,
,RTP 100
lbs/1000 Ibs
0.00
0.00
.4 - 7.7
0.00
0.00
0.00
0.00
0.00
-------
-J
to
TABLE VII-6
SUHHARY OF ANALYTICAL DATA FROM SAHPtED PLAHTS
HOT FORMING: FLAT - HOT STRIP AND SHEET
PAGE 2
Raw Haateuaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
Suspended Solids
Oil and Grease
pll (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
C&TT
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
0432A
087
C
4670
me/1 Ihn/innn.lhn
74
6
1.44
0.12
7.4 - 7.6
0.01
0.031
0.33
ND
0.034
0.00019
0.00060
0.0064
ND
0.00066
0432A
087
c
(C+D+E)F
4670
FLP,FLH,CL,SS,
SCR.VF.OT
mg/1
38
4
Ibs /I 000 Ibs*
0.73
0.088
7.4 - 7.6
0.014 0.00019
0.004 0.000075
ND ND
ND ND
0.12 0.0014
0020B(2)
281
B
5690
rap/1 lbs/1000 Ibs
112
NA
6.7 -
0.6
0.083
ND
0.61
0.080
0020B
281
n(4)
C
2.66
7.1
0.014
0.0020
ND
0.014
0.0019
5690
PSP,CL,FP,OT
* «K/1 lbs/1000 Ibs
4.7
NA
7.3 -
ND
ND
ND
ND
0.008
0.11
-~
7.5
ND
ND
ND
ND
0.0019
01120(02)
284A
B
6110
BR/l lbs/1000 Ibs
63
NA
NA
0.004
0.025
ND
ND
0.026
0112D
284A
D(4)
1.61
0.00010
0.00064
ND
ND
0.00066
2470
PSP.FLP.SL,
RUP 46.2,
RTF 13.4
mg/1 Ibs /I 000 Ibs
1.7
NA
NA
0.004
0.004
0.017
ND
0.035
0.018
"
0.000041
0.000041
0.00018
ND
0.00036
0432C
286B
D+E
3500
•e/1 lbs/1000 Ibs
NA
NA
NA
0.60
0.042
0.020
0.30
0.18
0432C
286B
-
0.0080
0.00061
0.00029
0.0044
0.0026
E )K
380
PSP,SS,FLL,FLP,NW,
CL,VF,CT,RUP 13.0,
RTP 76
.1
og/1 lbs/1000 Ibs
NA
0.069
0.011
ND
0.070
0.038
—
0584 B
287
B
4150
•g/1 lbs/1000 Ibs
48
NA
0.044
0.17
ND
ND
0.26
0584B
287
C
4150
PSP,SS,
0.83
NA
0.00076
0.00029
ND
ND
0.00045
SL,SS,OT
mg/1 Ibs /I 000 Ibs
18
Hi
O.J1
NA
0.00011
0.000017
ND
0.00011
0.000060
0.007
0.008
ND
ND
0.012
0.00012
0.00014
ND
ND
0.00021
-------
TABLE VII-6
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLAHTS
HOT FORMING: FLAT - HOT STRIP AND SHEET
PAGE 3
Raw Wastewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
0584F
288B
C+D
3160
mg/1 lbs/1000 Ibs
Suspended Solids
Oil and Grease
pi! (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal /ton):
C&TT
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
64
NA
0.84
NA
NA
0.006 0.000079
0.022 0.00029
ND ND
ND ND
0.16 0.0021
0584F
288B
(-£±5_)E
B+C+D'
3160
PSP,SSP,SS,FG,
mg/1
2.7
NA
ND
ND
ND
ND
0.043
i,ui
Ibs II OOP Ibs
0.036
7.3 - 7.4
ND
ND
ND
ND
0.00057
0684B
289B
6660
0860B(5)
292
B+C
3280
"ig/1 lbs/1000 Iba mg/1 lbs/1000 Ibs
56 1.56
NA
7.3 - 7.9
0.005 0.00014
0.024 0.00067
0.039 0.0011
ND ND
0.13 0.0036
0684B
289B
E
890
PSP,SS,CT,SL,
RUP 39.0, RTP
47.6
mg/1 lbs/1000 Ibs
32 0.12
NA
7.5 - 7.8
ND ND
0.021 0.000078
0.033 0.00012
0.017 0.000063
0.10 0.00037
40
MA
fin
NA
0.005
0.007
ND
ND
0.024
PSP.SS
0.55
0.000068
0.000096
ND
ND
0.00033
0860B
292
B+D(6)
3280
,SSP,T,VF,
FP
mg/1 Ibs /I OOP Ibs
1.7
HA
[fn
NA
ND
ND
ND
ND
0.012
0.20
0.000027
0.000041
ND
ND
0.00027
mg/1
62
NA
7
ND
0.013
KD
ND
0.060
PSP,
HE/1
5
NA
7
ND
ND
ND
ND
0.050
0920N
294B
F+G+I
8200"'
Ibs /I OOP Ibs
2.1
.3
ND
0.00044
ND
ND
0.0021
0920N
294B
F+H+I(6)
4860(7)
FP.RTP 10.1,
RUP 30.6
lbs/1000 Ibs
0.42
.1
ND
ND
ND
ND
0.0011
Average
5300
mg/1 lbs/1000 jbs
55 1.26
14 0.34
6.3 - 8.4
0.14 0.0027
0.029 0.00063
0.043 0.00087
0.10 0.0020
0.080 0.0016
-------
TABLE VII-6
SUMMARY OF AHALTTICAL DATA FROH SAMPLED PLAMTS
HOT FORMING: FLAT - HOT STRIP AND SHEET
PAGE 4
(1) Sample includes uaatewater from hot forming operations other than hot strip and sheet. Data is therefore
not included in the average.
(2) Visited earlier as Plant E which is not shown here.
(3) The lbs/1000 Ibs values cannot be directly derived from the flourate and concentrations shown.
Refer to Section VII text for further explanation.
(4) Contains uastewater fron iron and steel operations other than flat.
(5) Visited earlier as Plant J-2 which is not shown here.
(6) The effluent discharge is a combination of treated and untreated wastewater. The effluent quality
presented here reflects the'treated portion, but effluent loads represent the total discharge.
(7) The gallons per ton flow is based on 1976 tonnage.
- : Insufficient data
NA: Hot Available
ND: Hot Detected
H
-------
TABLE VII-7
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING; FLAT - PLATE. CARBON
Raw Wastewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
Suspended Solids
Oil and Grease
pll (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
C&TT:
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Nickel
Zinc
mg/1
61
11
NA
NA
NA
NA
NA
0868B
K-2
1
3690
lbs/1000 tbs
0.94
0.17
6.9 - 7.2
-
0868B
K-2
2
100
PSP,SSP,T,
Filter.CT.RTP 97.3
mg/l
5.3
6.3
NA
NA
NA
NA
NA
ibs/1000 Ibs
0.0022
0.0026
7.0 - 7.3
_
-
0496(01)
082(140")
H-A
mg/1
120
lbs/1000 Ibs
65 0.033
34 0.017
7.7 - 8.9
0.04
0.15
0.26
0.33
0.03
0.000020
0.000075
0.00013
0.00017
0.000015
0496(01)
082(140")
,
H+
PSP,
ng/1
1
10
7
0.02
0.04
ND
0.03
0.02
H »/.,.»'
IY1. T ' ^ P— AJ
D-frJ,
1
120
SSP.DR.FG.OT
Ibs /I OOP Iba
0.000088
0.0088
.4
0.000056
0.000016
ND
0.000016
0.00
HE/1
0496(03404)
082(112/120")
I\_A
IT^A
870
lbs/1000 Ibs
22 0.080
8 0.029
7.2
0.0
0.18
0.04
0.11
0.05
0.00
0.00065
0.00015
0.00040
0.00018
0496(03404)
082(112"/120")
*
PSP,
se/i
i
10
7
0.02
0.04
ND
0.03
0.02
D ;
D+H-f J
870
SSP,DR,FG,OT
lbs/1000 Iba
0.0064
0.064
.4
0.00
0.00012
ND
0.000034
0.00
mg/1
O —
48
4
0.04
0.31
0.05
0.12
0.06
0496(02)
082(140"/206")
J--A
lbs/1000 Ibs
0.042
0.0035
7.4
0.000035
0.00027
0.000044
0.00011
0.000053
0496(02)
082(140"/206")
, J2
2
7ln
PSP,SSP,DR,FG,OT
mg/1
1
10
0.02
0.04
ND
0.03
0.02
lbs/1000 Ibs
0.0021
0.018
7.4
0.000061
0,000028
ND
0,000004
0.000004
-------
TABLE VII-7
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING: FLAT - PLATE, CARBON
PAGE 2
H
-------
TABLE VtI-7
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING: FLAT - PLATE, CARBON
PAGE 3
3
(3) The
- : Insufficient data
ND: Not Detected
NA: Not Available
the
Va*v}aite* earli« « Plant 086 which is not shown here.
contains wastewater from iron and steel operations other than flat.
-J
-J
-------
TABLE VII-8
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLAHTS
HOT FORHIHC: FLAT - PLATE. SPECIALTY
Raw Waatewatera
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
H C&TT
03
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
(1) The lbs/1000
085611
F
8
4290
BE/1 lbs/1000 Iba
75 1.34
32 0.57
6.6 - 6.7
ND ND
ND ND
214 3.83
0.04 0.00072
0.03 0.00054
0856H
F
8
4290
PSP.OT
DE/1 lbs/1000 Ibs
75 1.34
32 0.57
6.6 - 6.7
ND ND
ND ND
214 3.83
0.04 0.00072
0.03 0.00054
Iba value cannot be
0496(01)
082(140")
G-A
140
ng/l lbs/1000 Ibs
110 0.064
60 0.035
7.8
0.07 0.000041
0.18 0.00011
0.47 0.00027
0.94 0.00055
0.05 0.000029
0496(01)
082^140")
(>,.«., ) (0-A)
PSP,SSP,DR,FG,OT
•E/l lbs/1000 lbs(1)
1 0.0085
13 0.076
7.5
ND ND
0.05 **
ND ND
0.04 0.000013
ND ND
derived directly from
0496(03504)
082(112/120")
C-A
2650
•E/l lbs/1000 Ibi
31 0.34
6 0.066
7.5
0.12 0.0013
0.15 0.0017
ND ND
0.28 0.0031
0.04 0.00044
0496(03&04)
08g(112"/120")
*C+G+H W~*'
PSP,SSP,DR,FG,OT
Bg/l lbs/1000 Ibs
1 0.018
13 0.23
7.5
ND ND
0.05 **
ND ND
0.04 0.00018
ND ND
Average
2360
ng/1 lbs/1000 lb»
72 0.58
33 0.22
6.6 - 7.8
0.063 0.00045
0.11 0.00060
71 1.28
0.42 0.0015
0.04 0.00034
the flowrate and concentration shown.
Refer to Section VII text for further explanation.
ND: Not Detected
**: Less than 0.
0000005 lbs/1000 Ibs
-------
TABLE VII-9
SUMMARY OF ANALYTICAL DATA FROM SAMPLED PLANTS
HOT FORMING; PIPE AND TUBE
Raw Wastewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
Suspended Solids
Oil and Grease
pll (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
C&TT:
Suspended Solids
Oil and Grease
pll (units)
Chromium
Copper
Lead
Nickel
Zinc
0196A
E-2
1
12,800
me/1 lba/1000 Ibs
39 2.08
2Q 1.07
8.2
HA
NA
HA
NA -
NA
0196A
E-2
(1/1+2+3)5
4570
PSP,SS,SSP,SS,SL,
CL,FP,CT,RTP 64
mg/1 Iba/iOOO Ibs(1)
10 0.14
9.8 0.22
8.3
NA
NA
NA
NA
NA
0240B
GG-2
1
1,700
0916A
II-2
1-5
2760
0728
JJ-2
2
2290
lbs/1000 Ibs me/1 lbs/1000 Ib8(1)gg/l lbs/1000 Ibs
44
8.3
NA
NA
NA
NA
NA
PSP,
0.31
0.059
7.0 - 7.8
_
-
-
-
—
0240B
GG-2
1
0
Oil Separator,
202
4.3
NA
NA
NA
NA
NA
2.97
0.066
7.0
_
_
_
—
-
091 6A
II-2
(1-5/1) 4
PSP
SL,RUP 100
•8/1
44
8.3
NA
NA
NA
NA
NA
. lbs/1000 Iba
0.00
0.00
7.0 - 7.8
0.00
0.00
0.00
0.00
0.00
SB/I
34
2.0
NA
NA
NA
HA
NA
2760
,SS,FP,SL,OT
lbs/1000 Ibs
0.50
0.026
7.7
_
_
_
-
120
12
NA
NA
NA
NA
NA
1.15
0.11
6.8 - 6.9
NA
NA
NA
NA
NA
0728
JJ-2
1
0
PSP,SL,RTP &
ng/1
20
4.5
NA
NA
NA
NA
NA
RET 100
Ibs /I 000 Ibs
0.00
0.00
7.1 - 7.4
0.00
0.00
0.00
6.00
0.00
-------
TABLE VII-9
SUMMARY OF ANALYTICAL DATA FROM SAHPIBD PLAHTS
HOT FORHIHG: PIPE & TUBE
PAGE 2
co
o
Raw Wastewaters
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
Effluents
Reference Code:
Plant Code:
Sampling Points:
Flow (gal/ ton):
C&TT:
Suspended Solids
Oil and Grease
pH (units)
Chromium
Copper
Lead
Nickel
Zinc
0256G
KK-2
I
520
me/1 lbs/1000 Ibs
120 0.26
6.7 0.015
6.8 - 7.1
NA NA
NA NA
NA NA
NA NA
NA NA
0256G
KK-2
2
520
PSP,SS,SSP,OT,
me/1 lbs/1000 Ibs
116 0.25
7 0.015
6.8 - 7.4
,NA
NA
NA
NA -
NA
0432A
087
E
8080
Be/1 lbs/1000 Iba
66 2.22
5 0.17
7.1 - 7.4
ND ND
0.045 0.0015
0.5 0.017
0.26 0.0088
ND ND
0432A
087
(E7lfcT5)F
8080
CNT,FLP,FLM,CL,
SS,SCR,VF,OT
BB/1 lbs/1000 lbs(1)
38 1.42
4 0.13
7.4 - 7.6
0.014 0.00
0.004 0.000022
-
-
0.123 0.00
068411
088
I+J+K+L
7010
me/1 lbs/1000 Ibs
34 0.99
7.9 0.23
7.2 - 7.8
0.0 0.00
0.071 0.0021
0.028 0.00082
0.08 0.0023
0.057 0.0017
0684H
088
(I+J+K+L/H) P
21
FP,VF,FLL,FLP,CT,
CL.T.RTP 99.7
me/1 lbs/1000 Ibs
2 0.00021
4 0.00087
7.6 - 7.8
ND ND
ND ND
ND ND
0.01 Neg.
0.01 Neg.
0856N
293C
D
2140
Be/1 lbs/1000 Ibs
19 0.17
NA
NA
0.002 0.000018
0.01 0.000090
0.008 0.000072
0.036 0.00032
0.12 0.0011
0856N
293C
E<2)
2140
PSP,SS,SL,OT
me/1 lbs/1000 Ibs
13 0.12
NA
NA
0.001 0.000009
0.008 0.000072
0.009 0.000081
0.035 0.00031
0.15 0.0013
094 8A
295
C
5620
Be/1 lbs/1000 Ibs
82 1.96
NA
7.3 - 7.5
0.046 0.0011
0.13 0.0031
0.11 0.0026
0.022 0.00053
0.36 0.0086
0948A
295
C
5620
PSP.SS.CT
me/1 lbs/1000 Ibs
82 1.96
NA
7.3 - 7.5
0.046 0.0011
0.13 0.0030
0.11 0.0026
0.022 "0.00052
0.36 0.0084
Average
4770
ne/1 lbs/1000 Ibs
81 1.35
9.2 0.25
6.8 - 8.2
0.012 0.00028
0.064 0.0017
0.16 0.0051
0.10 0.0030
0.13 0.0029
(1) The lbs/1000 Ibs values cannot be derived directly from the flowrate and concentrations shown.
Refer to Section VII text for further explanation.
(2) ' The sample contains wastewater from hot forming operations other than pipe and tube.
NA: Not Available
ND: Not Detected
- : Insufficient data
-------
CO
TABLE VII-10
SUMMARY OF LONG-TERM DATA
HOT FORMING SUBCATEGORY
Plant
Code
0112B
0112C-011
0112C-122
0112C-334
0112C-617
0684H
0684F
0320
0584A
0584 B
0856N
Total
No. of
Observations
87
580
496
415
399
40
78
151
101
98
101
Suspended
Average
10.6
8.9
13.3
2.3
4.8
6.0
22.2
15.8
25.4
24.6
32.1
Solids (ms/l)
Maximum
24.4
44.0
63.4
23.5
33.8
21.0
60.0
39.0
55.0
50.0
114.0
S tandard
Deviation
3.9
7.0
12.4
3.0
5.5
5.5
13.7
7.4
9.1
8.6
21.6
Oil and Creaae. (mo/1\
No. of
Observations
87
690
684
727
647
27
79
35
98
58
103
Average
1.1
6.7
2.0
1.3
1.3
3.4
9.6
0.1
5.9
8.4
7.0
Maximum
3.8
47.1
20.3
12.2
7.9
20.0
27.0
0.3
20.6
29.0
20.3
S tandard
Deviation
0.6
6.5
2.2
1.4
1.3
4.0
4.3
0.06
4.3
4.2
2.7
Principle Treatment
Component
Fil tration
Fil tration
Filtration
Filtration
Filtration
Filtration
Filtration, Lagoon
Lagoons
Settling Basin
Lagoons
Settling Basin
Note:
Additional details on long-term data analysis are provided in Volume I.
-------
TABLE VII-11
D-DCP SCALE AND OILS GENERATION DATA
HOT FORMING SUBCATEGORY
Subcategory
Primary
Section
Flat
Pipe & Tube
AVERAGE
0868A
0320
0864A
0432J
0920A
0460A
0440A
0112B
0068B
0136B
0088A
0136B
0672B
0672B
0684H
0860H
0612
0060
0176
0432C
0448A
0448A
0684B
0684F
0684V
0920N
0240B
0652A
0728
Suspended
Pounds of Scale
Per Ton
lode of Production
50-75
47
47
r 23
i 42
t 36
k. • • 41 '
j NA
j 60
5 40
i. 30
J NA
3 50
5 50
a 26
a 20
36
20
NA
C 23
A 46
A NA( .
R 12
F ^^1?
V 2
N 32
B 40
A 50
82
41.1(1)
Solids
% of
Production
2.5-3.75
2.35
2.35
1.15
2.1
1.8
2.05
NA
3.0
2.0
1.5
NA
2.5
2.5
1.3
1.0
1.8
1.0
NA
1.15
2.3
oVn
°:84u)
0.05U'
1.6
2.0
2.6
4.1
2.05%(1)
Say: 2.1%
Oils and Greases
Gallons of oils
Per Ton
of Production
0.14
NA
0.126
0.15
Negligible
NA
NA
NA
NA
0(2)
NA
0.45
Unknown
NA
NA
0.01'
0.22
,(2)
NA
Unknown
NA
NA
0..05
0.01
NA
(2)
(2)
0.23
(2)
Summary;
Suspended Solids
Mills without scarfers: 2.1%, 42 Ibs/ton
Mills with scarfers : 4.2%, 84 Ibs/ton
Oils and Greases
Based on oils with densities 85% that of water
0.23 gal/ton, 1.6 Ib/ton
(1) The data from those mills reporting a solids generation rate less than 1% (less than
20 Ib/ton) were not included in the average as these values were considered to be
(2) Thoileneration values less than 0.1 gal/ton were not included in the average as
these values were considered to be atypically low.
NA: Not Available.
182
-------
TABLE VI1-12
NET CONCENTRATION AND LOAD ANALYSIS
HOT FORMING - PRIMARY OPERATION
Make-up Water
Hot Forming
Primary
Model Size: 4,770 TPD
< Raw Wastewater
oo
OJ
1,090 GPT x 4,770 TPD = 5.2 MGD
2,780 GPT x 4,770 TPD = 13.3 MGD
Regulated Pollutants
Oil & Grease
Total Suspended Solids
M9 Chromium
122 Lead
128 Zinc
n
aKe-up
Cone. (mE/1)
Min.
3.0
2.0
<0.005
<0.005
<0.020
Max.
15
346
0.080
0.17
0.68
J^yg.
10
49
0.007
0.029
0.16
Avg. Load
(Ibs/day)
433.7
2,125
0.30
1.26
6.94
Ra
Avg. Cone.
