DEVELOPMENT DOCUMENT

                   FOR

     EFFLUENT LIMITATIONS GUIDELINES
     NEW SOURCE  PERFORMANCE  STANDARDS

                   AND

          PRETREATMENT STANDARDS

                 FOR THE

        METAL MOLDING AND CASTING
                (FOUNDRIES)
          POINT SOURCE CATEGORY
                 VOLUME  I
             Anne M. Gorsuch
              Administrator

             Steven Schatzow
                 Director
Office of Water Regulations and Standards
         Jeffery Den.it, Director
       Effluent  Guidelines  Division

                Ernst  Hall
    Chief,  Metals  and  Machinery  Branch

             John  G. Williams
             Project Officer
              November 1982
       Effluent  Guidelines  Division
Office of Water Regulations and Standards
  U. S. Environmental Protection Agency
         Washington, D.C.  20460

-------

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SECTION

I.

II.

III.
 IV.
 VI.
   	TABLE OF CONTENTS

                    SUBJECT

SUMMARY AND CONCLUSIONS

RECOMMENDATIONS

INTRODUCTION
  Legal Authority
  Background - The Clean Water Act
  General^Description of the Metal Molding
    and Casting Industry
  Plant Data Collection
  Profile of Plant Data
  Description of Metal Molding and Casting
    Industry Processes
  Anticipated Industry Growth
  Profile of Plants in the Metal Molding
    and Casting Point Source Category
  Additional Data Collection Activities

INDUSTRY: SUBCATEGORIZATION
  Introduction
  Selected Subcategories
  Subcategory Definitions
  Subcategorization Basis
  Production Normalizing Parameters

WATER USE AND WASTE CHARACTERIZATION
  Introduction
  Information Collection
  Production Profile
  Process Wastewater Flow
  Selection of Plants for Sampling
  Water :Use and Waste Characteristics
    Incoming Water Analysis
    Raw Waste Analysis
    Effluent Analysis
    Aluminum Casting Subcategory
    Copper Casting Subcategory
 r;!  Iron and Steel (Ferrous) Casting
      Subcategory
    Lead Casting Subcategory
    Magnesium Casting Subcategory
    Zinc Casting Subcategory

SELECTION OF POLLUTANTS
  Pollutants Not Detected in Raw
 23
 23
 23

 25
 30
 33
 34

 46;


 47
 52

111

111
112

115

121

127

128
129
129
130
135
135
135
135
136
144

147
164
166
167

287
287'

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SECTION
 VII.
VIII.
         TABLE  OF  CONTENTS (Continued)

                     SUBJECT                  PAGE

    Wastewaters
  Pollutants Detected  in Raw Wastewaters      287
    Below Quantifiable Limits
  Pollutants Present in Raw Wastewaters       287
  Regulation of Specific Pollutants
    Aluminum Casting Subcategory              377
    Copper Casting Subcategory                389
    Ferrous Casting Subcategory               396
    Lead Casting Subcategory                  409
    Magnesium Casting  Subcategory             411
    Zinc Casting Subcategory                  416
  Summary

CONTROL AND TREATMENT  TECHNOLOGY              441
  Introduction                                 441
  End-of-Pipe Treatment Technologies          441
  Major Technologies                          442
    Emulsion Breaking                          442
    Oxidation By Potassium Permanganate       450
    Chemical Precipitation                    451
    Granular Bed Filtration                   462
    Pressure Filtration                       466
    Settling                                   468
    Skimming                                   471
  Major Technology Effectiveness              476
  Minor Technologies                          496
    Carbon Adsorption                          492
    Centrifugation                            498
    Coalescing                                 500
    Evaporation                                502
    Flotation                                  505
    Gravity Sludge Thickening                 507
    Sludge Bed Drying                          509
    Ultrafiltration                            511
    Vacuum Filtration                          515
    In-Plant Technology                       516

COST,  ENERGY, AND  NON-WATER QUALITY IMPACTS   543
  Introduction                                 543
  Sampled Plant  Treatment  Costs               543
  Development of Cost  Models                  544
  Basis for Model  Cost  Estimates              546
  Model Cost Estimates                         547
  Cost, Energy,  and  Non-Water Quality
    Impacts Summary                            547
                                11

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SECTION
  IX.
  XI


 XII
XIII
         TABLE OF CONTENTS, (Continued)

                    SUBJECT

EFFLUENT QUALITY ATTAINABLE THROUGH THE
APPLICATION OF THE BEST PRACTICABLE
CONTROL TECHNOLOGY CURRENTLY AVAILABLE
  Introduction
  Factors Considered
  Approach To BPT Development
  Identification of Proposed BPT
    Aluminum Casting Subcategory
    Copper Casting Subcategory
 -. Ferrous Casting Subcategory
    Lead Casting Subcategory
    Magnesium Casting Subcategory
    Zinc Casting Subcategory
  Analysis of BPT Discharge Options
    Review
    Cost Comparison of BPT Options
    Comparison" of Discharge Loads Between
      BPT Options
    Major Assumptions of BPT Options
      Analysis

EFFLUENT QUALITY ATTAINABLE THROUGH THE
APPLICATION OF THE BEST AVAILABLE
TECHNOLOGY ECONOMICALLY ACHIEVABLE
  Introduction
  Development of BAT
  Identification of BAT

