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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
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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
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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
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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
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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
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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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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
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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
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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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