(mg/1)
67
2,550
2.0
5.6
3.3
w Waste
Avg. Load
(Ibs/day)
7,431.8
282,851
221.8
621.2
366.0
Make-up as a
% of
Raw Haste Load
5.84
0.75
0.35
0.21
1.90
-------
TABLE VII-13
NET CONCENTRATION AND LOAD ANALYSIS
HOT FORMING - SECTION OPERATIONS
Make-up Water
Hot Forming
Section
Model Size: 2,760 TPD
Raw Wastewater
2,150 GPT x 2,760 TPD = 5.9 MGD
4,600 GPT x 2,760 TPD = 12.7 MGD
CO
Regulated Pollutants
Oil & Grease
Total Suspended Solids
119 Chromium
122 Lead
128 Zinc
Make-up
Cone, (mg/1)
Min.
2.0
3.0
<0.006
<0.005
<0.020
Max.
15
69
0.028
1.0
0.37
Avg.
5.0
36
0.018
0.070
0.14
Avg. Load
(Ibs/day)
246.01
1,771
0.89
3.44
6.89
Raw Waste
Avg. Cone.
(mg/1)
44
1,150
0.51
3.2
4.4
Avg. Load
(Ibs/day)
4,660
121,806
54.02
338.9
466.0
Make-up as a
% of
Raw Waste Load
5.28
1.45
1.65
1.01
1.48
-------
TABLE VII-14
co
Make-up Hater
NET CONCENTRATION AND LOAD ANALYSIS
HOT FORMING - FLAT OPERATIONS
_ .>»
Hot Forming
Flat
Model Size: 6,360 TPD
Raw Wastewater
2,180 GPT x 6,360 TPD = 13.9 MGD
5,320 GPT x 6,360 TPD = 33.8 MGD
Regulated Pollutants
Oil & Grease
Total Suspended Solids
119 Chromium
122 Lead
128 Zinc
Cone, (mg/1)
Min.
2.0
1.0
^0.010
<0.030
0.005
Max.
15
346
0.280
1.0
0.37
Avg •
7
25
0.012
0.033
0.095
Avg. Load
(Ibs/day)
811.48
2,898
1.39
3.83
11.01
Avg , Cone .
(mg/1)
45
1,180
1.8
1.8
1.4
Avg. Load
(Ibs/day)
12,685
332,633
507.4
507.4
394.7
Make-up as a
% of
Raw Waste Load
6.40
0.87
0.27
0.75
2.79
-------
I
TABLE VII-15
UET CONCENTRATION AND LOAD ANALYSIS
HOT FORMING - PIPE & TUBE OPERATIONS
Make-up Water
Hot Forming
Pipe & Tube
Model Size: 890 TPD
.Raw Wastewater
1,270 GPT x 890 TPD = 1.1 MGD
5,520 GPT x 890 TPD = 4.9 MGD
H
03
•CTi
Regulated Pollutants
Oil & Grease
Total Suspended Solids
119 Chromium
122 Lead
128 Zinc
Mm.
2.0
12
<0.010
<0.046
<0.106
Make-up
Cone, (mg/1)
Max.
5.0
69
0.28
1.00
0.57
0.049
0.19
0.33
Avg. Load
(Ibs/day)
27.52
357.8
0.45
1.74
3.03
Raw Haste
Avg. Co'nc.
(mg/1)
35
910
0.20
2.1
1.7
Avg. Load
(Ibs/day)
1,430
37,188
8.17
85.82
69.47
Make-up as a
% of
Raw Waste Load
1.92
0.96
5.51
2.03
4.36
-------
PROCESS: HOT FORMING (BAR MILL)
PLANT: C
PRODUCTION: 26.3 metric tons steel/day
(29 tons steel/day)
SURFACE
WATER
18.8 I/sec
(299 gpm)
CO
6.7 I/sec
(106 gpm)
BAR
MILLS
OVERFLOW
TO RIVER
COOLING
RESERVOIR
I
26.2 I/sec
(416 gpm)
125 I/sec
(1993 gpm)
I
OTHER
PROCESSES
126.4 I/sec
(2004 gpm)
SURFACE
OIL
RECYCLED
TO OTHER
PROCESSES
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTION)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn. 3/6/79
FIGURE
-------
PROCESS: Hot Forming-Universal Mill
PLANT; D
PRODUCTION"
2231 l/kkg
(535 gal/ton)
PROCESS.
WATER
H
CD
00
UNIVERSAL MILL
SCALE PIT
2231 l/kkg
(535 gal/Ion)
DISCHARGE
TO RIVER
SURFACE
OIL
A
SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING-PRIMARY
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dm. 3/2/79
FIGURE 301-2
-------
PROCESS: HOT FORMING (HOT STRIP)
PLANT: D
PRODUCTION:
UNIVERSAL
MILL
13,819 l/kkg
(3314 gal/ton)
00
PROCESS
WATER
HOT
STRIP
MILL
DISCHARGE
TO RIVER
ENVIRONMENTAL. PROTECTION' AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (FLAT)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwa3/23/7!
t=t
FIGURE
-------
HOT STRIP
MILL
605.6 I/sec
(9600 gpm)
A
UNTREATED
RIVER WATER
283.9 I/sec (4500 gpm)
COLLECTION SUMP
PROCESS: Hot Forming - Blooming a Universal Mills
PLANT!E
PRODUCTION: 2144.1 metric tons steel/day
(2364 tons steel/day)
[xj
\
II
1
'
CLARIFIE
R
-
1
CLARIFIER
*l DEEP BED FILTER
DEEP BED FILTER
889.5 I/sec
(14,100 gpm)
/\ SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING- PRIMARY
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 3/2/7 9
FIGURE ZLT-4
-------
PROCESS:. HOT FORMING - PLATE MILL
PLANT; F
PRODUCTION: 478.9 METRIC TONS STEEL/DAY
(528 TONS STEEL/DAY)
SERVICE WATER/
REHEAT FURNACES
COOLING
WATER
PLATE MILL
446.9 I/sec
(7084 gpm)
744 I/sec
(11,806 gpm)
297.9 I/sec
(4722 gpm)
/^SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (FLAT)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn.3/22/7'
t=t
FIGURE 1ZE-5
-------
FURNACE COOLING WATER'
GLOOMING MILL
-2756 l/kkg
(661 gal/ton)
SCARFER'
PROCESS: Hot Forming - Blooming Mill
PLANT: H
PRODUCTION:
SCALE PIT
-7581 l/kkg
(1818 gal/Ion)
/\ SAMPLING POINTS
ENVIRONTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING-PRIMARY
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 3/2/79
FIGURE YLI-6
-------
PROCESS: HOT FORMING-MERCHANT MILL
PLANT: H
PRODUCTION:
SERVICE WATER
MERCHANT MILL
17528 l/kkg
(4210 gal/ton)
/^SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTION)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 3/6
FIGURE 21-7
-------
PROCESS: HOT FORMING (BLOOMING MILL)
PLANT: K
PRODUCTION 163.3 metric tons steel/day
(180 tons steel/day)
63 I/sec
(100 gpm)
RECYCLED
PLANT
WATER
BLOOMING
MILL
37.9 I/sec
(600 gpm)
44.2 I/sec
(700 gpm)
DISCHARGE
TO RIVER
SURFACE
OIL
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING .(PRIMARY)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn.3/2/79J
FIGURE 1ZLI-8
-------
PROCESS: HOT FORMING (BAR MILLS)
PLANT: K
PRODUCTION 45.4 metric tons steel/day
(50 tons steel/day) :
MINOR
RECYCLE
<£>
RECYCLED
PLANT
WATER
BAR
MILLS
, DISCHARGE
*TO RIVER
3.2 I/sec
(51 gpm)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTION)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn. 3/6/79
FIGURE3ZE-9
-------
MUNICIPAL /
WATER
1.3 I/sec
v (20 gpm)
PROCESS: HOT FORMING (BLOOMING MILL)
PLANT: M
PRODUCTION: 895.2 metric tons steel/day
(987 tons steel/doy)
~1
HOT pcnvoi en
SCARFER ^ i TO PROCESS
10.1 I/sec BILLET AND
17.7 I/sec
\ (280 gpm)
\
MUNICIPAL
WATER
Dl f\f\
k* i ktr*
BLOUmmu
Ml
1
LL
1
1
Ubu gpm; BAR MILLS 126.2
(2000 gpm)
134.4 I/sec
(2130 gpm)
I i
SCALE , SUMP SPRAY
PIT / PIT I POND
/ 1
/ 1
RECYCLE i
~~ 165.3
/ 18.9 I/sac /TV
(300 gpm) | 37.2 I/sec '
1(590 gpm) 15.8 I/sec
™ (250 gpm)
I/sec (2620 gpm) T0
SANITARY
,,_,.,_„ COOLING
SEWER WATER
ENVIRONMENTAL PROTECTION-AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (PRIMARY)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
)wn.3/2/
1 I I
FIGURE 331-10
-------
5.05 I/sec
PURCHASED (8° 9Pm)
WATER
BILLET MILL
PROCESSl HOT FORMING (BILLET MILL)
PLANT: M
PRODUCTION: 740.1 metric Ions steel/day
(816 tons steel/day)
18.9 I/sec
^ (300 gpm)
BLOOMING MILL
BAR MILL
RECYCLED
TO OTHER
PROCESS
\
18.9 l/s
(300 gi
24.0 I/sec
(380 gpm)
HOT SAW
sc
>m)
9.5 I/sec
(ISO gpm)
1 19.9 I/sec
(1900 gpm) _
-
PUMP
PIT
.U
1
PUMP
14.5 I/
(230 g
[
PIT
DISCh
sec |
pm)
37.2 I/sec
(590 gpm)
1ARGE
i
i
126 l/s
(2000
SPRAY POND
NON CONTACT —
COOLING WATER
15.75 I/sec (250 gpm)
\
/^SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 3/6/79
FIGURE 3ZE-II
-------
PROCESS: HOT FORMING-SECTION a FLAT
PLANT: o
PRODUCTION: 203.2 METRIC TONS STEEL/DAY
(224 TONS STEEL/DAY)
3.2 I/sec (50 gptn)
SERVICE WATER
CD
ROD AND STRIP
MILLS
126.2 I/sec
(2000 gpm)
3.2 I/sec
(50 gpm)
123.0 I/sec (1950 gpm)
COMBINED
WATER
TREATMENT
PLANT
RECYCLED
SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTIONS FLAT)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn.3/26/7"
td:
FIGURE3ni-l2
-------
PROCESS: HOT FORMING (BLOOMING MILLS!
PLANT: Q
PRODUCTION: SSI.-e metric tons steel/day
(421 tons steel /day)
OTHER
PROCESSES
63.1 I/sec
(1000 gpm)
SO
SURFACE
OIL
214.5 I/sec
(3400 gpm)
A
OTHER
PROCESSES
277.6 I/sec
(4400 gpm)
DISCHARGE
TO RIVER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (PRrMARY)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 3/2/7'
1
FIGURE W-13
-------
PROCESS-- HOT FORMING (BAR MILLS)
PLANT: Q
PRODUCTION 1443.0 metric Ions steel/day
(1591 tons steel/day)
OTHER
PROCESSES
124.1 I/sec
(1967 gpm)
to
o
o
WELL
WATER
BAR
MILLS
277.6 I/sec
(4400 gprn)
SURFACE
OIL
DISCHARGE
TO RIVER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTION)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 3/7/79
FIGURE 3IEI4
-------
PROCESS! HOT FORMING-BAR MILLS
PLANT! R
PRODUCTION'. 328 metric Jons steel/day
(362 tons steel/day)
MISC. PROCESS
WATER
BLOOMING
MILL
RIVER
WATER
PLANT
OUTFALL
^SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTION)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 3/8/7'
1
FIGURE 3ZE-I5-
-------
SCALE PITS
(PRIMARY
CLARIFICATION)
MILL COMPLEX
(BLOOMING, BILLET
AND RAIL MILLS)
-Raw untreated process effluent
«.. ., ,,,„. ,„ , {fee l/sec(2620 gpm)Flume & sprays
214 I/sec (3385 gpm) Primary '
143 I/sec (2260 gpm) Sect Ion
140 l/sec(765 gpm )Avg. scarfing flow
Partially clarified
PROCESS: HOT FORMING-PRIMARY a SECTION
PLANT: A-Z
PRODUCTION 4951 METRIC TONS
OF STEEL/DAY
(5458 TONS OF STEEL/DAY)
PRIMARY;
4951 METRIC TONS
OF STEEL/DAY
(5458 TONS OF STEEL/DAY)
SECTION
-A*
z
.Plant intake
water
Influent
(lake water)
Typical for all seven(7)
3.66 Meters (12 ft. dla)
4.42 Meters(l4.5ft. high)
Media-supporting gravel and sand
Downflow rate 6.79 l/sec^sq.m.
(10 gpm/ftn
to
o
to
Recycle 146-150 I/sec.
(2320-2380 gpm)
SETTLING CONE
SECONDARY CLARIFICATION)
2,157,450 LITERS,VOLUME
(570,000 GALS.)
DEEP
BED
FILTER
DEEP
BED
FILTER
DEEP
BED
FILTER
DEEP
BED
FILTER
Sludge to
scale pit
— Backwash water to
scale pit
209 I/sec.
, ,J[3008 gprnj^ ^_
To lake
Treatment plant
effluent
^SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
DW8.6/3AM
REV.I-Z/24/76
FIGURE 3ZEH6
-------
SCALE PITS
(PRIMARY
CLARIFICATION)
to
o
w
MILL COMPLEX
BLOOMING AND STRUCTURAL
MILLS
(STRUCTURAL NOT OPERATING
DURING SAMPLING PERIODS)
-Raw process wastewatere
from primary operations
172 I/sec (2730 gpm)
PROCESS: HOT FORMING-PRIMARY
PLANT: e-2
PRODUCTION: 6967 METRIC TONS OF STEEL/
DAY
(7680 TONS OF STEEL/DAY)
/—Influent (lake water)
I—&k fl « Plant intake water
SETTLING CONE
(SECONDARY CLARIFICATION)
2,002,265 LITERS,VOLUME
(529,000 GALS.)
Typical for all five (5)
3.66 Meters dia. (12 ft.)
4.42 Meters high (14.5 ft.)
Media'. Supporting gravel
and sand
Downflow rate: 6.79 l/sec./sq.m
(10 gpm/ft?)
Treatment plant effluent
Backwash water to
scale pit
ASAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
PWQJ/20/74
REV2-2-2476
REV.I'2/20/76
FIGURE 3ZE-I7
-------
to
o
No. 5
MERCHANT BAR MILL
No. 2
MERCHANT BAR MILL
No. 6
BAR MILL
284 I/sec
(4,500i
309 I/sec
(4,900 gpm) 4p
Other Contact
Voter Uses
i 1
BLOOMING MILL
A 173
***
SCALE PIT
59 I/sec
(940 gpm)
No
35 I/sec
(550 gpm)
2
THICKENER
J
To No. I Thickener
3.16 I/sec
(50 gpm)
I/sec
(2,740 gpm)
PROCESS: HOT FORMING-PRIMARY a SECTION
PLANT; 0-2
PRODUCTION:4,509 metric tons(4,97l tonsJ/ctay total
2773 metric tons(3,057 tonsl/day primary
1,736 metric tons(l,9!4 tons)/day section
Section
Mill
No. 2
No. 5
No. 6
Total Section
Metric
Tons/Day
367
670
699
1,736
Tons/Day
405
738
771
1,914 •
1,078 I/see
(17,080 gpm)
• From No. I Thickener
505 I/sec (8,000 gpm)
NON-CONTACT
BLAST FURNACE
COOLING
1
2524 I/sec
(40,000 gpm)
To stream
MAIN PLANT
PUMPING STATION
SEE PLANT L, PAGE 205 IN
PHASE I DEVELOPMENT DOCU-
MENT (June, 1974)
573 I/sec
(9,080 gpm)
CYANIDE
DESTRUCTION
SCALE PIT
WITH ~
OIL SKIMMER
BACKWASH
THICKENER
DEEP BED
FILTERS
1078 I/sec
(17,080 gpm)
2524 I/sec
^(40,000 gpm)
RIVER INTAKE
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwn.7/3/74
Rev. 2/23/76
FIGURE 3ZDrl8
-------
ft — /6\ Make-Up From
44 I/sec Reservoir
(695 gpm)
350 I/sec ,^fvr
(S.RRRnpm) . 394 I/sec
Jl Ib.ilbOgpm)
1 '
» II" BAR Ml| L : /\
230 l/sec(3,650 gpm) *
Mill Operating
57 l/sec(900 gpm)
Mill Down
„ SEAMLESS A
TUBE MILL 30^sec
(4,860 gpm)
i
Recycle Water .• . ^
.,
SURGE MAIN
RESERVOIR > j RESERVOIR .
-513,000 liters " "" =* 1,540,000 liters *
1 (-135,000 gallons) | | (~406,900 gallons) |"
Ove
Recei
-» PRIMARY „,. ,. „,
ft SETTLING » sec(
PROCESS: HOT FORMING -SECTION. PIPE a TUBE
PLANT: E-2
PRODUCTION: Hot Forming- Section Total =
1,929 metric tons/day(2,!27 tons/day)
925 metric tons(l,O20 tons)/day Rod
1,004 metric tons(l,l07 tonsl/day Bar
(2 shifts/day)
496 metric tons(547 tonsl/day Pipe 8 Tube
4,760gpm) with Ban Mill Ooeratina
_^ BASIN 758 l/sec(!2,OIO gpm) with Bar Mill Down
— o
rx
— o
3-CELL S~\
— rnni IMH A. » *^ /^
TOWER \ /
— SIANUPIPE 1 (V
^ — HIGH RATE SAND FILTERS16)
^L " Each 3.66 m(!2 ft.) dia. *. 5.03m
(16.5ft.) long.
Filler range = 10 l/sec/m2(l4.8gpm/ft2)
A /CLAR
' 2^S ( 30.
, MIOOft
SETTLING „ ,,
PIT Filter
LAGOON r" nn^u,».K
-» (44.900 gallons)
l_ SETTLING , Clorifier Underflow ,
IFIER\
5m J
Idiay
T533 I/see P'T
5,275 gpm)
rflow to
^ing Stream
^SAMPLING POINT
- •
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT. FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
S™L. FIGURE ^.jg
-------
Contact Wastewater
From Mill 8 Scarfer
189.2-220.3 I/sec
(3,000-3,500 gpm)
PRIMARY
SCALE
PIT
SECONDARY
SCALE
PIT
SECONDARY
SCALE
PIT
PROCESS; HOT FORMING-SECTION
PLANT:p-2
PRODUCTION'- 2,048 metric tons of steel/day
(2,257 tons steel/day)
Non-Contact
Cooling Water
From Mill
473.1-504.6 I/sec
(7,500-8,000 gpm)
Contact and
Non-Contact
Water to Mill
COOLING
TOWER
(Two-Cell)
Sludge Cake
-»-To Scavenger
Cold Well Slowdown
App. 2% of Recirculation
13.9 l/sec(220 gpm)
A= SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING-SECTION
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Rev. I' 2/20/7
Dwn.4/8/74 lRev.2'2/25/76
FIGURE 2H-2C
-------
Non-contact cooling water
246 I/sec (3900 6PM)
PROCESS:
PLANT:
HOT FORMING-SECTION
6-2
Total flow
328.0-378.5 -I/sec
(5200-6000 gpm)
PRODUCTION: 534 METRIC TONS OF STEEL/
DAY
(589 TONS OF STEEL/DAY)
Pumps (2)
441.6 I/sec.
(7000 gpm)
Pumps(3)
315.4 I/sec. (5000 gpm)
Vertical waste ejectors(2)
Total flow
328.0-378.5 I/sec.
(5200-6000 gpm)
FILTER
3I&4 I/sec
(5000 GPM1
FILTER
315.4 I/sec.
(5000 GPM)
Wet solids
to lagoon
Filter backwash water
32aO-3785 Msec.
(5200-6000gpm)
COOLING
TOWER
362 I/sec.
(5733 gpm)
Pumps(3)
315.4 I/sec.
(5000 gpm)
ENVIRONMENTAL
STEEL INDUSTRY STUDY
BAR MILLS
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Service water
from river
ASAMPLING POINT
IFIGURE3HI-2I
-------
SERVICE
WATER
PROCESS: HOT FORMING-SECTION
PLANT: H-2
PRODUCTION: 724 METRIC TONS OF STEEL/DAY
(798 TONS OF STEEL/DAY)
to
o
oo
SCALE
PIT
242.4 I/sec
(3850 gpm)
-*-TO SEWER AND RIVER
230.2 I/SEC.
(3650 GPM)
CYCLONES
(5)
SOLIDS RETURN
A
SAMPLING POINT
12.7 I/sec.
(200 GPM)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dvrg.4/2/74
R«v. 2/19/76
FIGURE MT-22
-------
MILL SERVICE
WATER
-353 I/SEC.