BEST CONVENTIONAL POLLUTANT CONTROL
TECHNOLOGY

EfFLUENT QUALITY ATTAINABLE THROUGH THE
APPLICATION OF NEW SOURCE PERFORMANCE
STANDARDS
  Introduction
    Identification of NSPS
    Rationale for NSPS
    NSPS Effluent Levels,
    Selection of NSPS Alternatives
PRETREATMENT STANDARDS FOR DISCHARGERS TO
PUBLICLY OWNED TREATMENT WORKS
  Introduction
    General Pretreatment Standards
    Categorical Pretreatment Standards
                                                             799
                                                             799
                                                             800.
                                                             810
                                                             810
                                                             822
                                                             824
                                                             831
                                                             835
                                                             838
                                                             843
                                                             843
                                                             344.
                                                             846

                                                             847


                                                             921
                                                             921
                                                             922

                                                             965
967
967
967
968
968
968

989

989
989
989
                                ill

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SECTION
 XIV.

  XV.

 XVI.
         TABLE OF CONTENTS  (Continued)

                    SUBJECT                   PAGE

    Identification of Pretreatment            991
    Rationale For PSES and PSNS
    PSES and PSNS Effluent Levels             994
    Selection of PSES and PSNS Alternative   993

ACKNOWLEDGEMENTS                             1015

REFERENCES                                   1017

GLOSSARY                                     1019
                               IV

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NUMBER
III-l
III-2
III-3
III-4 thru
III-8
II1-9 and
111-10
III-11 thru
111-1 5
111-16 and
111-17
III-18 and
111-19
              TABLES
                    TITLE
Foundry Shipments .in the United States
Penton Foundry Census Information
Distribution of Additional 1000 Foundry
  Plant Surveys
General Summary Tables - Aluminum Casting
  Subcategory
General Summary Tables - Copper and Copper
  Alloy Casting Subcategory
General Summary Tables - Ferrous Casting
  Subcategory
General Summary Tables - Lead Casting
  Subcategory
General Summary Tables - Magnesium Casting
   Subcategory
PAGE
  54
  55

  56
  57
  61
  62
  63
  64
  84
  86
  87
  88
  89
111-20 and
111-21
II1-22
II1-23

111-24
111-25

V-l

V-2 thru
V-7
V-8
General Summary Tables - Zinc Casting
  Subcategory
Operating Modes, Control and Treatment
  Technologies and Disposal Methods
Ferrous Mold Cooling Casting Quench
  Operations
Distribution of Plants
Percentage of Active "Wet" Operations
  Within Each Employee Group
Annual Production of Plants Which Generate
  Process Wastewaters
Metals Casting Industry Discharge
  Summaries
Active Foundry Operations; Discharge Mode
  90
  92
  93
  97

  98
  99
 171
 172
 180
 181

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NUMBER



V-9

V-10


V-ll



V-12
            TABLES (Continued)

                    TITLE
  Profile
List of Toxic Pollutants

Conventional and Nonconventional
  Pollutants

Plant Assessment of the Known or Believed
  Presence of Toxic Pollutants in Foundry
  Raw Process Wastewaters

Toxic Pollutants Considered to be Present
  in Foundry Process Wastewaters
PAGE



 182

 186


 187



 192
V-13
V-14
V-15 thru
V-19

V-20 and
V-21

V-22 thru
V-26

V-27
V-28 and
V-29

V-30 and
V-31

V-32 thru
V-37

VI-1
Inorganic Toxic Pollutants Selected for
  Sampling and Analysis During
  Verification Plant Visits

Types.and Amounts of Binders Used  in
  Foundries

Characteristics of Aluminum Process
  Wastewaters

Characteristics of Copper Process
  Wastewaters

Characteristics of Ferrous Process
  Wastewaters

Characteristics of Lead Process
  Wastewaters

Characteristics of Magnesium Process
  Wastewaters

Characteristics of Zinc Process Watewaters
Raw Wastewater Analyzed Data Profile
  Profile

Toxic Pollutants Not Detected in the Metal
  Molding and Casting Industry
                                                                 195
                                                                  196
 197
 201

 203
 204

 205
 222

 224
 225
 226

 227
 228

 229
 244

 427
                               VI

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NUMBER

VI-2



VI-3


VI-4


VI-5



VI-6
            TABLES (Continued)

                    TITLE

Toxic Pollutants Detected Below
  Quantifiable Limits in the Metal Molding
  and Casting Category

Toxic Pollutants Present in the Metal
  Molding and Casting Category

Toxic Pollutant Disposition; Metal Molding
  and Casting Category

Conventional and Non-conventional Pollutant
  Disposition; Metal Molding and Casting
  Industry

Toxic, Conventional and Non-Conventional
  Pollutants Considered for Regulation  in
  the Metal Molding and Casting Category
PAGE