(5600 6PM)
*4 PICKLE LINE
3.97 I/SEC
(63 6PM)
FRESH H2S04
337 I/SEC.
(5347 GPM)
PICKLE LINE
9.84 I/SEC.
(|56 6PM)
FUME HOOD
(NO SCRUBBING)
PROCESS: HOT FORMING-SECTION:
PICKLING HjjSQrHCI
HOT COATING GALVANIZING
PLANT: 1-2
PRODUCTION: 1393 METRIC TONS
(1536 TONS)/DAY ROD
834 METRIC TONS
(919 TONSVDAY
H2304 PICKLING
65 METRIC TONS
(72 TONS)/DAY HCI
PICKLING 8 6ALVANIZIN6
-WATER SPRAYS
I/SEC (I I GPM)
SPENT ACID
TO CONTRACTED
DISPOSAL
33T I/SEC
(53476PM)
13.8 I/SEC.
(2196PM)
4^
0.7 I/SEC.
(II 6PM)
TERMINAL SETTLIN6 LA600N
46,200,000 1
(12,200,000 6AL.)
»350 I/SEC.(5556 GPM)
TO RECEIVING STREAM
POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
COMBINED WIRE, ROD, PICKLING 8
WIRE GALVANIZING LINES
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
DWO.6/24/74 reVZ-2/2&76
REV.|-Z/2(y76
p. |nr --.. „
rlbUnt jtlL-23
-------
SCALE *
OIL*
THICKENER
OVERFLOW
SECONDARY
SCALE PITS-
to
H
O
SLUDGE TO
THICKENER *-
PRIMARY
SCALE PIT
690.7 I/SEC.
(10,950 GPM)
1
1
693.2 I/SEC.
A (10,990 GPM)
ULTRA-HIGH
RATE FILTER
SYSTEM
-FILTER BACKWASH
RETURN TO SECONDARY
SCALE PITS
COOLING
TOWER
^SAMPLING POINTS
PROCESS: HOT FORMING-FLAT PLATE
PLANT: K-Z
PRODUCTION: ases METRIC TONS OF STEEL/DAY
(2850 TONS OF STEEL/DAY)
EVAPORATION
MAKE-UP
WATER
34.4 I/SEC.
,(545 GPM)
18.9 I/SEC.
(300 GPM)
SLOWDOWN TO
RECEIVING STREAM
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT ROLLING MILL
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
aw.lo-lo-73
R«V.I Z-ZO
FIGURE 3ZE-2
-------
to
H
HI
^_\ PRIMARY ^ j 1 HS a STRIP 1 1
._ __ ._. 1
m r I
SLAB MILL PRIMARY ROUGHING SECONDARY RC
aSGARFER STANDS (3) STANDS (3)
197 I/sec (3120 gpm)^~l_-70-630 gpm) _ _ FLOCCULATOR
T^ * ' ' CLARIFIERS (3) |-)4f(— 1
|_^ FAST MIX 4lm(l35')DIA. I \
^TANKS(3) , RISE RATE=0.56 \/sec/^
1 (OR gpm/ft^l [ ^
f _». FLOCCULATOR ,
1 ^ TANKS (3) »
1 LKKIU ULARIrltKb 13) l~l M /-•
SULFATE 41m (135') DIA. I I
RISE RATE=056 l/sec/mS^^/
(OB gpm/ft2) I ^ .^
PROCESS: HOT FORMING- PRIMARY
HOT FORMING-FLAT-HOT STRIPS
PLANT; L-2
PRODUCTION: 9854 METRIC TONS
(10,864 TONS/DAY) PRIMARY
10,506 METRIC TONS
(11,583 TONS/DAY) FLAT
L- . *
UGHING FINISHING
STANDS RUNOUT TABLE AND COILERS
L i i — r
r; "' L , L — H
:ALE PIT SCALE PIT PUMP PUMP
SKIMMER W/3KIMMER PIT PIT
\ i i T^
A AS MAKE-UP
_ /3\AVG. FLOW=79 I/sec
»l nr (1250 gpm)
«-J —
WELL WELL 1 rt-T
« 1 ITfc
J * J\T
^AKE
SYST
. 1 ELSE
OGLING T
OWERS / /§\
/ T%- TD C
. , 1 ZZ}*1 JP 26.5
VACUUM SLUUOt DISPOSAL
_J
T
SHEET
-UP TO FUME SCRUBBER
iM AT PICKLER 8 NON-
\CT COOLING WATER
WHERE 48 I/sec
(760 gpm)
iECEIVING STREAM
I/sec (420 gpm)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER- FLOW DIAGRAM
)wn.3/26/7S
-25
-------
SCALE BREAKERS! TABLE ROLLS
a ROUGHING STANDS k SCALE BREAKERS
*l,283 \ROUGHINGSTANDS "
. J \ *3,485 J
SERVICE WATER
FEED
PROCESS: HOT FORMING-FLAT-HOT STRIP
a SHEET
PLANT:
M-Z
PRODUCTION: 9977 METRIC TONS OF STEEL/DAY
(11,000 TONS OF STEEL/DAY)
FINISHING
STANDS
*l,2,3a4
NON-CONTACT
COOLING
\
SCALE
PIT -i
\*\
\
OIL
QrDAPA"
\SCALE \SCALE
\ PIT Y \ PIT Tl
\*2 \ *30 |
u i
1
m (
1^1716 I/SEC. i
Y (27,200 GPM)
SKIMMER OIL
trw
I
te. MI
^ Ml
1262 I/SEC
(20,000 GPM)
WASTE
OIL
SAMPLE POINT
SOLIDS TO
DISPOSAL
,- 2804 I/SEC.
~> (44,450 GPM)
^X
1262 I/SEC.
(20,000 GPM)
TO RECEIVING
^STREAM
~*"4067 I/SEC.
(64,450 GPM)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
FIGURE 101-26
-------
PROCESS: HOT FORMING- FLAT- HOT STRIP
a SHEET
PLANT: N-2
PRODUCTION: 1796 METRIC TONS OF STEEL/DAY
MILL SERVICE (I98° TONS OF STEEL/DAY)
WATER FOR MAKF-IIP
A f* <
1^ rl «
| 30" HOT STRIP MILL 1.
: : : . 3 v , , !
ROUGHING STANDS FINISHING STANDS STRIP COOLING COILERS
i _ . .._• _ . ==T^J
SCALE SCALE SCALE 8CALE " "j
PIT PIT PIT PIT , 1 1
1 - v » t 1 \ COOLING /
9 •. ' •> » »l t_£V-»l \ TOWER /
\ / ™ """"""
f — * * i— 4 v „ {
v A fc HIGH FLOW A
" B»ii/ei:/' SAND FILTERS "^ * >
631 I/SEC. • •
-------
CITY WATER
STORM WATER
CREEK WATER
PROCESS:
PLANT:
PIPE a TUBES
GG-2
PRODUCTION: 211 METRIC TONS OF STEEL/DAY
(233 TONS OF STEEL/DAY)
WEST POND
SURFACE EVAPORATION ONLY
to
86.8 I/SEC.
^(1375 GPM)
NON-CONTACT
COOLING WATER
SEAMLESS TUBE MILL
ELECTRO WELD MILLS
EAST POND
FIRE WATER 8 MAKE UP WATER POND
SCALE PITS
k!7.4 I/SEC.
(275 GPM)
TO
OIL
RECOVERY
SAMPLING POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
PIPE a TUBE MILL
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
B/6/74|R«y.Z-2/2
-------
to
H
Ul
II
(1
RESERVOIR
~yex «
09 I/SEC.
730 GPM)
1
CONTACT
COOLING
OF FINAL
PRODUCT
1
VtK INT/
^KE PLANT:
PRODUCTION:
?*• : : P
<
r
CONTACT
COOLING NON-CONTACT
OF ROLLS COOLINQ
8 SHEARS USES
37.9 I/SEC.
(600 GPM)
> <
37.9 I/SEC.
(600 GPM)
25,2 I/SEC.
(400 GPM)
•' 101 I/SEC. (1600 GPM)
PROCESS: PIPES a TUBES
II-2
567 METRIC TONS/DAY
(625 TONS/DAY)
r
BACKWASH
CLARIFICATIO
TANK
TWO COMPARTMENT
SCALE PIT
SLUDGE DISPOSAL
BOXES
FINAL SETTLING LAGOON
3 FILTERS PERFORM-^
EACH OPERATION IN
SEQUENCE
MEDIA SCRUBBERS
SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
PIPE a TUBE MILL
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
DW8.1/29/74IREV. 2/2V7J
REV. 2/20/761
FIGURE M-29
-------
PROCESS: PIPE a TUBES-HOT WORKED
PLANT: JJ-2
PRODUCTION: 265 METRIC TONS OF STEEL/DAY
(292 TONS OF STEEL/DAY)
SERVICE
WATER
MAKE-UP
0.8 I/SEC.
12.0 6PM)
PICKLING RINSE
(INTERMITTENT
OVERFLOWS)
BUTT WELD
PIPE MILL
SCALE PIT
H2S04
PICKLE TANK
(BATCH)
H.O VAPOR
0.8 I/SEC.-!? A
(12.0 0PM) \J
r*
SPENT ACID
• TO CONTRACT
DISPOSAL
29.3 I/SEC.
(465 6PM)
LA600N
TO LANDFILL
28.6 I/SEC.
(453 6PM)
TO LANDFILL
/\^SAMPLIN6 POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
PIPE 8 TUBE MILL
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
WQ.6-6-7S IREV. 2-25-'
^EV. 2-20-76
[REV. 2-25-Trf"
FIGURE 501-3
-------
PROCESS:
PLANT:
PRODUCTION;
PIPE a TUBES-HOT WORKED
465 METRIC TON OF STEEL/DAY
(512.5 TONS OF STEEL/DAY),
SERVICE WATER
PIPE MILL
OIL SKIMMER
,517.35 I/SEC.
(275 6PM)
OIL RECOVERY
POLYELECTROLYTE
PRIMARY SCALE PIT
9.1 m x 3.7m x 4.0 m
(30* x 12' x 13')
132,500 LITERS
(35,000 GAL.)
17.0 I/SEC.
(270 6PM)
TO RECEIVING STREAM
SECONDARY SCALE PIT
10.3 m x 7.2m x 1.2 m
(33.83'x 23.5'x 4')
90,000 LITERS
(23,800 GAL.)
A SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
PIPE 8 TUBE MILL
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
DW6.6/6/T8 iREV.
;EV 2/20/761
2/26/76
FIGURE 501-31
-------
5.6 1/SEC.OO
I.I I/SEC.116.8 GPM)
0.38 I/SEC.(6.IGPM)
0.76 I/SEC.02 GPM)
0.88 I/SEC.04 GPM)
0.30 I/SEC.W.8 GPM)
0.95 I/SEC.U5 GPM)
1.3 I/SEC.(20 GPM)
0.20 I/SEC.0.0 GPM)
0 0.44 I/SEC.17.0 GPM)
6.6 I/SEC.W06 GPM)
0.22 I/SEC.13.5 GPM)
3 2.5 I/SEC.(40 GPM)
#3
HOT MILL
d
MAKE-UP
0.21 I/SEC.
A (3.3 GPM)
/A\
•ROCf.SS HOT FORMING, PICKLING, SALT BATH DESCALING.
WIRE COATING, ALKALINE CLEANING
PLANT 081,122,132,143,152
PRODUCTION'M-65 METRIC TONS/TURN(72 TONS/TURN)
N(*l 8*2 MILLS)-43 METRIC TONS/TURN
(48 TONS/TURN)
N(*4 MILL) -64 METRIC TONS/TURN(70 TONS/TURN)
W-*ZBlJOCK:85 METRIC TONS/TURNOO TONS/TURN)
BENCH CLEANING'-re METRIC TONS/TURN184 TONS/TURN)
X(KOLENE)-85 METRIC TONS/TURNO4 TONS/TURN)
X(HYDRIDE)-75 METRIC TONS/TURN(83 TONS/TURN)
Y-4.5 METRIC TONS/TURN (5 TONS/TURN)
Z-4.8 METRIC TONS/TURN(5.3 TONS/TURN)
-0.66 I/SEC.
(10.5 GPM)
1.8 I/SEC.
(28.2 GPM)
FURNACE COOLING WATER
OXIDIZING/HYDROCHLORIC RINSE
OTHER PROCESS
WASTE WATERS
SECONDARY RINSE
HCI SCRUBBER
HNO3 SCRUBBER
NORTH SCRUBBER
48.7 I/SEC
(772 GPM)
DISCHARGE
Cu-NaOH RINSE
Cu-PLATE RINSE
ENVIRONMENTAL PROTECTION AGENCY
LEAD COATING ACID RINSE
STEEL INDUSTRY STUDY
HOT FORMING,PICKLING, SALT BATH DESCALING
WIRE COAT ING, ALKALINE CLEANING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
SODIUM HYDRIDE
FIGURE HI-32
* COMPANY SUPPLIED (DCP RESPONSE) FLOW RATE
-------
SLUDGE TO
DISPOSAL
FLOCCULANT
AID
PROCESS: HOT FORMING, PICKLING,SCALE REMOVAL
WIRE COATING, ALKALINE CLEANING
PLANT: 081,122,132,142,152
PRODUCTION: SAME AS FIGURE 211-37.
TO EMERGENCY
OVERFLOW LAGOON
K!
Clorifier Woter
H2S04
ADDITION
NoOH
ADDITION
INFLUENT
COMPRESSED
AIR
TREATED WATER
FROM Cu/CN
NaOH
ADDITION
OUTFALL
COAGULANT/
FLOCCULATION AID
SLUDGE TO
DISPOSAL
SAMPLE POINTS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING .PICKING, SCALE REMOVAL,
WIRE COATING,ALKALINE CLEANING
CENTRAL TREATMENT PLANT
WATER FLOW DIAGRAM
DWN.II/21/78
FIGURE
-------
PROCESS: HOT FORMING-PRIMARY a FLAT
082
M - 1265 METRIC TONS/DAY
DDnniir-rirw 1393 TONS/DAY
PRODUCTION. Q _ |S|8 METR|C TONS/DAY
1670 TONS/DAY
RECYCLE FOR ROLL
COOLING AND OTHER
NON-CONTACT
COOLING
OIL TO
DISPOSAL
BACKWASH
SETTLING
BASIN
SETTLING BASIN
66.2 I/SEC
(1050 GPM)
66.2 I/SEC
(1050 GPM)
132.5 I/SEC
(2100 GPM)
COMBINED
SECONDARY
SCALE PIT
SETTLING BASIN
SETTLING BASIN
BACKWASH
PUMP
132.5 I/SEC
(2100 GPM
PRIMARY
SCALE
PIT
RECYCLE
£±STO NON-
CONTACT
COOLING
9.4 I/SEC
(ISO GPM)
/\- SAMPLING POINT
\ 56.8 I/SEC
X(900 GPM)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING PRIMARY 8 FLAT
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
COMBINED
SECONDARY
SCALE PIT
6.2 I/SEC
(1050 GPM)
FIGURE m-34
-------
HOT FORMING - PRIMARY(M), SECTION (N).
FLAT-PLATE (0)
4.4IT I/SEC
(700 GPM]
SUBCATEGORY(M)
53" BLOOMING
MILL SCALE PIT
ENTRAL PUMP
PRODUCTION:
M-53" BLOOMING MILL 9S3 METRIC TONS/TURN(lp50 TONS/TURN
N-34 STRUCTURAL MILL 409 METRIC TONS/TURN(450 TONS/TURN
N - ROD MILL 569 METRIC TONS/TURN(627 TONS/TURN
0-30' PLATE MILL 227 METRIC TONS/TURN(230 TONS/TURN
114.34 I/SEC '
279.2 I/SEC
14424
GPM)
(1812 GPM)
LAKE
* WATER
SUBCATEGORY(N)
34" STRUCTURAL
MILL SCALE PIT
COOLING
TOWER
SOUTH MILLS
r~SUBCATEGORY(0)
2942 I/SEC
(46,630 GPM)
30" PLATE MILL
SCALE PIT
DECANT
TANK
SUBCATEGORY(N)
ROD MILL
PUMP "STATION
5.33 I/SEC
(243 GPM)
WASTE TREATMENT
SYSTEM
114.3 I/SEC
(1812 GPM)
SLOWDOWN
TO POTW
SLOWDOWN
7.7 I/SEC.
GPM)
SOUTH
LIFT STATION
PUMP HOUSE
N« 3
3LARIFIER
3057 I/SEC
(48,442 GPM)
ENVIRONMENTAL
PROTECTION
STEEL INDUSTRY STUDY
HOT FORMING
WASTE WATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
DISTRIBUTION
LIFT STATION
SAMPLING POINT
FIGURE 3E-35
-------
RIVER-
WATER
CHLORINATOR
14"
MERCHANT
MILL
to
44" HOT
STRIP MILL
PROCESS; HOT FORMING SECTION AND FLAT, HOT STRIR
PIPE AND TUBE WELDED
PLANT: OBJ
PRODUCTION:
N -14" BAR MILL 481 METRIC TONS/TURNS
(530 TONS/TURNS)
0 - HOT STRIP MILL 1634 METRIC TONS/TURNS
(1800 TONS/TURNS)
P - WELDED TUBE MILL 172 METRIC TONS/TURNS
(190 TONS/TURNS)
1750 I/SEC
(27.700 GPM)
DISTRIBUTION
BOX
BUTT WELD
PIPE MILL
BLOOMING
MILL HOT
SCARFER
PRIMARY
SCALE PIT
COAGULANT
AIDS
PRIMARY
ASCALE PIT
PUMP
STATION
442 I/SEC
(7000 GPM)
fH04 I/SEC
'07,500 GPM)
I750 I/SEC
(27,700 GPM)
202 I/SEC
(3200 GPM)
SAMPLING POINT
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING SECTION 8 FLAT, HOT STRIR
AND PIPE 8 TUBE WELDED
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwg. 7-15-77
FIGURE Yff-36
-------
NJ
K)
U)
SCARFER
Mill 1
V
SCARFER
SC.AIE PII SCALE PIT
A A ?„<, I/SFC
1 .-M.,,M< iwi.fipMi J- -(3310 0PM) .
^"BLOOMING MILL
if-E_A I FURNACES f( 1 IIM •• 1 1
, to », l?..io(iPMl ^
EFFLUENT fc
FURHAO.S MILL
SCAlt SCALE
{!•> l(» i,l'M)^ , (.
ILUME cc/
SLUICING '*'
tt — tj
^H ,-4 -
1 nai dPMi, ,
NOI ' >
OPERATING
SAMP-
LING
1.4.
ii"
'. , <• i/'.l c A
]"REEIERS"
SCALE PIT
' A
.11 UUTLE.I
FURNACE
SrAtETiT
11 l.PMI ^
\.MLESS_PIPE A_ND
^illll
PIT
4" BAR MILL
i
\
B!
1
r
b
if
EP BED
iBmSi~
N
PUMP
IHUUStl '
I — MILL 1
^ EFFLUENT
MILL SCALE F'll
3ILLEI MILL
1764 I/SEC f<
(27,969 OPMr1'
1
— Q
C J< ->
FILTER
SLOWDOWN FROM
IITROU Mill
iBLOWDUWN FROM
i HOUSE CLEANING
PROCESS: HOT FORMING-PRIMARY(M), SECTION(N),
PIPE 8 TUBE(P)
PLANT: oee
PRODUCTION: M(44"BLOOMINGMILL)-I725 METRIC TON-.VTURN
(1900 TONS/TURN)
N(36" BILLET MILLJ-472 METRIC TONS/TURN(520 TONS/TURN)
NP4"BAR MILD-690 METRIC TONS/TURN(760 TONS/TURN)
N(32"BAR MILL)-517 METRIC TONS/TURN (570 TONS/TURN)
Ml 1710 BAR MILD-654 METRIC TONS/TURN(720 TONS/TURN)
PISEAMLESS PIPE 8 TUBE MILL)-I63 METRIC TONS/TURNS)
(180 TONS/TURN)
(I410EEP
if-P BED
FILTERS
764 I/SEC
7,969 GPMr
' A
t !