 428



 429


 431


 436



 437
                                Vll

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 NUMBER
 VII-1
 VII-2

 VII-3
 VI1-4
 VII-5

 VII-6

 VII-7

 VI1-8

 VII-9
 VII-10
 VII-11
 VII-12
 VII-13

 VII-14
 VII-15
 VII-16

 VII-17
             TABLES (Continued)
                     TITLE
 Emulsion Breaking Performance Data
 Emulsion Breaking Performance Data; Toxic
   Organic Pollutants
 Effect of pH Control on Metals Removal
 Effectiveness of NaOH for Metals Removal
 Effectiveness of Lime and NaOH for Metals
   Removal
 Theoretical  Solubilities of Hydroxides and
   Sulfides of Selected Metals in Pure Water
 Sampling Data from Sulfide Precipitation-
   Sedimentation  Systems
 Sulfide Precipitation-Sedimentation
   Performance
 Ferrite Co-Precipitation Performance
 Multimedia Filter  Performance
 Performance  of Selected Settling Systems
 Skimming Performance
 Trace Organic Removal  by Skimming;  API
   Plus  Belt  Skimmers
 Combined Metals  Data Effluent Values
 L&S Performance; Additional  Pollutants
 Combined Metals  Data Set  -  Untreated
  Wastewater
 Maximum  Pollutant Level  in  Untreated
  Wastewater
PAGE
 445
 446

 454
 454
 456

 457

 457

 459

 460
 465
 470
 473
 475
 483
 485
 486

 486
VII-18, 19
and 20
Precipitation-Sedimentation-Filtration
  (LS&F) Performance
488
490
                              viii

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NUMBER

VII-21

VII-22

VI1-23


VII-24


VII-25

VIII-1 thru
VIII-5

VII1-6 thru
VIII-10

VIII-11 and
VIII-12
VI11-13  thru
VIII-17

VI11-18  and
VIII-19
               .'•;..  ;; TABLES  (Continued)
                         .....     TITL)E

          Summary of Treatment Effectiveness

          Activated Carbon  Performance (Mercury)

          Treatability  Rating of Priority Pollutants
            Utilizing Carbon  Adsorption

          Classes of Organic  Compounds Adsorbed on
            Carbon

          Ultrafiltration Performance

          Effluent Treatment  Costs
           Foundry  Operations Control and Treatment
            Technology;  Aluminum Foundries

           Foundry  Operations Control and Treatment
            Technology;  Copper and Copper Alloy
            Foundries

           Foundry  Operations Control and Treatment
            Technology;  Ferrous Foundries

           Foundry  Operations Control and Treatment
            , Technology;  Lead Foundries
                                                 PAGE

                                                  494

                                                  497

                                                  512


                                                  513


                                                  514

                                                  553
                                                  557

                                                  558
                                                  587

                                                  592
                                                  594
                                                  597
                                                  613

                                                  621
                                                  625
VIII-
VIII-

VIII-
VIII-

VIII-
VIII'

VIII-
VIII

VIII
VIII
-20  and
-21

-22  and
-23

-24  thru
-34

-35  and
-36

-37  thru
-84
Foundry Operations Control and Treatment
  Technology; Magnesium Foundries

Foundry Operations Control and Treatment
 ^Technology; Zinc Foundries

Model Cost Data - Aluminum Foundries
Model Cost Data - Copper and  Copper  Alloy
  Foundries

Model Cost Data - Ferrous  Foundries
 VIII-85 thru   Model Cost Data - Lead Foundries
628
630

632
635

648
659

660
661,'

662
738

740
                                IX

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 NUMBER

 VIII-87

 VIII-88 and
 VIII-89

 VIII-90 thru
 VIII-94

 VIII-95
VIII-96  thru
VIII-98
VIII-99  thru
VIII-101
VIII-102  thru
VIII-113
VIII-114
VIII-115
VIII-116 thru
VIII-118
VIII-119 thru
VIII-126
             TABLES (Continued)

                     TITLE



 Model  Cost Data - Magnesium Foundries


 Model  Cost Data - Zinc Foundries
 Procedure  for  Determining Industry Wide
   Treatment  Costs  for  Each Process

 Metals  Casting Industry;  Wastewater
   Treatment  Cost Summary;  Aluminum
   Subcategory

 Metals  Casting Industry;  Wastewater
   Treatment  Cost Summary;  Copper
   Subcategory

 Metals  Casting Industry;  Wastewater
   Treatment  Cost Summary;  Ferrous
   Subcategory

 Metals  Casting Industry;  Wastewater
   Treatment  Cost Summary;  Lead
   Subcategory

 Metals  Casting Industry;  Wastewater
   Treatment  Cost Summary;  Magnesium
   Subcategory

 Metals  Casting Industry;  Wastewater
   Treatment-Cost Summary;  Zinc
   Subcategory

 Statistical  Estimates of  Foundry Operations
  Operations
PAGE
 742

 743
 744

 745
 749

 750
 751
 753
754
756
757
768


769



770
771
773
774
787
VIII-127


VIII-128
Energy Requirements Due to Water Pollution
  Control

Solid and Liquid Waste Generation Due to
  Water Pollution Control
788


791

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                           TABLES (Continued)
NUMBER

IX-1

IX-2

IX-3

IX-4



IX-5

IX-6


IX-7

IX-8


IX-9



IX-10



IX-11



IX-12


IX-13


IX-14





IX-1 5
              ;       TITLE.