? — u
i
IT ' '
i )
MAIN COLLECTION SU
,,.M,.tr-
FILTER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
DWN.8A»/78
FIGURE 3ZH-37
-------
REHEAT
FURNACE SKID
COOLING WATER
to
to
BAR MILL
A EFFLUENT
&
HOT SAWS
SHEARS
STANDS
PULL RODS
BAR ROTATORS
I I/SEC k^T~
CITY WATER
MAKE-UP
CLARIFIER
UNDERFLOW
POND
PROCESS":
PLANT--
SECTION MILL (N)
14" BAR MILL
088
PRODUCTION: 381 METRIC TONS STEEL/TURN
420 TONS STEEL/TURN
SCALE PIT RECYCLE COOLING
222 I/SEC
(3525 GPM)
/x BAR MILL
ASTANDS
MAKE-UP WATER
FROM RIVER WATER
PUMP HOUSE*! A
II I/SEC
(175 GPM)
o
SCALE PIT COOLING
WATER POND
EFFLUENT 8 SKIP
COOLING WATER
RECYCLE TO
BAR MILL
7.6 I/SEC
(120 GPM)
SLOWDOWN TO SEWER
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
SECTION MILL
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
DWN.9/20/7E
FIGURE 301-38
-------
PROCESS: Hot Forming-Hot Strip Mill
PLANT: 281
PRODUCTION' 660.Metric Tons Steel/Day
(730 Tons/Turn)
Backwash
to
to
Ul
ENVIRONMENTAL PROTECTION AGENCY
/^-Sampling Points
STEEL INDUSTRY STUDY
HOT FORMING (FLAT)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
3wn. 10/16/81
FIGURE3ZH-39
-------
-2.8 I/sec
145 gpm)
City Water-
BLOOMING
MILL
to
to
PROCESS'Hot Forming-Primary
PLANT: 282 A
PRODUCTION: 780 Metric Tons/Turn
(860 Tons/Turn)
-571 I/sec cl
(9045 gpm)
570 I/sec
(9000 gpm)
/\ -Sampling Points
Bar Mill Waste water'
2.8 I/sec (45 gpm)
-2.8 I/sec
1 (45 gpm)
WASTEWATER
TREATMENT
FACILITY
.Pickle Rinse Water (Batch)
0.03 I/sec (0.4 gpm)
= Blooming Mill Shear Pit
0.9 I/sec (14 gpm)
6.6 I/sec
(104 gpm)
Discharge to
Beaver River
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (PRIMARY)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 10/19/81
FIGURE 331-40
-------
-2.8 I/sec
(45 gptn)
to
to
PROCESS: Hot Forming-Section
PLANT: 282B
PRODUCTION: 410 Metric Tons/Turn
(450 Tons/Turn)
BLOOMING MILL
WASTEWATER
2.8 I/sec (45gpm)
380 I/sec
(6000 gpm)
- Sampling Points
WASTEWATER
TREATMENT
FACILITY
• PICKLE RINSE WATER(Batch)
0.03 I/sec (0.4gpm)
•BLOOMING MILL SHEAR PIT
0.9 I/sec (14gpm)
6.6 I/sec
(104 gpm)
Discharge to
Beaver River
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING (SECTION)
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 10/16/81
FIGURE 3ZH-41
-------
to
to
or
Creek
(Make-up Water)
18" MILL
*f
-------
Lake Water
Make-up
to
K)
PROCESS1 Hot Forming-Flat, Hot Strip 8 Plate
PLANT =284 A &B
PRODUCTION: Strip-3720 Metric Tons/Turn
(4100 Tons/Turn)
Plate: 1070 Metric Tons/Turn
(1180 Tons/Turn)
To Reuse at
Most Plant
Operations
TERMINAL
LAGOONS
From all other
Plant Operations
Except Cokemaking
1,350 I/sec
(21,500 gpm)
-Discharge to
Lake
2,750 I/sec.
(43,600 gpm)
540 I/sec
(8,500 gpm)
FLOCCULATING
CLARIFIERS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING-FLAT OPERATIONS
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 10/19/81
FIGURE 3ZE-43
-------
BLOOMING MILL
8 SCARFER
to
W
o
250 I/sec
(4000 gpm)
21" BAR MILL
150 I/sec
(2400 gpm)
To all other
mill sources•*•
PROCESS' Hoi Forming-Primary & Section
PLANT: 285 A B B
PRODUCTION: Primory-750 netric tons/turn
(827 tons/turn)
Section-335 metric tons/turn
(369 tons/turn)
From all other
mill sources
130 I/sec
(2000 gpm)
1
RIVER
PUMP
HOUSE
850 I/sec —
(13,450 gpm)
Oil
I
t
BIO I/sec Oj' oil
12,800 gpm) f i
PRIMARY
SETTLING
LAGOON
V
\-96<
(15,2
SECONDARY
SETTLING
LAGOON
3 I/sec
.00 gpm)
I
MAIN
SETTLING
LAGOON
From
River
To River
110 I/sec-/
(I740gpm)
During Sampling
All flows,except effluent to river, are plant estimates.
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING SUBCATEGORY
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 10/28/81
FIGURE 3ZE-44
-------
K)
CO
k .
ERSAL
BING
SCALE
l
t
•WrV.
380 I/sec—
(6000 gpm)
-420 I/sec
(6700 gpm)
PROCESS" Hot Forming-Primary
Hot Forming-Flat/Hot Strip and Sheet
PLANT* 286Aae
PRODUCTION: Primary-2760metric tons/turn
(3040 tons/turn)
Flat-2680 metric tons/turn
(2960 tons/turn)
0.19 I/sec
(3 gpm)
14 I/sec
(220 gpm)
CLARIFIERS
3.9 l/sec(62gpm)
ELECTRIC f
ARC f
90 I/sec (3000 gpm]
10 I/sec
(160 gpm)
13 I/sec
(200 gpm)
Pump and Vacuum
Filter Bearing and
Spray Waters
300 I/sec
(4740 gpm)
1250 I/sec
(19,900 gpm)
63 l/feecdOOOgpm)
18 I/sec
(280gpm)
FURNACE REHEATf
r—110 I/sec
\ (1800 gpm!
COOLING TOWER
FINISHING MILL?
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Water
River (Service]
Jftbter
1170 I/sec (18,500 gpm)
FIGURE ~SK -45
6.3 I/sec-
(100 gpm)
-------
Raw Intake
Water
80" HOT STRIP MILL
to
w
to
1 i I
Oils
2-CELLED ROUGHING PIT
PROCESS' Hot Forming-Flat/Strip 8 Sheet
PLANT: 287
PRODUCTION: 3080 metric tons/turn
(3400 tons/turn)
-^•Outfall
I860 I/sec
(29,400 gpm)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING-FLAT/STRIP 8 SHEET
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dm 10/29/81
FIGURE2ir-46
-------
to
w
U)
-240 I/sec
(3840 gpm)
510 I/sec-
(8140 gpm)
-1370 l/feec
(21,800 gpm)
Indirect
Cooling
SCALE
PIT
-240 I/sec
(3840 gpm)
c
ROUGHING
END SCALE
iPIT
SLUICE WAY |
a
PROCESS: Hot Forming-Primary
Hot Forming-Flat/Hot Strip a Sheet
PLANT: ass A a B
PRODUCTION: Primory-2040 metric tons/turn
(3250 tons/turn)
Hot Strip-2300 metric tons/turn
, (3300 tons/turn)
860 I/sec
(13,620 gpm)
Backwash
1620 l/feec
(25,600gpm)
SCALE
SETTLING
BASINS
I
Service
Water
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dm. 10/29/81
FIGURE3Ztt-47
-------
Raw River
Water
* II
To Outfall
-160 I/sec
I (2500 gpm)
t_
36"
BLOOMING
MILL
to
, Raw Water
280 I/sec
(4400 gpm}
J_
PROCESSED! Forming-Primary
Hot Forming -Flat/Hot Strip a Sheet
PLANT: 289 ABB
PRODUCTION: primory-1030 metric tons/turn
(1140 tons/turn)
Hot Strip-2010 metric tons/turn
(3220 tons/turn)
56"
HOT STRIP MILL
160 I/sec
(2500 gpm)
Discharge to
River
260 I/sec
(4100 gpm)
1940 I/sec
(30,800 gpm)
Overflow
To River
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING SUBCATEGORY
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 10/30/81
FIGURE 3ZI-48
-------
Oil
1210 I/sec
(19,200* gpm)
PUMP
HOUSE
AM " • 1
PRIMARY
ROLLING MILL
("/Scarfing)
3 SCALE PITS
("/Skimmers)
Make-up
U)
Cn
44 I/sec -
(700 gpm)
PROCESS: Hot Forming-Primary ft Section
PLANT: 290 A 8 B
PRODUCTION' Primary-1300 metric tons/turn
(1440 tons/turn)
Section-408 metric tons/turn
(450 tons/turn)
To River
=11 I/sec
(•=180 gpm)
1200 I/sec
(19,200 gpm)
•To River
-56 I/sec
(890 gpm)
Flow Data Provided By Plant Personnel.
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING SUBCATEGORY
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 10/30/81
FIGURE 301-49
-------
to
w
en
PROCESS' Hot Forming - Primary
PLANT'2 91
PRODUCTION: 1844 metric tons/turn
(2030 tons/turn)
Slowdown
to River
136 I/sec
(2l55gpm)
2§\ |? ^
/«,,,—/
PRESSURE
FILTERS
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 11/2/81
FIGURE51-50
-------
Intake
LAKESIDE
PUMPHOUSE
-1790 I/sec
(28,300 gpm)
84" HOT STRIP
MILL
-^
-*»
1 I
SCALE
PIT
ROUGHING
MILL
SCALE
PIT
PROCESS^Hot Forming- Flat/Hot Strips Sheet
PLANT1 292
PRODUCTION: 3770 metric tons/turn
(4160 tons/turn)
-990 I/sec
(15,700 gpm)
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Dwall/2/81
FIGURE 31-51
-------
Intake
1
To Sluicing
Operation*
-440 I/sec
(6930 gpm)
PROCESS1 Hot Forming-Primary/Seclion/Pipe 8 Tube
PLANT'293 A.BSC
PRODUCTION1 Primary- 2500metric tons/turn
(2,760 tons/turn)
Section - 1310 metric tons/turn
(1450 tons/turn)
Pipe STube" 510 metric tons/turn
(560 tons/turn)
380 I/sec
(6000 gpm)
820 I/sec—7
(I2,930gpm)/
PRIMARY
ROLLING
MILL
to
w
00
PRIMARY
MILL
SCALE PIT
570 I/sec
(9000 gpm)
10-12 INCH
BAR
MILL
BAR MILL
SCALE
PIT
160 I/sec
(2500 gpm)
No 3
SEAMLESS
MILL
No 3
SEAMLESS
SCALE PIT
Other Rolling Mill
Water Sources
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 11/3/81
FIGURE 101-52
-------
870 l/sec-
I gpm)
PROCESS: Hot Forming -Primary/Flat/Hot Strip 8 Sheet
PLANT- 294 A 8 B
(1)
PRODUCTION: Primary- 1374 metric tons/turn
(1515 tons/turn)
Flat -2417 metric tons/turn
(2664 tons/turn)
590 I/sec.
(9,400 gpm)
.240 I/sec.
(3,750 gpm)
NJ
OJ
860 I/sec.
\ »
BLOOMING
44" MILL
1
*
PRIMARY
SCALE PITS
»A A
SECONDARY
SCALE PIT
i
^
FILTERS
i
100 I/sec.
(1,600 gpm)
(1) Based upon 1976 production.
A CAMPLING POINT
DISCHARGE
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. 3/2/8)
FIGURE3ZH-53
-------
River
Water
PROCESS^ Hot Forming-Pipe 8 Tube
PLANT' 295
PRODUCTION: 600 metric tons/turn
(660 tons/turn)
No I a No 2
SEAMLESS MILLS
to
4^
O
PRIMARY
SCALE
PIT
490 I/sec
(7730 gpm)
Discharge
to River
ENVIRONMENTAL PROTECTION AGENCY
STEEL INDUSTRY STUDY
HOT FORMING
WASTEWATER TREATMENT SYSTEM
WATER FLOW DIAGRAM
Own. II/3/BI
FIGURE 3ZE-5
-------
HOT FORMING SUBCATEGORY
SECTION VIII
COST, ENERGY, AND NON-WATER QUALITY IMPACTS
Introduction
This section presents investment and annual costs associated with the
different levels of pollution control technology considered for the
hot forming subcategory. The analysis addresses energy requirements
non-water quality impacts, and the techniques, magnitude, and costs
associated with the application of the BPT, BAT, NSPS, PSES, and PSNS
limitations and standards.
Actual Costs Incurred By_ the Plants for Sampled Plants
In response to Agency requests, the industry supplied water pollution
control costs for hot forming operations sampled during this study and
for those operations solicited by D-DCPs. The Agency adjusted these
costs to July, 1978 dollars for comparison with EPA Model based
estimates. All estimates that were provided by industry for systems
treating only hot forming wastes were included in cost comparison of
hot forming treatment costs described below.
Table VIII-1 presents a comparison of actual investment costs incurred
by the industry for several hot forming operations with EPA model
based estimates of the installed treatment facilities. All costs are
in July 1978 dollars. As shown, the Agency's model based cost
estimates compare favorably with actual industry costs. The Agency's
estimates are over 20 percent higher than.actual industry costs for
the 24 facilities shown in Table VIII-1.
The Agency also verified its model-based cost estimates for central
treatment systems. The Agency compared its model-based treatment
costs with industry costs for several central treatment systems by
summing the model-based treatment costs for each subcategory included
in the existing central treatment systems. The results of this
comparison (presented in Volume I) demonstrate that the Agency's
costing methodology accurately reflects industry costs for central
treatment facilities in general, and for those systems including hot
forming wastewaters in particular. In fact, as shown by the data
presented in Volume I, the Agency's cost estimates for separate
treatment for all finishing operation wastewaters are likely to be
significantly higher than industry costs for central treatment.
Control and Treatment Technology (C&TT)
Recommended for Use iri the Hot Forming Subcateqorv
.The treatment system components considered for BPT and BAT are
presented in Table VII1-2. The C&TT steps are identical for all hot
241
-------
forming subdivisions. The limitations and standards do not require
the use of :the model treatment systems; any treatment system which
achieves the limitations and standards is acceptable.
The following items are described in Table VII1-2.
1. Description of individual treatment components
2. Implementation time
3. Land requirements
Tables VIII-3 and VIII-4 present the land requirements for the
components of the BPT and BAT treatment models.
Cost, Energy, and Non-water Quality Impacts
Introduction
Compliance with the BPT and BAT limitations and the NSPS, PSES, and
PSNS will require additional expenditures (both investment and
operating) and additional energy consumption. This section addresses
these requirements and the air pollution, water consumption and solid
waste disposal impacts associated with each treatment system
considered. Costs and energy requirements were estimated on the basis
of the alternative treatment models developed in Sections IX through
XIII of this report. Figures VIII-1 and VIII-2 illustrates the BPT
and BAT, NSPS, PSES, and PSNS alternative treatment models.
Development of Costs for the Hot Forming Subcateqory
To develop the compliance costs for the alternate treatment systems,
actual treatment practices within the hot forming subcategory were
analyzed to determine the types of treatment facilities currently in
use. First, the Agency found that wastewaters from over 90« of the
hot forming operations are treated in central treatment systems.
Although there are over 400 separate hot forming operations in tnis
country, there are over 200 joint treatment facilities. EPA model
treatment systems were initially costed on the basis of joint
treatment for mills in the same hot forming subdivision. For example,
if there are five section mills at one plant site, it was assumed that
the combined waste stream from these mills will be treated in one
system. Therefore only one treatment system was costed based upon tne
combined tonnage of the five mills. In this way the effect of joint
treatment of like wastewaters (same subdivision) was accounted for in
the cost estimates. The Agency believes that this_ approach is
justified since almost all hot forming plants treat the hot forming
wastewaters from the same types of mills in a joint treatment system.
Likewise, if different hot forming wastewaters are combined in one
system (i.e., primary and section wastewaters) still greater cost
reductions can be achieved.
In developing costs for the proposed regulation, the Agency
categorized hot forming operations by the type treatment systems in
place and used comingling factors to account for cost savings
242
-------
associated with 3oint treatment. The Agency used one model treatment
system for developing required investment and annual costs for this
regulation. Comingling factors across the hot forming subdivisions
were not used to develop costs for the final regulation in the
interest of providing more conservative estimated costs. Comingling
factors used^to develop costs for the proposed regulation are set out
in the draft development document.
Estimated Costs for the Installation of Pollution Control Technologies
A. Costs Required to Achieve the BPT Limitations
The Agency developed model systems upon which cost estimates are
based. The model size (tons/day) and applied flow rates for each
model were developed on the basis of the average production
capacity and average applied flow rate for each hot forming
subdivision. Reference is made to Section IX for identification
of the model BPT treatment system. Tables VIII-5 through VIII-16
present the BPT model treatment component capital and annual
costs. The Agency has calculated costs for facilities in-place
at each hot forming operation, and has estimated the costs of the
model system components required to achieve the BPT limitations.
On the basis of the cost comparison provided previously in this
section, the Agency believes that its cost estimates are
sufficiently generous to cover site-specific and other retrofit
costs.
The capital cost requirements for achieving the BPT limitations
were determined by applying the model treatment component costs,
adjusted for size, to each hot forming operation. Table VIII-17
presents a summary of the estimated expenditures already made or
required to achieve the BPT limitations. Based upon these data
the Agency estimates that as of July 1, 1981 approximately 94.9
million dollars remains to be spent for BPT facilities The
associated annual cost of operation of BPT for all hot forming
operations is estimated to be 12.0 million dollars.
B. Costs Required to Achieve the BAT Limitations
The Agency considered two BAT alternative treatment systems for
the hot forming subcategory. Reference is made to Section X for
a description of these treatment systems. Tables VIII-18 through
VIIl-29 present the BAT model costs. The additional capital and
operating costs associated with the implementation of BAT are
summarized below for the two alternatives:
Costs (Millions of Dollars)
Capital Annual
In-place Required In-place Required
BAT-1
BAT-2
74.46
74.46
214.79
1388.47
10.07
10.07
34.28
264.82
243
-------
C. Costs Required to Achieve the BCT Limitations
The BCT limitations are the same as the BPT limitations for all
segments and subdivisions. No additional treatment and costs
beyond BPT are, therefore, required.
D. Costs Required to Achieve NSPS
The Aqency selected an NSPS treatment system for all hot forming
operations which incorporates all of the components proposed in
the BAT Alternative 1 system. New facilities constructed after
proposal of these standards will be.required to achieve NSPS.
Model costs have been developed for two ^NSPS alternative
treatment systems as shown in Tables VI11-3.0 through VI11-41 for
the hot forming subdivisions.
E. Costs Required to Achieve Pretreatment Standards
The Agency has determined that only the General Pretreatment
Standards (CFR 40, Part 403) will apply to hot forming
operations.
Energy Impacts
A. BPT
The Agency estimated the energy expenditures for the BPT
treatment systems. These estimates are based upon the assumption
that all hot forming operations will install treatment systems as
described by the treatment models. It is estimated that
operation of the BPT model treatment system components for all
hot forming operations will consume approximately 195.7 milllon
kilowatts of electricity per year. This represents about 0.3j of
the 57 billion kilowatts used by the steel industry -,in 1978.
Table VIII-42 summarizes the energy requirements for each hot
'forming subdivision.
B. BAT
Additional power consuming equipment will be necessary to upgrade
the industry from the BPT treatment system to the two BAT
alternative treatment systems. The energy requirements for the
two BAT alternatives are presented in Table VIII-42.
C. NSPS, PSES, and PSNS
The NSPS/ PSES, and PSNS treatment systems are comprised of the
BPT model treatment system and BAT alternative treatment system
components. Therefore, the energy requirements per model plant
will be equivalent to the summation of the BPT and BAT energy
requirements. The Agency did not calculate the energy impacts
for NSPS and PSNS since the number of new source hot forming
244
-------
operations was not projected as part of this study,
requirements of PSES are shown on Table VIII-43.
Non-water Quality Impacts
The energy
In 9enera1' there are minimal non-water quality impacts associated
with the treatment technologies considered for the hot forming
subcategory. The Agency analyzed three impacts: air pollution- solid
waste disposal; and water consumption. The Agency found that no
significant non-water quality impacts will result from the
installation of the hot forming subcategory treatment systems under
consideration.
A. Air Pollution
The use of cooling towers in BAT Alternatives 1 and 2 will result
in the generation of water vapor plumes; however, these plumes
should not contain significant levels of particulates or volatile
organics. No other air impacts are expected to occur as a result
of the installation of the cooling towers. Therefore, no
significant air pollution impacts from this alternative are
expected. Nor are significant direct air pollution impacts
expected from operation of the evaporative systems included in
Alternative 2.
B. Solid Waste Disposal
Sedimentation of hot forming wastewaters, which are high in
suspended solids, results in the generation of significant
quantities of sludges. The Agency has estimated the amount of
solid waste generated in the BPT and BAT treatment systems and
has listed the BPT values in Table VIII-44.
About 5,800,000 tons of sludge are generated at the BPT level of
treatment. However, most of this solid waste, which consists of
both solids and oils, is collected in the primary scale pit. The
solids are removed either by clam shell or by drag link conveyor
Oils are usually collected by skimmers or oil troughs. The oils
are collected and disposed of off-site if they cannot by reused
or reclaimed for other uses. The scale, because of its high iron
content, is collected and often reused as feed to sinter plants.