 Pollutants Selected for Regulation at BPT

 Operations with Recycle Systems Installed

 Zero Discharge Operation Data Summary

 Process Segments in Which the Proposed BPT
    Limitations are No Discharge of Process
    Wastewater Pollutants

 Summary of Treatment In-Place

 Comparison of BPT Model Costs; Selected
   BPT Models vs. Discharge Options

 Dragout Tank Effluent Quality

 BPT and Discharge Option Monitoring Cost
   Criteria

 Comparison of BPT Model Waste Loads;
 "Selected BPT Models vs Discharge-
	Options

 Comparison of Metals Casting  Industry
   Pollutant Waste Loads; Direct
   Dischargers

 Toxic Organic Pollutants not  Treated by
   the BPT Discharge Alternative Treatment
   Technologies

 Expected Compliance Strategy; Selected BPT
   Treatment Models vs Discharge Options-

 Differences in Cost Between Complete
   Recycle and Partial Recycle

 Comparison of Metals Casting  Industry
   Treatment Costs and Total Pollutant
   Waste Loads; Proposed BPT Levels  of
   Treatment vs Discharge Options

 Alternative Effluent Limitations; 90%
   Recycle Discharge Alternative
PAGE

 850

 853

 854

 860



 861

 862


 864

 865


 866



 868



 869



 870


 871


 872




 873

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NUMBER

IX-16


X-l




X-2


X-3
            TABLES  (Continued)

                    TITLE

Alternative Effluent Limitations;  50%
  Recycle Discharge Alternative

Raw Wastewater and Treated Effluent
  Pollutant Loads; Direct and Zero
  Discharge Operations

Alternative Effluent Limitations; 90%
  Recycle Discharge Alternative

Alternative Effluent Limitations; 50%
  Recycle Discharge Alternative
PAGE

 883


 937




 940


 946
                              XII

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NUMBER

III-l

III-2 thru
111-9

111-10
III-ll
V-1 thru
V-40

VII-1
VI1-2


VII-3

VII-4

VII-5

VII-6


VI1-7  thru
VII-15

VII-16

VII-17

VII-18


VII-19

VI1-20
          v   : FIGURES

             ;    -... TITLE

Product Flow Diagram

Process Flow Diagrams


Cast Metals Production at Five-Year
  Intervals

Ferrous Foundry Trends in the  United
  States

Wastewater Treatment System  Water  Flow
  Diagrams (Sampled Plants)

Comparative Solubilities of  Metal
  Hydroxides and Sulfide as  a  Function
  of pH

Effluent Zinc Concentration  vs Minimum
  Effluent pH              ;

Lead Solubility  in Three Alkalies

Granular Bed Filtration

Pressure Filtration

Representative Types of
  Sedimentation

Hydroxide Precipitation  Sedimentation
  Effectiveness

Activated Carbon Adsorption Column

Centrifugation

Types  of Evaporation  Equipment


Dissolved Air  Flotation

Gravity Thickening
PAGE

:100

 101
 108

 109


 110
 246
 285

 519
 520


 521

 522

 523

 524


 525
 533

 534

 535

 536


 537

 538
                               XI11

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 NUMBER

 VII-21

 VII-22

 VII-23

 VIII-1


 VIII-2


 VIII-3


 VIII-4
IX-1 thru
IX-5

IX-6 and
IX-7
IX-8 thru
IX-1 3

IX-14 thru
IX-16

IX-17 and
IX-18

IX-19 and
IX-20

IX-21  and
IX-22

IX-23
IX-24
             FIGURES (Continued)

                     TITLE

 Sludge Drying Bed

 Simplified Ultrafiltration Flow Schematic

 Vacuum Filtration

 Aluminum Foundries Die Casting and Casting
   Quench;  BPT Co-Treatment Model

 Ferrous Foundries Dust Collection and Slag
   Quench;  BPT Co-Treatment Model

 Ferrous Foundries Dust Collection and Sand
   Washing;  BPT Co-Treatment Model

 Ferrous Foundries Slag Quench and Melting
   Furnace  Scrubber;  BPT Co-Treatment Model

 Aluminum Casting  Operations;  BPT Model
   Treatment System

 Copper  and  Copper Alloy Casting
   Operations;  BPT Model TReatment
   System

 Ferrous Casting Operations; BPT Model
   Treatment System

 Lead Casting Operations; BPT  Model
   Treatment System

 Magnesium Casting Operations;  BPT Model
   Treatment System

 Zinc Casting Operations; BPT  Model
   Treatment System

Discharge Options; Wastewater  Flow
  Diagrams

Metal Molding and Casting Alternative BPT
  Analysis; BPT Costs

Ferrous Subcategory; Dust Collection
  Operations - Discharge Alternative
PAGE


 539

 540


 541

 794


 795


 796


 797
892
896

897
898
899
904

905
907

908
909

910
911

912
913


914
                                                                 915
                               xiv

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NUMBER
IX-25 thru
IX-28
           .FIGURES (Continued)

                    TITLE

 "Treatment Model

Metal Molding and Casting; Alternative  BPT
  Analyses
                                                                 PAGE
916
919
X-1 thru
X-7