Because most solid and oil collection occurs at the BPT level of
treatment, sludge generation by the BAT alternative treatment
systems is small, on the order of 0.2-0.3% of the sludge
generation at the BPT level. Therefore, there would be very
little impact with respect to sludge generation as a result of
the implementation of either BAT alternative system.
As noted previously, NSPS, PSES, and PSNS systems are made up of
BPT and BAT treatment system components. Therefore, the sludge
generation at NSPS, PSES, and PSNS would be equivalent to the
sludge generation rates of the BPT and BAT systems. However as
245
-------
explained above, most of the sludge produced at the BPT level of
treatment can be reclaimed and reused. This, in combination with.
the small sludge generation rates in the BAT treatment system
components, results in negligible impacts at NSPS, PSES, and
PSNS.
C. Water Consumption
In the hot forming subcategory, cooling towers are components of
the BAT, BCT, NSPS, PSES, and PSNS alternative treatment systems.
Those towers would evaporate some water. Cooling towers have
been considered as treatment components in order to allow higher
degrees of recycle. The Agency analyzed the degree of water
consumption and its impact. However, it found^that the degree of
water consumption that results from the use of the alternative
treatment systems is not severe. The analysis detailed the type
of cooling devices in use at hot forming operations, the
evaporation rates for the cooling devices in use, and quantified
the amount of water that would be consumed in order to meet BAT
limitations. It was determined that of the 3900 MGD of process
water applied to the hot forming operations, less than 19.4 MOD
or 0 5% of this water will be consumed due to evaporation trom
BAT treatment components. This amount of water consumption is
not significant, even to plants in "arid" or "semi-arid regions.
This analysis is discussed in Section III of Volume I of the
Development Document. The Agency finds that the amount of water
consumed in complying with this regulation is not significant on
both a national and water scarce regional basis when compared to
the effluent reduction benefits achieved. High recycle rates
also serve to minimize necessary surface and subsurface water
withdrawals and run-of-the-river type cooling which can cause
nearly as much consumptive loss as evaporative cooling
facilities. Plants in arid and semi-arid regions have had high
rate recycle systems in operation for many years.
Summary of Impacts
The Agency concludes that the effluent reduction benefits described
below for the hot forming subcategory outweigh the adverse impacts
associated with energy consumption, air pollution, solid waste
disposal, and water consumption.
246
-------
Effluent Loadings (Tons/Year)
Flow, MGD
TSS
Oil and Grease
Toxic Metals
Raw Waste
3,680
5,878,201
174,540
49,460
BPT
1,419
15,081
3,078
114
The Agency also concludes that the effluent reduction benefits
associated with compliance with new source standards (NSPS) outweiqh
the adverse energy and non-water quality environmental impacts.
247
-------
TABLE VIII-1
COMPARISON OF ACTUAL COSTS REPORTED
BY INDUSTRY VERSUS EPA ESTIMATES
HOT FORMING
(July 1978 Dollars)
oo
PLANT
0020B
0060F
0088D
0112B
0112B
0112B
0196A
0240B
0396D
0440A
0460A
0612
0640A
0652A
0684B
0684H
0684H
0860B
0860H (03)
0868A
0916A
0920A
0920N
0920N
SUBDIVISION
Flat
Section .
Primary & Section
Primary
Primary & Section
Primary & Section
Pipe & Tube
Pipe & Tube
Flat
Pr imary
Primary
Primary & Section
Section
Pipe & Tube
Flat
Primary, Section, Pipe & Tube
Section
Flat
Section
Pr imary
Pipe & Tube ,
Pr imary
Primary
Flat
SOURCE OF
REPORTED COST
Plant Visit
D-DCP
D-DCP
D-DCP
Plant Visit
Plant Visit
Plant Visit
D-DCP
Plant Visit
D-DCP
D-DCP
D-DCP
Plant Visit
D-DCP
D-DCP
Plant Visit
D-DCP
Plant Visit
D-DCP
D-DCP
Plant Visit
D-DCP
D-DCP
D-DCP
COST REPORTED
BY INDUSTRY
$ 1,901,300
3,912,299
1,260,014
2,577,783
3,544,320
2,968,580
4,168,786
969,568
3,110,775
2,138,600
340,000
9,000,000
984,500
285,348
3,798,072
19,812,800
5,458,752
3,316,442
3,331,644
303,441
609,600
356,616
340,119
4,381,044
$78,870,403
EPA MODEL
COSTS
$ 4,009,400
5,485,100
2,904,400
5,133,300
8,271,140
7,603,000
7,768,076
791,110
3,845,489
473,700
1,017,100
14,129,200
2,393,650
213,700
5,587,000
11,393,950
3,807,800
8,953,260
4,502,200
2,317,400
712,300
1,971,400
1,785,400
3.865,400
$107,455,970
-------
TABLE VIII-2
CONTROL AND TREATMENT TECHNOLOGIES
HOT FORMING - PRIMARY. SECTION, FLAT, AND PIPE AND TUBE
Treatment and/or
Control Methods Employed*
A. Primary Scale Pit - This
step provides the initial stage
for removal of heavy mill scale
and the heavier suspended solids.
Implamentat ion
Time
6-9
months
Land
Requirements
Refer to
Table VIII-3
B. Surface Skimming - Removes
oils and greases from the surface
of the wastewater.
3 months
Refer to
Table VIII-3
C. Recycle - Recycles a portion
of the primary scale pit effluent
back to the hot forming operation
(principally for flume flushing).
12-15
months
Refer to
Table VIII-3
D. Roughing Clarifier - Provides
the capability for additional
suspended solids removal.
15-18
months
Refer to
Table VIII-3
E. Vacuum Filter - Used to dewater
the sludges removed in Step D.
15-18
months
Refer to
Table VIII-3
249
-------
TABLE VIII-2
CONTROL AND TREATMENT TECHNOLOGIES
HOT FORMING - PRIMARY, SECTION, AND FLAT, AND PIPE AND TUBE
PAGE 2 '
Treatment and/.or
Control Methods Employed*
Implem ent at i on
Time
Land
Requirements
F. Pressure Filter - These filters
provide additional suspended solids
removal capability. The backwash is
returned to the roughing clairifier.
15-18
months
Refer to
Table VIII-3
G. Cooling Tower - Used to reduce
the heat load of the wastewater
recycle system.
18-20
months
Refer to
Table VIII-4
H. Recycle - Increase the recycle
rate the discharge flows to the
BAT/BCT levels.
12-15
months
Refer to
Table VIII-4
I. Vapor compression distillation -
This step produces distillates quality
water for recycle to the process.
6 months
Refer to
Table VIII-4
J. Recycle - The water produced in
Step I is completely recycled to the
process.
12-15
months
Refer to
Table VIII-4
250
-------
TABLE VIII-3
LAND REQUIREMENTS SUMMARY
HOT FORMING SUBCATEGORY
BPT Treatment Models
Subdivision
A
(PSP)
B
(ss)
C
(RUP)
C&TT Steps
D
(CL)
E
(VF)
F
(Filter)
PRIMARY
a.
b.
Carbon
w/o scarfers
w/scarfers
Specialty
w/o scarfers
w/ scarfers
1500 ft2
3600
600
1400
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
1600 ft2
3600
600
1400
225 ft2
900
260
600
2000ft2
5000
600
.1400
to SECTION
H
a.
b.
Carbon
Specialty
2500
900
(1)
(1)
(1)
(D
3025
900
900
400
4000
900
FLAT
a.
b.
c.
d.
Carbon Hot Strip
and Sheet
Speciality Hot Strip
and Sheet
Carbon Plate
Specialty Plate
5625
1225
1600
400
(1)
(1)
(1)
(1)
(1)
(1)
(1)
(1)
6400
1225
2025
625
1600
400
625
225
8000
1500
2400
625
PIPE AND TUBE
a.
b.
Carbon
Specilaity
900
900
(1)
(1)
(1)
(1)
900
625
225
225
625
625
(1) No additional land required
Note: For definitions of C&TT codes refer to Table VII-1.
-------
TABLE VIII-4
LAND REQUIREMENTS SUMMARY
HOT FORMING SUBCATEGORY
BAT TREATMENT MODELS
C & TT Steps
BAT Alternative No. 1
BAT Alternative No. 2
(1)
Subdivision
Primary
a. Carbon w/o scarfing
b. Carbon w/ scarfing
c. Specialty w/o scarfing
d. Specialty w/ scarfing
Section
a. Carbon
b. Specialty
Flat
a. Carbon hot strip & sheet
b. Specialty hot strip & sheet
c. Carbon plate
d. Specialty plate
Pipe & Tube
a. Carbon
b. Specialty
G
(CT)
H
(RTF)
710
2045
225
511
1548
336
3870
480
893
125
238
133
2000 ft"
3000
1000
1500
2500
1200
4000
1500
2000
800
1000
800
I
(EME)
3600 ft'
4900
3025
3600
4225
3600
10,000
3600
3600
3600
3600
3025
J
(RTF)
625 ft'
1000
625
625
800
625
1500
625
625
625
625
625
(1) These land requirements are in addition to those of Alternative 1. Each model's
Alternative No. 2 incorporates all of the components of Alternative 1.
252
-------
TABLE VIII-5
BPT TREATMENT MODEL COSTS; BASIS 7/1/78 DOLLARS
Subcategory: Hot Forming
Subdivision: Primary, Carbon
: Without Scarfers
C&TT Step
Oil Disposal
Energy & Power
Steam
Waste Acid
Crystal Disposal
Chemical
TOTAL
Credits
Scale
Sinter
Oil
Acid Recovery
TOTAL CREDITS
NET TOTAL
Model Size-TPD : 3,800
Oper. Days/Year: 260
Turns/Day : 3
_•»
Investment ($ x 10 )
Annual Costs ($ x 10 )
Capital
Operation & Maintenance
Land
Sludge Disposal
268.3
24.1
9.4
0.1
25.0
2.2
0.9
601.0
54.0
21.0
315.2
28.3
11.0
0.1
180.2
16.2
6.3
0.1
3.5
910.0
81.8
31.8
0.1
2,299.7
206.6
80.4
0.4
3.5
0.3
2.3
33.6
336.3
336.3
-302.7
3.4 75.0
17.4
17.4
-14.0 75.0
KEY TO C&TT STEPS
41.7
41.7
4.1
30.2
30.2
A: Primary Scale Pit
B: Surface Skimming
C: Recycle
D: Roughing Clarification
E: Vacuum Filtration
F: Pressure Filtration
.11.6
125.3
125.3
18.3
309.2
336.3
17.4
353.7
-44.5
-------
TABLE VIII-6
BPT TREATMENT MODEL COSTS; BASIS 7/1/78 DOLLARS
Subcategory: Hot Forming
Subdivision: Primary, Carbon
: With Scarfers
' Model Size-TPD : 7,400
Oper. Days/Year: 260
Turns/Day : 3
C&TT Step
Total
—3
Investment ($ x 10 )
Annual Costs ($ x 10 )
Capital
Operation & Maintenance
Land
Sludge Disposal
423.5
38.1
14.8
0.2
60.5
5.4
2.1
1,167.4
105.0
40.9
492.0
, 44.2
17.2
0.2
327.1
29.4
11.4
0.1
10.0
2,392.0
215.0
83.7
0.3
4,862.5
437.1
170.1
0.8
10.0
Hazardous Haste Disposal
Oil Disposal
Energy & Power
Steam
Waste Acid
Crystal Disposal
Chemical
TOTAL
Credits
Scale
Sinter
Oil
Acid Recovery
TOTAL CREDITS
NET TOTAL
0.6
2.3
53.1
1,314.8
1,314.8
-1,261.7
8.1
145.9
63.9
29.8
29.8
-21.7 145.9
KEY TO C&TT STEPS
63.9
5.2
56.1
56.1
A: Primary Scale Pit
B: Surface Skimming
C: Recycle
D: Roughing Clarification
E: Vacuum Filtration
F: Pressure Filtration
20.4
319.4
319.4
28.5
646.5
1,314.8
29.8
1,344.6
-698.1
-------
TABLE VIII-7
BPT TREATMENT MODEL COSTS: BASIS 7/1/78 DOLLARS
Subcategory: Hot Forming Model Size-TPD : 1,200
Subdivision: Primary, Specialty Oper. Days/Year: 260
: Without Scarfers Turns/Day : 3
C&TT Step A B C D E
Investment ($ x 10~3) 142.5 21.0 374.1 157.9 126.0
Annual Costs ($ x 10~ )
Capital 12.8 1.9 33.6 14.2 11.3
Operation & Maintenance 5.0 0.7 13.1 5.5 4.4
Land 0.1 0.1 . 0.1
Sludge Disposal 1.3
Hazardous Waste Disposal
Oil Disposal
Energy & Power 0.3 0.6 3.5
Steam
Waste Acid
Crystal Disposal
Chemical
TOTAL 17.9 2.9 46.7 20.4 20.6
Credits
Scale 104.8
Sinter
Oil 5.5
Acid Recovery
TOTAL CREDITS 104.8 5.5
NET TOTAL -86.9 -2.6 46.7 20.4 20.6
F Total
539.3 1,360.8
48.5 122.3
18.9 47.6
0.1 0,4
1.3
5.8 10.2
73.3 181.8
104.8
5.5
110.3
73.3 71.5
KEY TO C&TT STEPS
A: Primary Scale Pit
B: Surface Skimming
C: Recycle
D: Roughing Clarification
E: Vacuum Filtration
F: Pressure Filtration
-------
TABLE VIII-8
BPT TREATMENT MODEL COSTS; BASIS 7/1/78 DOLLARS
Subcategory: Hot Forming
Subdivision: Primary, Specialty
: With Scarfers
Model Size-TPD : ^1,850 }
Oper. Days/Year: ""' 260
Turns/Day : 3
C&TT Step
Total
to
in
Investment ($ x 10 )
_o
Annual Costs ($ x 10 )
Capital
Operation & Maintenance
Land
Sludge Disposal
220.3
19.8
7.7
0.1
25.0
2.2
0.9
f 538.0 )
48.4
18.8
-
258.8
23.3
9.1
0.1
162.5
14.6
5.7
0.1
2.5
758.3
68.2
26.5
0.1
1,962.9
176.5
68.7
0.4
2.5
Hazardous Waste Disposal
Oil Disposal
Energy & Power
Steam
Waste Acid
Crystal Disposal
Chemical
TOTAL
Credits
Scale
Sinter
Oil
Acid Recovery
TOTAL CREDITS
NET TOTAL
0.3
1.2
27.6
323.2
323.2
-295.6
3.4 67.2
7.5
7.5
-4.1 67.2
KEY TO C&TT STEPS
33.7
33.7
3.5
26.4
26.4
A: Primary Scale Pit
B: Surface Skimming
C: Recycle
D: Roughing Clarification
E: Vacuum Filtration
F: Pressure Filtration
8.7
103.5
103.5
13.7
261.8
323.2
7.5
330.7
-68.9
-------
TABLE VIII-9
BPT TREATMENT MODEL COSTS: BASIS 7/1/78 DOLLARS
Subcategory: Hot Forming Model Size-TPD : 3,050
Subdivision: Section, Carbon Oper. Days/Year: 260
Turns/Day : 3
C&TT Step A B C D E F
Investment ($ x 10~3) 336.9 35.2 893.0 408.6 304.0 , 2,007.4
Annual Costs ($ x 10~ )
Capital 30.3 3.2 80.3 36.7 27.3 180.5
Operation & Maintenance 11.8 1.2 31.3 14.3 10.6 70.3
Land 0.1 0.2 0.1 0.2
Sludge Disposal 7.5
Hazardous Waste Disposal
Oil Disposal
in Energy fi Power 0.6 2.3 4.7 17.4
^ Steam
Waste Acid .
Crystal Disposal
Chemical
TOTAL 42.2 5.0 111.6 53.5 50.2 268.4
Credits
Scale 253.3
Sinter
Oil 10.3
Acid Recovery
TOTAL CREDITS 253.3 10.3
NET TOTAL -211.1 -5.3 111.6 53.5 50.2 268.4
KEY TO CSTT STEPS
Total
3,985.1
358.3
139.5
0.6
7.5
25.0
530.9
253.3
10.3
263.6
267.3
A: Primary Scale Pit
B: Surface Skimming
C: Recycle
D: Roughing Clarification
E: Vacuum Filtration
F: Pressure Filtration
-------
TABLE VIII-10
to
i_n
00
C&TT Step
Investment ($ x 10 )
Annual Costs ($ x 10 )
Capital
Operation & Maintenance
Land
Sludge Disposal
Subcategory: Hot Forming
Subdivision: Section, Specialty
A B C
162.6 23.0 410.5
14.6 2.1 36.9
5.7 0.8 14.4
0.1
Model Size-TPD J 1,200
Oper. Day s /Year: 260
Turns/Day : 3
DBF
201.2 138.2 589.5
18.1 12.4 53.0
7.0 4.8 20.6
0.1 0.1 0.1
1.7
Total
1,525.0
137.1
53.3
0.4
1.7
Hazardous Waste Disposal
Oil Disposal
Energy & Power
Steam
Waste Acid
Crystal Disposal
Chemical
TOTAL
Credits
Scale
Sinter
Oil
Acid Recovery
TOTAL CREDITS
NET TOTAL
0.3
1.7
3.5
20.4
104.8
104.8
-84.4
3.2 51.3
5.0
5.0
-1.8 51.3
KEY TO C&TT STEPS
26.9
22.5
26.9
22.5
5.8
79.5
79.5
A: Primary Scale Pit
B: Surface Skimming
C: Recycle
D: Roughing Clarification
E: Vacuum Filtration
F: Pressure Filtration
11.3
203.8
104.8
5.0
109.8
94.0
-------
TABLE VIII-11
BPT TREATMENT MODEL COSTS! BASIS 7/1/78 DOLLARS
Subcategory: Hot Forming Model Size-TPD : 7,250
Subdivision: Flat, Carbon Oper. Days/Year: 260
: Hot Strip & Sheet Turns /Day : 3
C&TT Step A B C D F. F
Investment ($ x 10~ ) 684.8 103.7 1,856.2 739.5 347.0 2,857.5
Annual Costs ($ x 10~ )
Capital 61.6 9.3 166.9 66.5 31.2 256.9
Operation & Maintenance 24.0 3.6 65.0 25.9 12.1 100.0
Land 0.3 0.4 0.1 0.5
Sludge Disposal 18.2
Hazardous Waste Disposal
Oil Disposal
Energy & Power 1.2 2.3 5.8 23.3
Steam
Waste Acid •
Crystal Disposal
Chemical
TOTAL 85.9 14.1 231.9 95.1 67.4 380.7
Credits
Scale 585.3 .