X-8 and
X-9

X-10 thru
X-1 2

XII-1  thru
XII-10

XII-11 thru
XII-13

XII-14 thru
XII-17

XIII-1 thru
XIII-10

XI11-11  thru
XIII-13

XII1-14  thru
XIII-17
Aluminum Casting Operations; BAT
  Alternatives

Lead Casting Operations; BAT Alternatives
Zinc Casting Operations; BAT Alternatives
Aluminum Casting Operations;  NSPS
  Alternatives

Lead Casting Operations;  NSPS Alternatives


Zinc Casting Operations;  NSPS Alternatives
Aluminum  Casting Operations;  PSES and PSNS
  Alternatives

Lead Casting  Operations;  PSES and PSNS
  Alternatives

Zinc CastinglOperations;  PSES and PSNS
  Alternatives
952
958

959
960

961
963

972
981

982
984

985
988

997
1006

1007
1009

1010
1013
                                 xv

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               ••             SECTION I

                     "SUMMARY;	AND CONCLUSIONS

Pursuant to Sections 301,  304, 306, 307, and  501  of  the  Clean
Water  Act  and  the  Settlement  Agreement  in Natural Resources
Defense Council  v. Train 8 ERC 2120 (D.D.C.  1976)  modified  12
ERCi~83!  TD.D.C. 1979),  EPA has collected and analyzed data for
plants in the Metal Molding and Casting  Point  Source  Category.
There   are  no  existing  effluent  limitations  or  performance
standards   for   this   industry.    This   document   and   the
administrative  record  provide the technical basis for proposing
effluent limitations guidelines for existing direct  dischargers,
pretreatment standards for new and existing indirect dischargers,
and standards of performance for new source direct dischargers.

This  category  is  made  up of three thousand six hundred  (3600)
plants employing people.  Nine hundred sixty five  (965) of  these
plants use wet processing methods which can generate wastewaters.
Of  the  965  plants, 287 discharge directly to rivers, lakes, or
streams; 327 discharge to publicly owned treatment works   (POTW);
and 351 achieve zero discharge of process wastewaters.

The Agency developed a data collection portfolio  (DCP) to  collect
information  regarding  plant size, age, productin, the number of
employees, the  production  processes  used,  the  quantities, of
process   wastewaters   generated   and   discharged,  wastewater
treatment facilities in-place, and disposal practices  at   plants
practicing  metal  molding  and casting.  Using the Penton  "Metal.
Casting Industry Directory" as  a  basis,   the  Agency  selected,
using  statistical  survey  methods,  1269  plants for receipt of
DCPS.  Responses were received from  960  plants    In  order  to
characterize  the  industry,  statistical weights, based upon the
statistical survey methods, were applied  to  each  item   in  the
plant  survey  data.   The Agency conducted a telephone survey in
mid-1981 to update the plant  information and data.

In addition to the DCP distribution described  above,  DCPS were
sent  to  all.of the plants  (226)  identified as producers  of lead
castings.  These plants are primarily involved in  the manufacture
of batteries.  Ten of   the  respondents  indicated  that   process
wastewaters   are   generated   in   metal  molding  and   casting
activities.

EPA sampled the raw  and  untreated  process  wastewaters   at  40
plants.   Nineteen of these plants were visited during a previous
study of this  industry, and the remainder were visited as  part of
current guidelines development efforts.  In the   previous   Agency
study,  analyses   were  performed  for  the conventional  and  for

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 selected non-conventional and toxic  metal  pollutants.    In  the
 current   industry   study,    analyses  were  performed  for  the
 conventional,  toxic metal,  and toxic organic pollutants  and  for
 selected   non-conventional   pollutants.   In  each  subcategory,
 wastewater samples were collected  from  the  metal  molding  and
 casting   processes   and   from  associated  process  wastewater
 generating equipment (i.e.,  scrubbers).
 In developing  the  subcategorization  and  process
 scheme,  the Agency examined the following factors:
                        segmentation
      1.    Type of metal  cast
      2.    Manufacturing  process
      3.    Air pollution  sources and control  devices
      4.    Water use
      5.    Process wastewater characteristics
      6.    Raw materials
      7.    Process chemicals
      8.    Wastewater  treatability
      9.    Plant size  (production and number  of  employees)
      10.   Plant age
      }1.   Geographic  location
      12.   Non-water quality  impacts;  solid waste  generation and
           disposal; and  energy  requirements

The   type  of  metal  cast   is  the  principal  factor affecting the
Agency's subcategorization scheme.   Differences in  the  physical
and chemical  properties  of the  various  types  of metal  cast result
in a  diversity  of  manufacturing processes, raw  materials, process
chemical   use,   sources  of  air pollution, water  use,  and process
wastewater characteristics.   Accordingly, the  six  subcategories
reflect  the  six   types  of  base metal.  EPA has determined that
differences   in  alloys  of   the same  bases  metal   were   not
significant enough to warrant subcategorization by  alloy.

The   subcategories were  further  divided   into  nineteen process
segments to allow   for  dissimilar  manufacturing   processes  and
ancillary  operations among the  different subcategories.

Following  are  the subcategories  of the metal molding  and casting
point source  category:
Subpart

A.   Aluminum Casting
Subcategory

1.   Investment Casting
2.   Melting Furnace Scrubber
3.   Casting Quench
4.   Die Casting
5.   Die Lube

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B.   Copper Casting


C.   Iron & Steel (Ferrous)
     Casting
D.   Lead Casting
E.   Magnesium Casting
F.   Zinc Casting
     1.   Dust Collection Scrubber
    ,2.   Mold Cooling and Casting Quench

     1.   Dust Collection Scrubber
     2.   Melting Furnace Scrubber
     3.   Slag Quench
     4.   Mold Cooling and Casting Quench
     5.   Sand Washing

     1.   Continuous Strip Casting
     2.   Melting Furnace Scrubber
     3.   Grid Casting Scrubber

     1.   Grinding Scrubber
     2.   Dust Collection Scrubber

     1„   Die Casting and Casting Quench
     2.   Melting Furnace Scrubber
The Agency reviewed the raw wastewater characteristics  data  and
process  information  to  select  those pollutants which would be
considered for specific regulation.  These pollutnts follow:
     Antimony
     Arsenic
     Cadmium
     Chromium
     Copper
     Lead
     Nickel
     Zinc
     Ammonia  (N)
Fluoride
Iron
Manganese
Phenols (4AAP)
Sulflde
Oil and Grease
Total suspended solids
Specific toxic organic pollutants
The Agency studied  various end-of-pipe  technologies  to  treat   the
assorted  process   wastewaters  generated   in  this   point  source
category.  These technologies include:

      Sedimentation
      Chemical precipitation  and sedimentation
      Flocculation
      Neutralization
      Multimedia filtration
      Vacuum  filtration
      Chemical emulsion  breaking
      Evaporative cooling
      Oxidation by potassium  permangauate
      Activated Carbon Adsorption

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 EPA also studied in-plant control and  wastewater  recycle.    The
 use  of  wastewater recycle was reported extensively in the plant
 survey data and was observed in many of the sampled plants.

 Model treatment system costs were  prepared  for  each  level  of
 treatment  considered in each process segment.   Using these model
 costs,  the information provided in the DCPs  and  in  the  update
 survey,   and  the statistical survey methods employed,  the Agency
 estimated the cost impact  of  the  proposed  regulation  on  the
 industry.    The  Agency  estimated,  for each process segment, the
 number of potential closures, the number of  employees  affected,
 and  the impact on price and balance of trade.   These results are
 reported in the economic, impact analysis.

 EPA is proposing BPT limitations for 18  process  segments.    For
 one  process segment,  lead continuous strip casting,  there are no
 direct  dischargers;   therefore  EPA   is   not    proposing    BPT
 limitations for this process segment.

 EPA  is   proposing  no discharge of  process wastewater  pollutants
 for 14 process  segments (the 9  process segments  of the   iron  and
 steel,   the  copper and the magnesium casting subcategories  and 5
 process  segments associated  with the  other 4  subcategories).
 These  five  process  segments  are:   the aluminum casting quench,
 the aluminum die lub,  the lead  melting furnace scrubber,  the lead
 grid casting scrubber,  and the  zinc  casting quench process.

 EPA is proposing BPT discharge  limitations  for   the  remaining  4
 process  segments based on treatment  followed by  a discharge.   The
 4   process   segments   are:   aluminum investment  casting,  aluminum
 melting  furnace scrubber,  aluminum die casting,  and zinc   melting
 furnace  scrubber.   Generally,   the  treatment  provided  in  these
 segments consists of chemical precipitation,  sedimentation,   oil
 removal, and/or partial  recycle.

 For   the  fourteen  process   segments   for   which  the  Agency is
 proposing complete  recycle  of process   wastewaters at  BPT,   the
 Agency   considered   two   less   stringent  treatment alternatives.
 These options call  for   partial   recycle  and  treatment   of   the
 wastewater   not    recycled.    Both  discharge   alternatives   are
 designed  to  be   compatible  with   existing  in-place  treatment
 technologies  and  are   based   upon  solids  and   metals   removal
 technologies currently used by   foundries   (i.e.,   lime   addition
 followed  by clarification).  The options differ  by the extent of
partial recycle after simple sedimentation.  One  option is  based
 upon  90  percent   recycle and  the other is based  upon 50 percent
recycle.  Oil skimming devices  are included for both options,  as
required, for oil removal.

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After  comparing complete recycle with the two discharge options,
the Agency concluded that  100  percent  recycle  is  preferable,
based upon the extent to which 100% recycle is practiced and upon
cost and pollutant removal considerations.  However, comments are
solicited  on  these and similar treatment technologies.  Further
analysis, based upon comments, may show that one of these options
is  an  appropriate  basis  for  BPT  limitations  in  the  final
regulation..   T  '•--..".'•          ^

For  14  process  segments,  the  BPT levle of treatment achieves
complete recycle.  As this is the best available technology,  BAT
is equal to BPT for these process segments.

There  are  no  direct  dischargers  in the lead continuous strip
process segment.  Therefore, no BAT limitations are proposed  for
this process segment.  In the aluminum investment casting and the
aluminum  melting  furnace  scrubber process segments exclusions,
provided in paragraph 8  of  the.  Revised  Settlement  Agreement,
preclude  the  proposal  of  BAT  effluent limitations.  In these
process segments, the toxic organic and  toxic  metal  pollutants
were either not detected or detected below treatable levels.