Sinter
Oil 20.1
Acid Recovery
TOTAL CREDITS 585.3 20.1
NET TOTAL -499.4 -6.0 231.9 95.1 67.4 380.7
Total
6,588.7
592.4
230.6
1.3
18.2
32.6
875.1
585.3
20.1
605.4
269.7
KEY TO C&TT STEPS
A: Primary Scale Pit
B: Surface Skimming
C: Recycle
D: Roughing Clarification
E: Vacuum Filtration
F: Pressure Filtration
-------
TABLE VIII-12
BPT TREATMENT MODEL COSTS; BASIS 7/1/78 DOLLARS
NJ
OV
o
C&TT Step
_o
Investment ($ x 10 )
Annual Costs ($ x 10 )
Capital
Operation & Maintenance
Land
Sludge Disposal
Hazardous Waste Disposal
Oil Disposal
Energy & Power
Steam
Waste Acid
Crystal Disposal
Chemical
TOTAL
Credits
Scale
Sinter
Oil
Acid Recovery
TOTAL CREDITS
NET TOTAL
tegory: Hot Forming
vision: Flat, Specialty
: Hot Strip & Sheet
ABC
208.9 24.0 505.3
18.8 2.2 45.4
7.3 0.8 17.7
0.1
0.3
26.2 3.3 63.1
74.3
2.5
74.3 2.5
-48.1 0.8 63.1
Model Size-TPD : 900
Oper. Days/Year: 260
Turns/Day : 3
D E F Total
249.2 153.5 730.2 1,871.1
22.4 13.8 65.6 168.2
8.7 5.4 25.6 65.5
0.1 0.1 0.1 0.4
2.3 2.3
1.7 3.5 8.7 14.2
32.9 25.1 100.0 250.6
74.3
2.5
76.8
32.9 25.1 100.0 173.8
KEY TO C&TT STEPS
A: Primary Scale Pit
B: Surface Skimming
C: Recycle
Ds Roughing Clarification
E: Vacuum Filtration
F: Pressure Filtration
-------
TABLE VIII-13
BPT TREATMENT MODEL COSTS1 BASIS 7/1/78 DOLLARS
Subcategory: Hot Forming Model Size-TPD : 3,150
Subdivision: Flat, Carbon Oper. Days/Year: 260
: Plate Turns/Day : 3
C&TT Step A B C D E F
Investment ($ x 10~3) 329.0 26.8 621.4 361.5 241.0 1,039.6
Annual Costs ($ x 10~ )
Capital 29.6 2.4 55.9 32.5 21.7 93.5
Operation 6 Maintenance 11.5 0.9 21.7 12.7 8.4 36.4
Land 0.1 0.1 0.1 0.1
Sludge Disposal . 4.3
Hazardous Haste Disposal
Oil Disposal
Energy & Power 0.3 2.3 4.1 8.7
Steam
Haste Acid
Crystal Disposal
Chemical
Total 41.2 3.6 77.6 47.6 38.6 138.7
Credits
Scale 270.8
Sinter
Oil 12.7
Acid Recovery
TOTAL CREDITS 270.8 12.7
NET TOTAL -229.6 -9.1 77.6 47.6 38.6 138.7
KEY TO CfiTT STEPS
Total
2,619.3
235.6
91.6
0.4
4.3
15.4
347.3
270.8
12.7
283.5
63.8
A: Primary Scale Pit
B: Surface Skimming
C: Recycle
D: Roughing Clarification
E: Vacuum Filtration
F: Pressure Filtration
-------
TABLE VHI-14
BPT TREATMENT MODEL COSTSt BASIS 7/1/78 DOLLARS
Subcategory: Hot Forming Model Size-TPD : 1,000
Subdivision: Flat, Specialty Oper. Days/Year: 260
: Plate Turns/Day : 3
C&TT Step ABODE F
Investment ($ x 10"3) 113.0 19.9 308.5 111.2 98.8 460.4
Annual Costs ($ x 10~ )
Capital 10.2 1.8 27.7 10.0 8.9 41.4
Operation & Maintenance 4.0 0.7 10.8 3.9 3.5 16.1
Land 0.1 0.1 0.1 0.1
Sludge Disposal 0.6
to Hazardous Waste Disposal
£ Oil Disposal
Energy & Power 0.2 0.6 1.7 3.5
Steam
Waste Acid
Crystal Disposal
Chemical
TOTAL 14.3 2.7 38.5 14.6 14.8 61.1
Credits
Scale 87.4
Sinter
Oil 5.0
Acid Recovery
TOTAL CREDITS 87.4 5.0
NET TOTAL -73.1 -2.3 38.5 14.6 14.8 61.1
KEY TO C&TT STEPS
Total
1,111.8
100.0
39.0
0.4
0.6
6.0
146.0
87.4
5.0
92.4
53.6
AJ Primary Scale Pit
B: Surface Skimming
Cs Recycle
D: Roughing Clarification
E: Vacuum Filtration
F: Pressure Filtration
-------
TABLE VIII-15
BPT TREATMENT MODEL COSTS; BASIS 7/1/78 DOLLARS
Subcategory: Hot Forming
Subdivision: Pipe & Tube, Carbon
C&TT Step ABC
Investment ($ x 10~3) 181.9 23.0 537.0
Annual Costs ($ x 10 )
Capital 16.3 2.1 48.3
Operation & Maintenance 6.4 0.8 18.8
Land 0.1
Sludge Disposal
Hazardous Waste Disposal
Oil Disposal
Energy & Power 0.3
Steam
Waste Acid
Crystal Disposal
Chemical
TOTAL 22.8 3.2 67.1
Credits
Scale 8.7
Sinter
Oil 2.9
TOTAL CREDITS 8.7 2.9
NET TOTAL 14.1 0.3 67.1
KEY TO C&TT STEPS
Model Size-TPD : 900
Oper. Day s /Year 8 260
Turns /Day 8 3
DBF
163.7 126.0 540.0
14.7 11.3 48.5
5.7 4.4 18.9
0.1 0.1 0.1
1.2
1.7 2.9 5,8
22.2 19.9 73.3
22.2 19.9 73.3
Total
1,571.6
141.2
55.0
0.4
1.2
10.7
208.5
8.7
2.9
11.6
196.9
A: Primary Scale Pit
B: Surface Skimming
C: Recycle
D: Roughing Clarification
E: Vacuum Filtration
Fs Pressure Filtration
-------
to
TABLE VIII-16
^
BPT TREATMENT MODEL COSTS; BASIS 7/1/78 DOLLARS
Subcategory: Hot Forming
Subdivision: Pipe & Tube, Specialty
C&TT Step ABC
Investment ($ x 10~3) 142.5 21.0 399.1
Annual Costs ($ x 10~ )
Capital 12.8 1.9 35.9
Operation & Maintenance 5.0 0.7 14.0
Land 0.1
Sludge Disposal
Hazardous Waste Disposal
Oil Disposal
Energy & Power 0.3
Steam
Waste Acid
Crystal Disposal
Chemical
TOTAL 17.9 2.9 49.9
Credits
Scale 39.3
Sinter
Oil 1.6
Acid Recovery
TOTAL CREDITS 39.3 1.6
NET TOTAL -21.4 1.3 49.9
KEY TO C&TT STEPS
Model Size-TPD : 500
Oper. Days/Year: 260
Turns /Day : 3
D E F
115.0 110.2 476.1
10.3 9.9 42.8
4.0 3.9 16.7
0.1 0.1 0.1
0.6
1.2 1.7 3.5
15.6 16.2 63.1
15.6 16.2 63.1
Total
1,263.9
113.6
44.3
0.4
0.6
6.7
165.6
39.3
1.6
40.9
124.7
A: Primary Scale Pit
B: Surface Skimming
Cs Recycle
D: Roughing Clarification
E: Vacuum Filtration
F: Pressure Filtration
-------
TABLE VIII-17
BPT COST SUMMARY (MILLIONS OF 7/1/78 DOLLARS)
HOT FORMING SUBCATEGORY
BPT
Subdivision
Primary
a. Carbon w/o scarfing
b. Carbon w/ scarfing
c. Specialty w/o scarfing
d. Specialty w/ scarfing
Section
a. Carbon
b. Specialty
Flat
a. Carbon hot strip & sheet
b. Specialty hot strip & sheet
c. Carbon plate
d. Specialty plate
Pipe & Tube
a. Carbon
b. Specialty
Confidential Plants
Hot Forming Total
Capital
In-Place
34.15
76.45
6.49
6.74
123.83
88.95
13.28
102.23
102.04
5.05
13.66
3.01
123.76
12.76
3.68
16.44
13.87
380.13
Required
9.85
20.78
0.76
0.00
31.39
19.05
4.17
, 23.22
23.26
0.14
6.49
0.18
30.07
9.35 .
0.00
9.35
0.82
94.85
Annual
In-Place
- 5.29
-29.62
- 0.15
- 0.75
-35.81
- 0.96
-» 0.15
- 1.11
- 4.83
0.23
- 1.23
0.07
- 5.76
1.42
0.27
1.69
0.21
-40.78
Required
1.32
2.68
0.00
0.00
4.00
2.48
0.30
2 . 78
3.06
0.02
0.87
0.02
3.97
1.23
0.00
1.23
-0.02
11.96
265
-------
TABLE VIII-18
BAT/PSES TREATHEHT MODEL COSTS; BASIS 7/1/78 COLLARS
Subcategory: Hot Forming
Subdivision: Primary, Carbon
: Without ScarCera
Model Size - TPD: 3,800
Oper. Days/Year : 260
Turns/Day : 3
to
en
en
C&TT Step
Investment ($ x 10 )
Annual Costs ($ x 10 )
Capital
Operation & Maintenance
Land
Sludge Disposal
Hazardous Waste Disposal
Oil Disposal
Energy S Power
Steam
Waste Acid
Crystal Disposal
Chemical
TOTAL
Total
BPT
2,299.7
206.6
80.4
0.4
3.5
18.3
309.2
BAT Alternative 1
BAT Alternative 2
Alt. 1 Plus:
Credits
Scale
Sinter
Oil
Acid Recovery
TOTAL CREDITS
NET TOTAL
336.3
17.4
353.7
-44.5
740.9
66.6
25.9
0.1
28.5
121.1
H
499.0
44.9
17.5
0.1
62.5
Total
1,239.9
111.5
43.4
0.2
28.5
183.6
3,854.2
346.5
134.9
0.2
207.1
688.7
93.3
8.4
3.3
0.1
11.8
Total
5,187.4
466.4
181.6
0.5
235.6
884.1
121.1
62.5
183.6
688.7
11.8
884.1
KEY TO TREATMENT ALTERNATIVES
PSES-1 = BPT
PSES-2 = BPT + BAT-1
PSES-3 = BPT + BAT-2
KEY TO CSTT STEPS
G: Cooling Tower
H: Recycle
I: Vapor Compression Distillation
J: Recycle *^
-------
TABLE VIII-19
BAT/PSES TREATMENT MODEL COSTS; BASIS 7/1/78 DOLLARS
Subcategory: Hot Forming
Subdivision: Primary, Carbon
: With Scarfera
Model Size - TPD: 7,400
Oper. Days/Year : 260
Turns/Day : 3
en
C&TI Step
Investment ($ x 10 )
Annual Costs ($ x 10~3)
Capital
Operation & Maintenance
Land
Sludge Disposal
Hazardous Waste Disposal
Oil Disposal
Energy & Power
Steam
Waste Acid
Crystal Disposal
Chemical
TOTAL
Total
BPT
4,862.5
437.1
170.1
0.8
10.0
28.5
646.5
BAT Alternative 1
BAT Alternative 2
Alt. 1 Plus:
Credits
Scale
Sinter
Oil
Acid Recovery
TOTAL CREDITS
NET TOTAL
1,314.8
29.8
1,344.6
-698.1
1,664.7
149.7
58.3
0.1
72.1
280.2
80.3
31.3
0.2
111.8
Total
2,557.7
230.0
89.6
0.3
72.1
392.0
7,265.3
653.1
254.3
0.3
595.8
1,503.5
308.5
27.7
10.8
0.1
38.6
Total
10,131.5
910.8
354.7
0.7
667.9
1,934.1
280.2
111.8
392.0
1,503.5
38.6
1,934.1
KEY TO TREATMENT ALTERNATIVES
PSES-1 = BPT
PSES-2 = BPT + BAT-1
PSES-3 =• BPT + BAT-2
KEY TO C&TT STEPS
G: Cooling Tower
H: Recycle
I: Vapor Compression Distillation
J: Recycle
-------
TABLE VIII-20
BAT/PSES TREATMENT HOEEL COSTS! BASIS 7/1/78 DOLLARS
Subcategory: Hot Forming
Subdivision: Primary, Specialty
: Without Scarfers
Model Size - TPD: 1,200
Oper. Days/Year : 260
Turns/Day : 3
to
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-------
HOT FORMING SUBCATEGORY
SECTION IX
EFFLUENT QUALITY ATTAINABLE THROUGH THE
APPLICATION OF THE BEST PRACTICABLE CONTROL
TECHNOLOGY CURRENTLY AVAILABLE
The Agency has promulgated best practical control technology currently
available (BPT) limitations that are different than those originally
promulgated in March, 1976 and proposed on January 1, 1981. These
limitations are based upon the same model treatment system used to
develop the prior limitations and upon an expanded industry data base
acquired as part of this rulemaking. The 1976 limitations (and the
proposed limitations) were based upon limited data for hot forming
operations available at that time. The expanded data base includes
nearly all hot forming operations and more accurately reflects the
industry in terms of applied process water flows, and the installation
and. performance of wastewater treatment facilities. Some of the BPT
limitations are more stringent than the proposed limitations and some
are less stringent.
The subdivision of the Hot Forming subcategory is as follows:
Hot Forming - Primary
Carbon and Specialty Mills Without Scarfers
Carbon and Specialty Mills With Scarfers
Hot Forming - Section
Carbon Mills
Specialty Mills
Hot Forming - Flat
Hot Strip and Sheet Mills
Plate Carbon Steel Mills
Plate Specialty Steel Mills
Hot Forming Pipe and Tube
Identification of_ BPT
The original BPT model treatment systems for primary, section, and
•flat operations included primary scale pits equipped with oil skimming
facilities, partial recycle, roughing clarifiers, vacuum filters, and
.filters. In these models, recycle followed sedimentation of the
process wastewaters in primary scale pits with the high blowdown from
the partial recycle loop undergoing additional treatment. -The BPT
model treatment system for integrated hot working pipe and tube
operations is similar to the system described above, however; recycle
in this system follows sedimentation in a roughing clarifier' instead
307
-------
of after the scale pit. Filtration was provided for the recycle
blowdown. The model treatment system for isolated pipe and tube
operations incorporated a primary scale pit equipped with oil skimming
facilities, settling basin, and recycle. Partial recycle followed
sedimentation in the settling basin, with the blowdown of the recycle.
loop receiving no further treatment. Makeup water is required to
compensate for system losses in each of the cases presented above.
In the model treatment system the wastewater discharged from the mill
is collected in a scale pit where large particles settle out and
surface skimmers remove floating oils. Depending upon the hot forming
subdivision, anywhere from 58 to 77 percent of the primary scale pit
effluent is recirculated to the mill. The remaining wastewater
effluent is processed in a roughing clarifier and then a filter for
additional suspended solids and oil removal. A vacuum filter is used
to dewater the under flow from the clarifier.
Figure IX-1 depicts the model treatment systems discussed above.
Table IX-1 presents a summary of the characteristics of untreated hot
forming process wastewaters. Sampled plant monitoring data were used
to determine the raw wastewater pH values; however, the raw wastewater
suspended solids and oil and grease concentrations were determined
from information supplied in the D-DCPs (refer to Section VII).
Sampled plant monitoring data could not be used for this purpose
beca'use, in most instances only samples of the effluents of primary
scale pits could be obtained. The Agency believes its estimates of
raw waste loadings are accurate.
model treatment
Thus, the use of
As noted in Section VII, the components of the BPT
systems are in use at most hot forming operations.
each treatment system component is substantiated.
Development gf_ the BPT Effluent Limitations
a- Model Treatment System Flow Rates
Tables IX-2 through IX-9 present the applied process water flow (mgd
and gal/ton) and production capacity for each hot forming operation
for which the Agency has such data. These data were grouped by
subdivision and the average applied flow was determined by dividing
the total applied flow for all plants within the subdivision by the
total production capacity of the subcivision. Production weighted
average applied flow rates were developed for each segment for the
purpose of establishing the model flow rates, which are, in turn, used
for sizing and costing the model treatment systems and for
establishing effluent limitations. The Agency believes that the
weighted average method of determining the model flow rates results in
the most representative flows for this subcategory. The data indicate
wide variations in production and flow rates between the hot forming
mills in each of the segments. The Agency could not identify subsets
of hot forming mills which would be representative of the best plants
in each segment, since no discernable patterns were evident in the
data. Thus, the Agency decided to use all of the reported production
308
-------
and flow data to develop the model flow rates. The production
weighted method for calculating the average minimizes the bias of the
extremes in production and flow rates arid results in a representative
average model flow for each segment. The applied flows determined in
this manner are presented below:
Subdivision
Primary
wo/scarfer
w/scarfer
Section
carbon
specialty
Flat
hot strip
plate carbon
specialty
Pipe and Tube
Applied Process Water Flow
(Gallons/Ton)
2300
3400
5100
3200
6400
3400
1500
5520
The Agency has determined that these flow rates are more
representative of the flow rates achievable by operations in this
subcategory than those used to develop the 1976 effluent limitations
and the proposed limitations.
Primary scale pit recycle serves to minimize the flow requiring
further treatment and thus the cost of such treatment. Table IX-10
presents primary scale pit recycle rate data for plants with primary
scale -pit recycle systems for which reported flow data recycle rates
range from ^ less than 10 percent of the applied flow to several
reported values of 100 percent. The Agency believes that recycle
rates in the range of 40 to 80 percent are representative of good
wastewater management practices for primary, section, and flat
operations. The average of values in this range for each of these
operations is about 60 percent. This degree of recycle provides for
significant cost reduction in downstream treatment facilities and, as
demonstrated at many plants, can be achieved without cooling of the
return water. For pipe and tube operations, the Agency determined
that higher primary scale pit recycle rates are typical of these mills
with primary scale pit recycle and a rate of 77 percent was selected
as the model plant recycle rate. The Agency does not believe that
scale pit recycle rates greater than 80% for these operations can be
achieved at all plants. Based upon the applied flows presented above
and these primary scale pit recycle rates, the following model plant
BPT effluent flows were developed:
309
-------
Subdivision
Primary
wo/scarfer
w/scarfer
Section
carbon
specialty
Flat
hot strip
plate - carbon
- specialty
BPT Model Plant
Effluent Flow
(Gallons/Ton)
897
1326
2142
1344
2560
1360
600
Pipe and Tube 1270
b. Model Treatment System Effluent Quality
The final treatment component in the BPT model treatment system is
filtration of the discharge flow. The Agency determined that the
following concentrations of total suspended solids and oil and grease
represent consistently achievable effluent quality for filtration
systems:
Total Suspended Solids
Oil and Grease
30 Day
Average
15 mg/1
Daily
Maximum
40 mg/1
10 mg/1
These performance values were determined from long term filtration
data (nearly 6000 points) for several hot forming and other steel
industry operations with similar wastewaters as shown in Tables IX-11
and IX-12. Refer to Tables A-9 through A-13 of Appendix A to Volume I
for the development of these concentration values. Only a daily
maximum oil and grease limitation was selected to avoid possible
problems with sampling and analytical detection and accuracy at
concentrations of less than 5 mg/1.
c. BPT Effluent Limitations
The resulting BPT effluent limitations are presented in Table IX-13.
Those limitations were determined with the effluent flow and
concentration data presented above.
Demonstration of, BPT Effluent Limitations
Based upon a review and update of all forming operations for which it
has data the Agency has determined that about 75 percent of the hot
forming operations are currently in compliance with the BPT effluent
310
-------
limitations. Treatment systems installed at these facilities range
from less than the model treatment systems with to extensive high rate
recycle systems with small blowdowns. Tables IX-14 to IX-21, present
data for some of the plants in compliance with the limitations. Those
listed plants that do not meet the limitations have flows that greatly
exceed the limitations, or lack one of the treatment components, e.g.,
oil skimmers. The Agency believes these plants will comply with the
limitations if the flows are reduced or the missing treatment
components are installed. Table IX-22 presents data for treatment
plants that demonstrate compliance with the hot forming limitations.
311
-------
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312
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TABLE IX-2
APPLIED FLOW DETERMINATION
HOT FORMING-PRIMARY: CARBON & SPECIALTY
Plant
Reference
Code
0020B
0060
0060D
0060G
00601
0176
0188A
0188B
0248C
0320-02
0384A-01
0396E
0424
0430C-01
0430C-02
0440A
0476A
0492A
0528A
0612-01
0612-02
0640
0652A
0672B
0684A
0684B
0684E
0684F-01
0856H-01
0856H-02
0856T-01
0860B-04
0860H-01
0860H-02
0860H-03
0864A-01
0864A-02
0864C
0868A-01
Basic Flow,
Applied
Flow
(Gal/Ton)
1594
1012
254
3891
3782
760
5585
3656
2186
805
7483
4465
800
288
1655
27,163
3273
1551
1090
3913
4926
4332
1087
6517
742
1050
857
3698
2725
2787
1281
3587
6747
1866
320
1272
2124
1280
1236
Excluding Machine Scarfing
Production
Capacity
(Tons /Day)
4065
8537
2268
2868
495
285
825
804
415
9600
3864
1419
450
90
114
387
1699
3714
5550
3312
2631
1878
795
453
4851
4905
2520
1752
1872
1830
4059
2529
2988
8490
3441
6795
2373
450
3000
Total
Applied Flow
(MGD)
6.48
8.64
0.58
11.16
1.87
0.22
4.61
2.94
0.91
7.73
28.91
6.34
0.36
0.026
0.19
10.51
5.56
5.76
6.05
12.96
12.96
8.14
0.86
2.95
3.60
5.15
2.16
6.48
10
10
20
07
20.16
15.84
1.10
8.64
5.04
0.58
3.71
313
-------
TABLE IX-2
APPLIED FLOW DETERMINATION
HOT FORMING-PRIMARY: CARBON & SPECIALTY
PAGE 2
Plant
Reference
Code
0868A-02
0868A-03
0920A
0920B
0940
0946A
0948A
0948B
0948C-01
0948C-02
Production Weighted
Applied Flow Average*
Applied
Flow
(Gal/Ton)
614
1886
3100
2382
1067
1296
1105
1095
710
3308
Production
Capacity
(Tons/Day)
2340
4692
5361
5325
135
3066
3909
3930
4461
7923
Total
Applied Flow
(MGD)
1.44
8.85
16.62
12.68
0.14
3.97
4.32
49
17
26.21
Z Total Applied Flow (MGD)** _ 355,101,000 GPP
2 Production Capacity (TPD)** 162,242 TPD
Use:
2276 Gal /Ton
2300 Gal/Ton
* :
**.
Based upon available data. Data for those operations with unknown flows or
with flows which included scarfing or noncontact cooling water are not included.
These totals include flow and production data for confidential plants.
314
-------
TABLE IX-3
APPLIED FLOW DETERMINATION
HOT FORMING-PRIMARY: CARBON & SPECIALTY
MACHINE SCARFING OPERATIONS
Plant
Reference .,--.'
Code
0060
0060G
0320-02
0528A
0684F-01
0920A
0946A
0948H
0948C-02
Production Weighted
Applied Flow Average*
Applied
Flow
(Gal/Ton)
1012
1004
1370
1038
2466
365
254
2376
600
Product ion
Capacity
(Tons/Day)
8537
2868
9600
5550
1752
5361
3066
3909
7923
Total
Applied Flow
(MGD)
8.64
2.88
13.15
Z Total Applied Flow (MGD)
Z Production Capacity (TPD)
Use:
5.76
4.32
1.96
0.78
9.29
4.75
56,300,000 Gal/Day
54,131 Ton/Day
1040 Gal/Ton
1050 Gal/Ton**
**•
Based upon available data. Data for those operations with unspecified or
nonsegregated scarfer flow data are not included.
An additional applied flow of 50 gal/ton is provided to account for blowdowns
.from scarfer fume scrubbers. Total applied flow from scarfing operations is
1100 gal/ton.
315
-------
TABLE IX-4
APPLIED FLOW DETERMINATION
HOT FORMING-SECTION: CARBON MILLS
Plant
Reference
Code
0060F-05
0060G-01
0060G-02
0060G-03
0060G-04
0060H-01
0060K-01
0068B
0112A-01
0136B-01
0136B-02
0136C
0188B
0188C
0288A-05
0288A-06
0288A-07
0288A-08
0316
0316A
0316B
0384A-02
0384A-03
0384A-04
0384A-05
0384A-06
0432A-02
0460A-01
0460A-02
0460B
0468B
0468F
0476A-01
0476A-02
0476A-03
0584F
App 1 led
Flow
(gal/ton)
11,576
2,342
3,429
12,490
6,515
3,025
8,045
20,386
4,627
8,372
22,942
11,859
7,258
7,480
1,995
7,014
316
1,328
9,044
7,543
10,383
3,055
3,797
3,860
8,029
3,376
6,340
4,816
7,744
32,686
7,811
29,465
16,719
9,018
10,075
14,900
Production
Capacity
(tons /day)
1,224
2,337
1,008
294
1,326
1,071
537
353
3,735
522
354
411
804
462
21
4
334
37
446
420
423
3,420
1,479
933
816
1,758
1,167
897
702
441
1,294
312
190
502
800
807
Total Applied
Flow
(MGD)
14.17
5.47
3.46
3.67
8.63
3.24
4.32
7.20
17.28
4.37
8.12
4.87
5,84
3.46
0.042
0.028
0.11
0.049
4.03
3.17
4.39
10.45
5.
3.
62
60
6.55
94
39
4.32
5.44
14.41
10.10
9.19
3.18
4.53
8.06
12.02
316
-------
TABLE IX-4
APPLIED FLOW DETERMINATION
HOT FORMING-SECTION: CARBON MILLS
PAGE 2
Plant
Reference
Code
0612-01
0612-02
0612-03
0612-04
0612-05
0640
0640A-01
0640A-02
0652A-01
0652A-02
0672A-01
0672A-02
0684A-Q1
0684A-02
0684F-01
0684F-02
0684F-03
0684G-01
0684G-02
0684G-03
0684G-04
0684H-01
0684H-03
0684H-04
0684H-05
0684H-06,07
0804B-01
0804B-02
0856 F-01
0856F-02
0856F-04
0856F-05
0856H-01
0856H-02
0856K-01
0856K-02
0856K-03
Applied
Flow
(gal/ton)
4S204
9,870
12,527
4,204
5,462
3,352
11,449
13,775
7,111
6,261
5,418
10,967
1,705
10,052
3,767
8,282
8,190
2,240
4,774
5,026
9,722
4,710
910
3,792
3,507
3,400
138
131
1,258
952
12,238
8,101
1,515
1,906
61
198
1,770
Production
Capacity
(tons/day)
3,162
1,386
1,092
948
1,239
903
203
507
243
345
817
328
2,112
573
1,338
765
756
900
1,131
573
237
2,898
2,898
1,314
1,707
1,428
150
342
6,867
6,867
1,057
2,133
1,683
1,338
123
255
732
Total Applied
Flow
(MGD)
13 = 29
13.68
13.68
3,99
6.77
3.03
2.32
6.98
1,
2.
73
16
4.43
,60
,60
,76
,04
6.34
6.19
,02
,40
,88
,30
13.65
2.64
4.98
,99
,86
0.021
0.045
8.64
6.54
12.94
17.28
2.55
2.55
0.0075
0.050
1.30
3.
3,
5«
5,
2.
5.
2,
2.
5.
4.
317
-------
TABLE IX-4
APPLIED FLOW DETERMINATION
HOT FORMING-SECTION: CARBON MILLS
PAGE 3
Plant
Reference
Code
0856N-01
0856N-02
0856P
0856T-01
0856U-01
0856U-02
0856U-03
0856U-04
0856U-05
0860B-01
0860B-02
0860B-03
0860B-04
0860B-05
0860B-08
0860B-09
0860B-10
0860B-11
0860F-01
0860F-02
0860H-01
0860H-02
0860H-03
0864A
0864B
0864C-01
0864C-02
0868A-01
0868A-02
0868A-03
0868A-04
0868A-05
0920B-01
0920B-02
Applied
Flow
(gal/ton)
3,226
6,272
5,656
535
14,894
6,699
5,638
12,288
8,125
3,309
5,909
6,522
2,663
9,399
11,993
7,590
12,751
6,880
7,934
4,936
7,796
4,720
6,930
10,729
9,054
3,840
10,000
1,020
709
1,647
3,909
963
1,037
1,674
Production
Capacity
(tons/day)
3,348
1,722
1,233
1,029
204
690
378
225
693
2,132
536
486
1,135
429
492
474
892
1,464
726
1,167
2,616
1,380
2,058
2,040
1,161
450
360
1,902
2,307
1 ,-386
249
537
1,806
516
Total Applied
Flow
(MGD)
10.80
10.80
6.97
0.55
3.04
4.62
2.13
2.76
5,
7.
,63
.05
3.17
3.17
3.02
4.03
5.
3.
.90
.60
11.37
10.07
5.76
5.76
20.39
6.51
14.26
21.89
10.51
1.73
.60
,94
.64
.28
0.97
0.52
1.87
0.86
3.
1,
1,
2.
318
-------
TABLE IX-4
APPLIED FLOW DETERMINATION
HOT FORMING-SECTION: CARBON MILLS
PAGE 4 .
Plant
Reference
Code
0946A-01
0946A-03
0948B
0948F-03
Applied
Flow
(gal/ton)
7,589
7,798
2,625
3,750
Production
Capacity
(tons/day)
759
831
768
29
Total Applied
Flow
(MGD)
5.76
6.48 .
2.02
0.11
Production Weighted
Applied Flow Average*"
2 Total Applied Flow**
2 Production Capacity**
Uses
661,980,000 gal/day
130,892 tons/day
5058 gal/ton
5100 gal/ton
**.
Based upon available data. Data from those operations with unknown or
unavailable flows are not included.
This total includes flow and production data for confidential operations,
319
-------
TABLE IX-5
APPLIED FLOW DETERMINATION
HOT FORMING SECTION-SPECIALTY MILLS
Plant
Reference
Code
00601-01
00601-02
0088A
0088D
0112-07
0176-01,02,03
0176-04
0240A-01,02
0288A-01
0288A-02
0288A-03
0288A-04
0384A-01
0384A-07
0424-01
0424-02
0424-03
0440A
0672B-01
0672B-02
0684D-01
0684D-02
0684E-01
0684E-02
0684H-02
0776H-01
0946A-02
Production Weighted
Applied Flow Average*
Applied
Flow
(gal/ton)
10,636
13,040
561
6,430
33,391
3,570
8,228
2,600
4,114
2,527
2,359
3,136
3,055
3,276
7,283
11,707
10,537
3,200
4,880
5,922
1,493
1,689
3,087
8,571
580
2,347
8,742
1 Z Total
Production
Capacity
(tons /day)
176
138
531
885
138
119
210
1,422
7
14
22
11
2,418
879
44
25
25
45
270
462
1,929
1,626
1,185
504
2,280
37
906
Applied Flow** 64,
;e* 2 Production Capacity 20
Total Applied
Flow
(MGD)
1.87
1.80
0.30
5.69
4.61
0.42
1.73
3.70
0.029
0.035
0.052
0.034
7.39
2.88
0.32
0.29
0.26
0.14
1.32
2.74
2.88
2.75
3.66
4.32
1.32
0.087
7.92
910,000 gal/day _ 3157 gal/ton
,563 tons/day use 3200 gal/ton
**:
Based upon available data. Data for those operations with unknown or
unavailable flows are not included.
This total includes flow and production data for confidential operations,
320
-------
TABLE IX-6
APPLIED FLOW JUSTIFICATION
HOT FORMING-FLAT! HOT STRIP AND SHEET
Plant
Reference
Code
0020B
0060
0060D
0112AC03)
0112AC04)
0112D
0176
0248B
0320(02)
0384A(02)
0384AC03)
0384A(04)
0396D(01)
03960(02)
0424(02)
0432A
0432C
0476A
0492A
0528A
0584B
0584C
0584F
0684B
0684F(02)
06841(01)
0684V(02)
0776H(02)
0856D
0856F(01)
0856F(02)
0856P
0856U(01)
Applied
Flow
(gal/ton)
5,690
8,297
7,143
4,911
5,619
5,790
9,630
7,680
9,951
10,193
17,511
8,573
24,935
7,033
716
4,800
3,500
6,282
3,471
4,686
4,150
3,680
3,160
6,660
9,347
5,802
8,803
6,400
4,450
5,497
2,840
5,125
11,277
Production
Capacity
(tons /day)
2,550
10,032
2,520
6,978
7,893
12,744
240
1,500
8,232
12,291
3,666
5,400
231
1,638
20.1
5,400
10,404
828
3,152
5,549
14,022
9,375
8,322
6,396
8,223
3,429
20.7
18
8,445
9,168
3,042
253
558
Total Applied
Flow
(MGD)
14.5
83.24
18.00
34.27
44.35
73.79
2.31
11.52
81.92
125.28
64.20
46.29
5.76
11.52
0.01
25.92
36.41
5.20
10.94
26.00
58.19
34.50
26.30
42.60
76.86
19;90
0.18
0.12
37.58
50.40
8.64
1.30
6.29
321
-------
TABLE IX-6
APPLIED FLOW JUSTIFICATION
HOT FORMING-FLAT: HOT STRIP AND SHEET
PAGE 2
Plant
Reference
Code
0856UC02)
085611(03)
0856U(04)
0856UC05)
0860B(01)
0860B(02)
0864A
0868AC02)
0868AC03)
0920C
0920N
0948A
0948C
Applied
Flow
(gal/ton)
22,944
6,400
4,847
11,809
8,448
5,594
4,666
21,356
2,905
7,767
8,200
6,076
6,602
Production
Capacity
(tons/day)
150
639
915
2,907
12,204
5,895
6,018
177
4,854
3,300
7,992
7,584
8,724
Tptal Applied
Flow
(MGD)
3.44
4.09
4.44
34.33
103.10
32.98
28.08
3.78
14.10
25.63
65.53
46.08
57.60
Production Weighted
Applied Flow Average*
TOTAL APPLIED FLOW**
TOTAL PRODUCTION CAPACITY**
_ 1,506,470,000 gal/day
233,899 tons/day
Say 6,400 gal/ton
6440 gal/ton
**•
Based upon available data. Data for those operations with unknown or
unavailable flows are not included.
These totals do not include confidential data from one plant.
322
-------
TABLE IX-7
APPLIED FLOW JUSTIFICATION
HOT FORMING-FLAT: PLATE (CARBON)
Plant
Reference
Code
0060F(01)
0112A(01)
0112AC02)
0112D(01)
0384A(01)
0496(140")
0496(140"/206")
0496(112"/120')
06841(02)
0856H(01)
0856H(Q2)
0856H(03)
0860B(03)
0860H(01)
0860HC02)
0868A(01)
0868B
Applied
Flow
(gal/ton)
3,976
2,455
2,778
3,240
7,867
120
206
870
7,558
117
5,473
3,652
2,550
9,790
5,489
3,922
4,992
Production
Capacity
(tons/day)
2,115
1,056
2,592
3,360
972
1,830
6,300
1,740
1,629
984
3,939
2,916
3,162
648
2,886
1,800
3,894
Total Applied
Flow
(MGD)
8.41
2.59
7.20
10.89
7.65
0.22
1.30
1.51
12.31
0.12
21.56
10.65
8.06
6.34
15.84
7.06
19.44
Production Weighted
Applied Flow Average*
TOTAL APPLIED FLOW
TOTAL PRODUCTION CAPACITY
141 100,000 gal/day =3374 gal/ton
41,ozJ
Say - 3400 gal/ton
Based upon available data. Data for those operations with unknown or
unavailable flows are not included.
323
-------
TABLE IX-8
APPLIED FLOW JUSTIFICATION
HOT FORMING-FLAT; PLATE (SPECIALTY)
Plant
Reference
Code
0424(01)
0496(140")
0496(112"/120")
0684V(01)
0776H(01)
Applied
Flow
(gal/ton)
800
144
2,653
8,803
960
Production
Capacity
(tons/day)
450
1,830
1,740
119.4
60
Total Applied
Flow
(MGD)
0.36
0.26
4.62
1.05
0.06
Production Weighted _
Applied Flow Average
TOTAL APPLIED FLOW*
TOTAL PRODUCTION CAPACITY*
6,350,000 gal/day
4199.4 tons/day
Say - 1500 gal/ton
= 1512 gal/ton
*: These totals do not include the confidential data from one plant.
324
-------
TABLE IX-9
APPLIED FLOW JUSTIFICATION
HOT WORKING PIPE AND TUBE
Plant
Reference
Code
0088A-03
0088C-01
0088C-02
0196A
0240B-05
0256G
0396E
0432A-01
047 6A
0492A-05
0548
0548A-01
0548A-02
0652A
0684A-02
0684H
0728
0856C
0856F-01
0856F-02
0856N-01
0856N-02
0856N-03
0856N-04
0916A-01
0920C-01
0920C-02
0948A-01
0948A-02
0948A-03
0948C-01
0948C-02
Production Weighted
Applied Flow Average*
Applied
Flow
(gal/ton)
2,712
3,552
6,436
12,794
1,858
515
450
8,080
4,672
10,154
4,573
8,000
6,857
3,672
4,311
7,010
2,560
1,667
7,111
3,418
3,648
3,083
3,730
2,765
4,706
5,788
6,207
3,077
21,405
6,611
TOTAL
;* TOTAL
99,290
Production
Capacity
(tons /day)
171
283.8
268.5
822
213
564
480
699
381.6
156
196.8
126
42
363
1,002
540
240
36
663
957
1,011
1,500
981
888
600
229.5
373.2
615
777
468
444
501
APPLIED FLOW**
PRODUCTION CAPACITY**
,000 gal/day _ „,,..
Total Applied
Flow
(MGD)
0.46
1.01
1.73
10.52
0.40
0.29
0.22
5.65
1.78
1.58
0.90
1.01
0.29
1.33
4.32
3.79
0.61
0.06
11.52
17,985 tons/day
Say 5,520 gal/ton
gal/ton
3,
5,
3,
46
47
02
3.31
,66
,08
2.16
8.64
1.44
9.50
3.31
**;
Based upon available data. Those operations with unknown or unavailable
flows are not included.
These totals include confidential data.
325
-------
TABLE IX-10
ANALYSIS OF RECYCLE RATES
FROM PRIMARY SCALE PITS
HOT FORMING SUBCATEGORY
Subdivision
A. Primary
B. Section
Plant Code
0946A
0684G
0856F
0432C
0856N
0868A-03
0060-01
0112A-01
0948A
0920B
0640
0112A-03
0864A-01
0724A
0864A-02
0060G-01
0320-02
0940
Recycle Percentage
9.0*
14.7*
25.0*
44.9
47.0
48.8
50.0
53.0
63.5
68.0
70.8
75.0
75.0
79.2
85.7*
86.0*
96.2*
100.0*
Average of Unstarred Values = 61.4%
0060G-01
0684G-01
0060H-01
0384A-06
0684H-05
0684H-04
0856F-03
0856F-02
0060F-04
0856F-02
00601-02
0864A
0476A-03
0864B
0460B
0068B
0256N-01
0256N-02
0256N-03
0316A
6.3*
8.8*
32.0*
33.0*
42.0
44.4
50.0
50.0
56.5
66.7
75.0
78.9
97.2*
97.3*
99.0*
100.0*
100.0*
100.0*
100.0*
100.0*
Average of Unstarred Values = 57.!
,(1)
326
-------
TABLE IX-10
ANALYSIS OF RECYCLE RATES
FROM PRIMARY SCALE PITS
HOT FORMING SUBCATEGORY
PAGE 2
Subdivision
C. Flat
D. Pipe & Tube
Plant Code
0060
0860B-01
0684F-02
0856F
0384A-02
0320-02
0920C
0920N
0856F-02
0112A-03
0496(140")
0112A-04
Recycle Percentage
4.3
14.0
19.5
22.9
27.6
32.3
33.7
40.8*
66.7*
71.2*
87.5
89.6
Average of Starred Values = 59.<
0856F(01
047 6A
0548
0856C
& 02)
50.0
78.7
80.0
99.4
Average of Unstarred Values = 77.0%
(1) Average includes some confidential values
327
-------
TABLE IX-11
LONG-TERM DATA ANALYSIS
FILTRATION SYSTEMS
TOTAL SUSPENDED SOLIDS
Plant
0112C-334
0112I-5A
0112C-617
0684H-EF
0112C-011
0112B-5A
0384A-4L
0112C-122
0384A-3E
0684F-4I
Average (mg/1)
2.3
3.6
4.8
6.0
8.9
10.6
10.8
13.3
17.4
22.2
Variability Factors
Average
1.4
1.5
1.3
1.3
1.3
1.1
1.3
1.3
1.2
1.2
Maximum*
6.8
8.9
5.4
5.3
3.5
2.3
3.0
4.0
2.5
3.7
Median Values • 9.8 1.3
30-Day Average Concentration Basis = (9.8 mg/1) (1.3) = 12.7 mg/1
Daily Maximum Concentration Basis = (9.8 mg/1) (3.9) = 38.2 mg/1
3.9
Note: For the purposes of developing effluent limitations and standards,
the following values were used for total suspended solids.
Average » 15 mg/1
Maximum - 40 mg/1
* For plants with more than 100 observations:
Daily Variability Factor = 99th
Average
320
-------
TABLE IX-12
LONG-TERM DATA ANALYSIS
FILTRATION SYSTEMS
OIL AND GREASE
Plant
0112B-5A
0112C-334
0112C-617
0112C-122
0684H-EF
0112C-011
0384A-4L
Number
of
Sample
Points
87
727
647
684
27
690
290
Median Values
30-Day Average Concentration Basis
Daily Maximum Concentration Basis
Variability Factors
Average (mg/1)
1.1
1.3
1.3
2.0
3.4
6.7
6.7
2.0 1.3
(2.0 mg/1) (1.3) - 2.6 mg/1
(2.0 mg/1) (4.5) = 9.0 mg/1
Average
1.1
1.4
1.4
1.3
1.4
1.3
1.2
Maximum*
2.9
5.3
4.5
5.3
3.8
5.1
3.4
4.5
Note: A maximum value of 10 mg/1 has been used to develop
effluent limitations and standards for oil and grease.
* For plants with more than 100 observations:
„ 99th Percentile
Daily Variability Factor = Average
329
-------
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338
-------
TABLE IX-22
EXAMPLES OF PLANTS IN COMPLIANCE WITH BPT LIMITATIONS
HOT FORMING
Total Suspended Solids
30-Day Average (Ibs/Day)
Plant Code
020B
060
060K
08 8A
112B
112D
424
432C
496
584C
584F
684E
684F
796A
856B
856D
856H
856N
856R
860H
864A
920A
920B
920D
920N
NPDES
Permit
_
1461
50
—
4.03
9040
5~70(1)
—
2503
-
1353
2000
250
—
—
-
2820
-
—
1870
530
—
—
78
Actual
546
-
-
9
-
2500
400-1000(2)
125
1044
2562
118
1000
<80
237
20
36
3368
26
200
- •
-
1483
20
-
BPT
Limitation
648
4632
254
501
2163
6584
97
5014
472
4595
5072
604
2990
990
1112
2706
2814
—
934
3900
3903
890
1506
135
754
Oil and Grease
Daily Maximum (Ibs/Day)
NPDES
Permit Actual
977-
30
271
12,000
465(1)
2086
906
1950
334
626
1640
558
102
312
12
830
3
400-500
190
728
3241
37
500
(2)
178
13
24
2245
6
220
890
25
BPT
Limitation
432
3088
177
334
1442
4390
65
3342
315
3063
3382
402
1990
660
741
1804
1877
622
2600
2602
593
1004
88
503
Note:
NPDES permit limitations and actual discharges include operations in
addition to hot forming for noted plants (*). Only hot forming operations
were considered in developing 1982 regulation limitations for all plants.