The proposed BPT limitations for the aluminum die casting process
segment  are  based  upon  hydroxide precipitation-sedimentation,
filtration and chemical emulsion breaking with 85 percent recycle
of process wastewater.  EPA is proposing BAT limitations based ,on
the BPT technology with recycle increased to 95 percent.

EPA is using complete recycle  as  the  basis  for  porposed  BAT
effluent limitations in the zinc melting furnace scrubber process
segment.   Complete  recycle  has  been  demonstrated,  and  high
recycle rates are common, in this process.

The basis for new source performance standards is to be the  best
available  demonstrated  technology  (BDT).   New plants have the
opportunity to design the best and most efficient  metal  molding
and casting processes and wastewater treatmetn technologies.

The  90% and 50% recycle options considered as possible bases for
BPT were rejected for the reasons set  forth  above  in  the  BPT
discussion.  Complete recycle is economically achievable and will
remove  substantial  quantities of toxic pollutants.  A number of
process  segments  would  discharge  toxic   organic   pollutants
(principally phenolic compounds) if complete recycle were not the
basis  for BAT.  Neither the  90% nor the 50% recycle options were
based upon technologies that  would  treat  these  toxic  organic
pollutants.   If  a  discharge  option  were selected for BAT and
these pollutants required treatment,  the  total  cost  of  these
options would far exceed the  cost of complete recycle.

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EPA  is  proposing  NSPS  for  all 19 process segments of all six
subcategories.  This number includes the 18 process segments  for
which  BPT  and  BAT  limitations  are  proposed  plus  the  lead
continuous strip casting process segment,  (in which there are  no
existing  direct dischargers).  For the 15 process segments where
the proposed  BPT  and  BAT  limitations  are  complete  recycle,
pollutant  discharges  have  been  reduced  to the maximum extent
possible.  The  Agency  has  selected  NSPS  technology  that  is
equivalent  to  BPT/BAT technology for these 15 process segments.
BAT  technology  achieves  no  discharge  of  process  wastewater
pollutants and is demonstrated in the industry.

In  the  aluminum  investment  casting  and  the aluminum melting
furnace  scrubber  process  segments,  EPA   has   selected   the
equivalent  of  BPT as the bases for the proposed NSPS.  Complete
recycle has not been demonstrated in these process  segments  and
cannot be readily transferred.
In  the  aluminum  die casting process segment, the proposed NSPS
are equivalent to the proposed BAT limitations, with the addition
of standards for TSS, oil and  grease,  and  pH.   The  treatment
technologies  and  associated pollutant removal capabilities have
been demonstrated in this process segment.

The proposed NSPS for the lead continuous strip  casting  process
segment  are  based  upon  lime precipitation, sedimentation, and
filtration.   Filtration  is  used  to   improve   lead   removal
performance,  these technologies are in use and well demonstrated
in this process segment.

EPA  is  proposing  PSES  for  the 19 process segments of all six
subcategories.  For the 13 process segments  where  the  proposed
BAT  limitations  are  based upon complete recycle the Agency has
selected the equivalent of BAT as  the  basis  for  the  proposed
PSES.   EPA  is proposing PSES equivalent to BAT for aluminum die
casting.  For lead continuous strip casting EPA is porposing PSES
based on the hydroxide precipitation, sedimentation,  and  filter
technologies  as  demonstrated  by  4  of  the 5 continuous strip
casting plants.  For the  aluminum  investment  casting  and  the
aluminum  melting  furnace  scrubber process segments, EPA is not
proposing PSES because the levels of total suspended  solids  and
oil  and  grease  discharged  from these processes are considered
compatible with treatment by POTWs.  For the two process segments
of the magnesium subcategory there are  no  indirect  dischargers
therefore EPA is not proposing PSES.

For  the  13  process  segments for which the Agency is proposing
complete recycle of process wastewater as the basis for PSES, the

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Agency considered  two  less  stringent  treatment  alternatives.
These  are the same alternatives as were considered for BPT.  The
Agency is proposing PSES based upon complete recycle rather  than
on  either  of  the other treatment alternatives because complete
recycle is achievable and will  result  in  additional  pollutant
removals.   PSES,  like  BAT,  should represent the best existing
performance in the industrial category or  subcategory.   As  was
the case for BPT it will be typically less expensive to implement
100  percent  recycle  after simple sedimentation than to install
and operate technology that would achieve lower recycle but would
treat the wastewaters not recycled.

EPA is proposing PSNS for 17 of the 19 process  segments  in  all
six  subcategories.   For  the  15  process segments in which the
proposed BAT/NSPS/PSES limitations and standards are no discharge
of process wastewater pollutants, the  Agency  is  proposing  the
equivalent  of BAT/NSPS/PSES as the basis for porposed PSNS.  EPA
is proposing PSNS equivalent to BAT for the aluminum die  casting
segment.   For  the  lead continuous strip casting segment EPA is
proposing PSNS equivalent to PSES.