(1) Net
(2) Gross
339
-------
E "-
ss
D.
m
Ul
IT
340
-------
HOT FORMING SUBCATEGORY
SECTION X
EFFLUENT QUALITY ATTAINABLE THROUGH THE
APPLICATION OF THE BEST AVAILABLE TECHNOLOGY
ECONOMICALLY ACHIEVABLE
Introduction
The best available technology economically achievable (BAT) effluent
limitations are to be achieved by July 1, L984. Best available
technology is determined by identifying the best economically
achievable control and treatment technology employed within the
subcategory. Also, where a technology is readily transferable from
one industry to another, such technology may be identified as BAT.
This section identifies the two BAT alternative treatment systems
considered by the Agency and the resulting effluent levels. In
addition, the rationale for selecting the treatment technologies,
discharge flow rates and effluent concentrations are presented. The
BAT model treatment system selected as the basis for the BAT effluent
limitations considered by the Agency is also described. However, as
noted below, the Agency determined that adequate control of toxic
pollutants found in hot forming wastewaters is provided with the model
BPT filtration systems and that more stringent BAT limitations for
toxic pollutants based upon the alternatives described below are not
warranted. .'---_
Identification of_ BAT
Based upon the information developed in Sections III through VIII
the Agency developed the following treatment technologies as BAT for
hot forming operations. Those alternatives are illustrated
schematically in Figure X-l.
BAT Alternative ]_
•* • . '
The BPT treatment system effluent is cooled and recycled such that an
overall 96 percent recycle rate is achieved.
BAT Alternative 2_
In this alternative, zero discharge is achieved by evaporating and
condensing the effluent from Alternative 1 with the condensate
returned to the process water system.
Table X-l presents the effluent quality attainable with the above
technologies. The Agency has determined that limitations for lead and
zinc based upon filter plant performance (see Appendix A of Volume I)
will result in similar control of all toxic metals found in hot
341
-------
forming wastewaters since these metals are found principally in
particulate form at low concentrations (<0.1 mg/1).
Rationale for Selection of the BAT Alternatives
The following discussion presents the rationale for selecting the BAT
alternative treatment systems, selecting model flow rates, and
determining the concentration levels of the pollutants selected for
limitation.
Treatment Scheme
The Agency considered additional recycle for the BAT alternatives.
The overall recycle rate (combining the BPT and BAT recycles) for hot
forming operations was established by reviewing recycle rates in each
subdivision and then selecting those recycle rates representative of
the best in each case. Those recycle rates greater than ninety
percent are considered to be representative of good treatment. Table
X-2 presents a summary (from highest to lowest) of the recycle rates
observed in the hot forming subcategory. The best recycle rates for
each hot forming subdivision follow.
Subdivision
Primary
Section
Flat
Pipe and Tube
Recycle Rate
97%
97%
96%
97%
Based upon these data, the Agency has determined that a ninety-six
percent recycle rate is achievable for all hot forming operations.
The Agency believes that a common recycle rate for all hot forming
operations is appropriate because many plants have central treatment
for wastewaters from two or more hot forming subdivisions.
In order to achieve a 96 percent recycle rate, cooling towers are
included as part of the alternative treatment system so as to reduce
the increased heat loads that can result with extensive recycle
systems. As noted in Section VII, many hot forming operations have
cooling towers as integral components of recycle systems.
Sulfide precipitation and filtration were also considered as a BAT
alternative for the purpose of reducing the levels of the various
toxic metals to 0.10 mg/1 or less. This technology would not result
in any significant improvement in effluent quality as the toxic metals
found in hot forming wastewaters are principally in particulate form
at concentrations less than 0.1 mg/1. Hence, it was not considered in
any detail.
Evaporative technologies are not used in the hot forming subcategory
or to any significant extent in the treatment of steel industry
wastewaters. Nonetheless, these technologies are demonstrated and
342
-------
available for the treatment of hot forming wastewaters. High capital
and operating costs and associated high energy consumption are
negative factors associated with this technology.
Applied Flows
The Agency determined average applied flows for each hot forming
subdivision for the purposes of sizing and costing treatment systems,
and establishing effluent limitations (see Section IX). Production
weighted flow averages were determined for each hot forming process
(Tables IX-2 through IX-9). All available flow data were used to
derive the average flow rates.
Discharge Flows
The discharge flows included in the treatment systems for BAT
Alternatives 1 and 2 are based upon recycle of ninety-six percent of
the applied flow. Depending upon the subdivision different degrees of
recycle were included in the BAT model treatment systems (see Figure
X-1). The industry has reported achieving high recycle rates without
any problems due to fouling, plugging, or scaling.
Wastewater Quality
The 30 day average effluent concentrations used as the basis for the
BAT Alternative 1 and 2 limitations are as follows. The daily maximum
values are enclosed in parentheses.
BAT Alt. 1
Lead, mg/1
Zinc, mg/1
15(0.45)
10(0.30)
BAT Alt. 2
No discharge
No discharge
As noted above, the Agency considered BAT effluent limitations for
lead and zinc. These toxic metals were chosen because of their
ability to serve as indicators for the other toxic metals present in
hot forming wastewaters. The development of these concentration
values is presented in Appendix A to Volume I.
Effluent Limitations for BAT Alternatives
The effluent limitations for the BAT alternative treatment systems
were calculated by multiplying the effluent flows of the alternative
treatment systems by the effluent concentration of each pollutant and
an appropriate conversion factor. Table X-1 presents the effluent
limitations for each hot forming subdivision for each BAT alternative
treatment system.
Selection of a BAT Alternative
In the proposed regulation, the Agency selected BAT Alternative 1 as
the model treatment system upon which the proposed BAT limitations
were based. Upon review of existing data and supplemental toxic
343
-------
metals data for BPT hot forming filtration systems, the Agency has
determined that high rate recycle of hot forming wastewaters is not
warranted for toxic metals control beyond that provided by the model
BPT treatment system. The toxic metals data for three hot forming
filtration systems are presented in Table X-3. These data show the
average concentration of all toxic metals found in filtration system
effluents is about 0.07 mg/1. The Agency determined that particulate
toxic metals at those levels are effectively controlled by the BPT
model treatment system and are not likely to cause toxic effects in
receiving waters. In accordance with the criteria established in
Paragraph 8(a)(iii) of the Settlement Agreement, the Agency has
determined that the BPT effluent limitations provide for sufficient
control of toxic metals found in hot forming operations and that more
stringent effluent limitations for toxic metals at BAT are not
warranted.
344
-------
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345
-------
TABLE X-2
ANALYSIS OF OVERALL RECYCLE RATES
HOT FORMING SUBCATEGORY
Subdivision.
A. Primary
Plant
Code
0940
00601
0440A
0684H
0088D
0248B
0060D
0612 (01 & 02)
0432J
0860A (01-03)
0320-02
0248C
0176
0864C
0432C
0248A
0060
0476A
0920N
0496
0920A
0060G
0684A-02
0424
0672B
0724A
0864A-01
0112A-03
0640
0920B
0948A
0112A-01
0396E
0868A-03
0188B
06841
0856N
0460A
0946A
0112B-03
0856F
0684G
0868A-02
!
RUP
100.0
0
0
0
99.0
0
0
0
90.0
0
96.2
0
0
0
44.9
0
50.0
0
0
87.5
0
86.0
85.7
0
80.0
79.2
75.0
75.0
70.8
68.0
63.5
53.0
0
48.8
0
0
47.0
0
9.0
0
25.0
14.7
0
Average
Average
Recycle Rates
RTP
0
100.0
100.0
99.7
0
98.8
98.4
98.0
7.5
96.5
0
93.3
93.0
92.7
47.4
90.3
39.6
88.3
88.2
0
86.2
0
0
80.0
0
0
0
0
0
0
0
0
53.0
2.6
49.5
47.0
0
37.3
26.0
34.5
0
0
2.4
of All Values
of Values >90%
Total
100.0
100.0
100.0
99.7
99.0
98.8
98.4
98.0
97.5
96.5
96.2
93.3
93.0
92.7
92.3
90.3
89.6
88.3
88.2
87.5
86.2
86.0
85.7
80.0
80.0
79.2
75.0
75.0
70.8
68.0
63.5
53.0
53.0
51.4
49.5
47.0
47.0
37.3
35.0
34.5
25.0
14.7
2.4
= 74.4%
= 96.6%
346
-------
TABLE X-2
ANALYSIS OF OVERALL RECYCLE RATES
HOT FORMING SUBCATEGORY
PAGE 2 -
Reeyele Rates
Subdivision
B. Section
00601-01
00601-02
0256N
0316A
0316B
0460A (01
0672B (01
0684H (01
0684H-05
0060K-01
0060F-05
0136B-02
0860F-03
0088D
0460B
0468B
0136B-01
0188C
0612 (01-
0188B
0384A-06
0864B
0476A-03
0640A (01
0612-05
0176 (01-
0060H-01
0860H (01
0946A-03
0136C
0684H-04
0864C (01
0864A
0804B-01
0860F (01
0672A (01
0112-07
0476A-02
0868A (03
0112A-01
0946A (01
0856F-01
0468F
0920B-01
0684E (01
& 02)
& 02)
-03)
04)
& 02)
04)
& 02)
& 02)
& 02)
& 02)
i-05)
& 02)
& 02)
RUP
75.0
0
100.0
100.0
0
0
0
0
42.0
0
56.5
0
0
0
99.0
0
0
0
0
0
33.0
97.3
97.2
0
0
0
32.0
0
0
0
0
0
78.9
0
0
0
0
0
0
0
0
66.7
0
0
0
RTP
25.0
100.0
0
0
100.0
100.0
100.0
99.7
57.7
99.6
43.0
99.5
99.5
99.2
0
98.9
98.8
98.1
98.0
98.0
64.6
0
0
97.0
96.8
96.4
64.0
96.0
95.8
95.1
94.9
92.7
12.3
90.7
90.0
89.6
89.0
88.8
86.4
83.3
82.0
0
66.6
59.4
53.3
Total
100.0
100.0
100.0
100.0
100.0
100.0
100.0
99.7
99.7
99.6
99.5
99.5
99.5
99.2
99.0
98.9
98.8
98.1
98.0
98.0
97.6
97.3
97.2
97.0
96.8
96.4
96.0
96.0
95.8
95.1
94.9
92.7
91.3
90.7
90.0
89.6
89.0
88.8
86.4
83.3
82.0
66.7
66.6
59.4
53.3
347
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TABLE X-2
ANALYSIS OF OVERALL RECYCLE RATES
HOT FORMING SUBCATEGORY
PAGE 3
Subdivision
B. Section
(Cont.)
Recycle Rates
Flat
D. Pipe & Tube
0856F (02 & 03)
0856F-04
0316
0476A-01
0424-01
0424 (02 & 03)
0060G-01
0248B
0060
0684F-02
0860H-02
0860H-01
0868B
0176
0112-04
0868A-03
0868A-02
0868A-01
0684B
0432C
0112A-03
0856F-02
0476A
06841-02
06841-01
0920N
0920C
0320-02
0856F-01
0860B-01
0060R (01 &
0856C
0684A
0728
0396E
0240B-05
02)
RUP
50.0
44.4
0
0
0
0
6.3
. Average
Average
0
4.0
18.9
0
0
0
0
89.6
0
13.6
0
0
11.5
71.4
66.7
0
0
0
40.8
33.7
32.3
22.9
11.1
Average
RTF
0
0
37.0
33.8
17.0
9.0
0
of All Values
of Values ^90%
98.8
94.0
78.7
97.2
96.3
96.3
92.8
0
88.5
77.9
88.5
84.5
69.8
0
0
59.8
53.0
47.0
0
0
0
0
0
of All Values
Average of Values >90%
0
99.4
0
0
0
0
100.0
0
97.0
96.8
91.0
87.5
Total
50.0
44.4
37.0
33.8
17; o
9.0
6.3
" 84.6%
= 97.5%
98.8
98.0
97.6
97.2
96.3
96.3
92.8
89.6
88.5
88.5
88.5
84.5
81.3
71.4
66.7
59.8
53.0
47.0
40.8
33.7
32.3
22.9
11.1
- 71.2%
= 96.7%
100.0
99.4
97.0
96.8
91.0
87.5
348
-------
TABLE X-2
ANALYSIS OF OVERALL RECYCLE RATES
HOT FORMING SUBCATEGORY
PAGE 4
Recycle Rates
Subdivision
D. Pipe & Tube
(Cont.)
0796B
0548
0476A
0548A-01
0196A
0088C-01
0548A-02
0856F (01
0796A-02
0492A-05
& 02)
RUP
0
80.0
78.7
0
0
0
0
50.0
0
0
RTF
82.4
0
0
77.6
64.3
61.4
50.0
0
41.6
18.9
Total
.4
.0
,7
.6
,3
.4
Average of All Values
Average of Values _>90%
82.
80.
78.
77,
64.
61,
50.0
50.0
41.6
18.9
73.5%
96.8%
KEY TO CODES
RUP: Recycle process water from primary scale pit.
RTF: Recycle treated process water.
349
-------
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351
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HOT FORMING SUBCATEGORY
SECTION XI
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY
Introduction
The 1977 Amendments added Section 301(b)(2)(E) to the Act,
establishing "best conventional pollutant control technology" (BCT)
for discharges of conventional pollutants from existing • industrial
point sources. Conventional pollutants are those defined in Section
304(a) (4) [biochemical oxygen demanding pollutants (BOD5J, total
suspended solids (TSS), fecal coliform, and pH] and any additional
pollutants defined by the Administrator as "conventional" (oil and
grease, 44 FR 44501, July 30, 1979).
BCT is not ah additional limitation but replaces BAT for the control
of conventional pollutants. In addition to other factors specified in
section 304(b)(4)(B), the Act requires that BCT limitations be
assessed in light of a two part "cost-reasonableness" test. American
Paper Institute v. EPA, 660 F.2d 954 (4th Cir. 1981). The first test
compares the cost for private industry to reduce its conventional
pollutants with the costs to publicly owned treatment works for
similar levels of reduction iri their discharge of these pollutants.
The second test examines the cost-effectiveness of additional
industrial treatment beyond BPT. EPA must find that limitations are
"reasonable" under both tests before establishing them as BCT.
case may BCT be less stringent than BPT.
In no
EPA published its methodology for carrying out the BCT analysis on
August 29, 1979 (44 FR 50732). In the case mentioned above, the Court
of Appeals ordered EPA to correct data errors underlying EPA's
calculation of the first test, and to apply the second cost test.
(EPA had argued that a second cost test was not required).
Because of the remand in American Paper Institute v. EPA (No. 79-115),
the Agency did not promulgate BCT limitations except for those
operations for which the BAT limitations are no more stringent than
the respective BPT limitations. Hot Forming is one of the
subcategories where BCT was promulgated equal to BPT.
353
-------
-------
HOT FORMING SUBCATEGORY
SECTION XII
EFFLUENT QUALITY ATTAINABLE THROUGH THE
APPLICATION OF NEW SOURCE PERFORMANCE STANDARDS (NSPS)
Introduction
New Source Performance Standards are to consider the degree of
effluent reduction achievable through application of best available
demonstrated control technology (BDT), processes, operating methods,
or other alternatives, including, where practicable, a standard
permitting no discharge of pollutants.
Identification of_ NSPS
NSPS Alternative 1
The first NSPS alternative treatment system includes the BPT model
treatment system and the BAT Alternative 1 components discussed in
Sections IX and X. This system includes sedimentation of the raw
wastewater in primary scale pits equipped with oil skimmers. Both oil
and scale removed by this step are reclaimed. A portion of the scale
pit effluent is recycled to the process for flume flushing or other
mill uses. The scale pit effluent is clarified, filtered, cooled and
recycled such that an overall recycle rate of 96 percent is achieved.
NSPS Alternative 2
This alternative is identical to BAT Alternative 2. The blowdown from
NSPS Alternative 1 is evaporated, condensed, and returned to the
process to achieve zero discharge.
The NSPS treatment systems described above are depicted in* Figure
VIII-2. The corresponding effluent standards for these systems are
presented in Table XII-1. Cost data for the treatment systems is
detailed in Tables VIII-30 through VI11-41.
Rationale for Selection of_ NSPS Alternative Treatment Systems
The NSPS alternative treatment systems developed for the hot forming
subcategory are the same as the BAT alternative treatment systems
described in Sections IX and X. Therefore, the rationale presented in
these sections'is applicable to NSPS and is not repeated here. These
technologies were considered because of the significant reductions of.
the total pollutant loadings from hot forming operations.
355
-------
Treatment Scheme
The NSPS alternative treatment systems include primary scale pits,
roughing clarifiers, oil skimming, deep bed pressure filters, cooling
towers, recycle and evaporation. With the exception of vapor
compression distillation, all of these technologies are well
demonstrated in the hot forming subcategory. As discussed in Section
X, sulfide precipitation was considered but not included because of
its limited effectiveness for hot forming wastewaters. The other
treatment technologies are reliable and demonstrated methods of
treatment and are appropriate for NSPS.
The resulting effluent quality for the NSPS alternatives is presented
in Table XI.I-1 . As discussed in Section X, the selected pollutants
and the respective effluent concentration values are based upon the
capabilities of the various water treatment technologies.
Flows
The applied and discharge flow rates that are used with the NSPS
Alternatives for the hot forming subcategory were developed in Section
X. The discharge flow within each hot forming subdivision is
applicable to both NSPS alternative treatment systems. These flows
are demonstrated by plants in the respective subcategories and
represent an overall system blowdown rate of 4%. The recycle rate of
96% is also well demonstrated in each of the hot forming subdivisions.
Selection of a NSPS Alternative
The Agency selected NSPS Alternative No. 1 as the NSPS model treatment
system upon which the NSPS effluent standards are based. The Agency
has promulgated NSPS for total suspended solids, oil and grease, and
pH. NSPS were promulgated for hot forming operations even though BAT
limitations were not promulgated for these operations because of the
significant conventional .pollutant removal attainable at new sources
with high rate recycle systems. Standards for toxic metals were not
included since the toxic metals are not likely to be discharged in
toxic amounts from NSPS treatment systems. Figure XII-1 depicts the
NSPS model treatment system.
Demonstration of NSPS
Tables XII-2 through XII-8 present a list of those plants achieving
the NSPS. As shown, these plants encompass all hot forming
subdivisions and several different treatment schemes. Since
wastewaters from all hot forming operations are similar in character
and can be treated to the same degree, demonstration of NSPS in any
hot forming subdivision is appropriate demonstration in any
subdivision.
356
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HOT FORMING SUBCATEGORY
SECTION XIII
PRETREATMENT STANDARDS FOR DISCHARGES TO
PUBLICLY OWNED TREATMENT WORKS
Introduction
The Agency found that wastewaters from less than 10% of the hot
forming operations are discharged to POTWs. Because of the hiqh
volume of untreated hot forming wastewaters it is not practical to
discharge these wastewaters to POTWs untreated on a once-through
basis. Accordingly, most steel industry discharges of hot forming
wastewaters to POTWs are blowdowns from high rate recycle systems that
are equivalent to the Agency's BAT Alternative 1 treatment system.
The^ Agency has determined that toxic pollutants are effectively
controlled at all hot forming operations with discharges to POTWs.
Thus, the Agency has determined that the general pretreatment
standards are sufficient to control the discharge of hot formina
operations to POTWs. j-utuung
General Pretreatment Standards
For detailed information on Pretreatment Standards refer to 46 FR 9404
f S«q,'i ^ner^ ^treatment Regulations for Existing and New Sources
?L,?°llutl°n' (January 28, 1981). See also 46 FR 4518 (February 1
982). In particular, 40 CFR Part 403 describes National Standards
(prohibited discharges and categorical standards), revisions of
categorical standards, and POTW pretreatment programs. The Agency
considered the objectives and requirements of the General Pretreatment
Regulations in deciding not to promulgate categorical pretreatment
standards for hot forming operations.
from about twenty hot forming operations are discharged to
POTWs. In many cases, these wastewaters are recycled to a high dearee
to minimize user fees to the industry and to avoid hydraulically
overloading POTWs. The Agency believes that future discharges of hot
forming wastewaters to POTWs, if any, will receive similar treatment
fu 4.W1JJ not contain high levels of toxic metals. The Agency believes
that the pass through of toxic pollutants from hot forming operations
is not a problem. Thus, categorical pretreatment standards for hot
forming wastewaters are not warranted.
*U.S. GOVERNMENT PRINTING OFFICE: 1982-361-085:4454
367
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