For the aluminum investment  casting  and  the  aluminum  melting
furnace  scrubber  process  segments,  EPA  is not proposing PSNS
because the levels of total suspended solids and oil  and  grease
discharged  from  these  processes are considered compatible with
treatment by POTWs.

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                           SECTION II

                         RECOMMENDATIONS
     EPA has divided the metal molding and casting category  into
nineteen  process segments for the purpose of developing proposed
effluent limitations and standards,  segments for the purpose  of
developing  proposed  effluent  limitations and standards.  These
process segments ares
Subpart
     A.
     B.
     E.
     F.
 	Subcategory/Segment	
Aluminum Casting Subcategory
1.    Investment Casting Operations
2.    Melting Furnace Scrubber Operations
3.    Casting Quench Operations
4.    Die Casting Operations
5.    Die Lube Operations

Copper Casting Subcategory
1.    Dust Collection Operations
2.    Mold Cooling and Casting Quench Operations

Ferrous Casting Subcategory
1.    Dust Collection Operations
2.    Melting Furnace Scrubber Operations
3.    Slag Quenching Operations
4.    Mold Cooling and Casting Quench Operations
5.    Sand Washing Operations

Lead Casting
1.    Continuous Strip Casting
2.    Melting Furnace Scrubber
3.    Grid Casting

Magnesium Casting Subcategory
1.    Grinding Scrubber Operations
2.    Dust Collection Operations

Zinc Casting Subcategory
1.    Die Casting and Casting Quench Operations
2.    Melting Furnace Scrubber Operations
     Following  are  the  proposed   effluent
standards for each of the process segments.
                                      limitations   and

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A.   Aluminum Casting Subcategory

1.   Investment Casting Operations

(a)  Proposed BPT Effluent Limitations
Pollutant or
Pollutant Property
Maximum for
Any One Day
  (kq/kkq)
  Maximum for
Monthly Average
   (kq/kkq)
TSS
Oil and Grease
pH	
 1.103                  0.538
 0.538                  0.323
 Within the range of 7.5 to 10
(b)  Proposed New Source Performance Standards
Pollutant or
Pollutant Property
Maximum for
Any One Day
 (kq/kkq)
  Maximum for
Monthly Average
   (kq/kkq)
TSS
Oil and Grease
Pi	
 1.103                  0.538
 0.538                  0.323
 Within the range of 7.5 to 10
2.   Melting Furnace Scrubber Operations

(a)  Proposed BPT Effluent Limitations
Pollutant or
Pollutant Property
Maximum for
Any One Day
 (kq/kkq)
  Maximum for
Monthly Average
   (kq/kkq)
TSS
Oil and Grease
PH	
 0.0166                 0.00809
 0.00809                0.0.0486
 Within the range of 7.5 to 10.0
                               10

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(b)  Proposed New Source Performance Standards
Pollutant or
Pollutant Property
Maximum for
Any One Day
 (kq/kkq)
  Maximum for
Monthly Average
   (kg/kkq)
TSS
Oil and Grease
PH	_.
 0.0166                 0.00809
 0.00809                0.00486
 Within the range of 7.5 to 10
3.   Casting Quench Operations

(a) .Proposed BPT Effluent Limitations

     No discharge of process wastewater pollutants  to  navigable
     waters.

(b)  Proposed BAT Effluent Limitations

     No discharge of process wastewater pollutants  to  navigable
     waters.

(c)  Proposed New Source Performance Standards

  •   No discharge of process wastewater pollutants  to  navigable
     waters.


(d)  Proposed Pretreatment Standards for Existing and New Source

     No discharge of process wastewater pollutants to a POTW.
                               11

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4.   Die Casting Operations

(a)  Proposed BPT Effluent Limitations
Pollutant or
Pollutant Property
Maximum for
Any One Day
 (kg/kkg)
  Maximum for
Monthly Average
   (kg/kkq)
Lead
Zinc
Phenols (4AAP)
TSS
Oil and Grease
PH
0.0000726
0.000740
0.000322
0.0109
0.00726
Within the range of
0.0000653
0.000305
0.000161
0.00799
0.00726
7.5 to 10
(b)  Proposed BAT Effluent Limitations
Pollutant or
Pollutant Property
Maximum for
Any One Day
 (kg/kkg)
  Maximum for
Monthly Average
   (kg/kkg)
Acenaphthene
2,4,6-trichlorophenol
Parachlorometacresol
Chloroform
Phenol
Butyl benzyl phthalate
Chrysene
Tetrachloroethylene
Lead
Zinc
Phenol s(4AAP)
0.0000092
0.0000305
0.0000281
0.0000668
0.0000063
0.000104
0.0000019
0.0000261
0.0000242
0.000247
0.000107
0.0000046
0.0000152
0.0000140
0.0000334
0.0000031
0.0000518
0.0000010
0.0000131
0.0000218
0.000102
0.0000537
                               12

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(c)  Proposed New Source Performance Standards
Pollutant or
Pollutant Property
Maximum for
Any One Day
(kg/kka)
Maximum for
Monthly Average
(kg/kkg) ;
Acenaphthene
2,4,6-trichlorophenol
Parachlorometacresol
Chloroform
Phenol
Buty benzyl phthalate
Chrysene
Tetrachlordethylene
Lead
Zinc
Phenols'UAAP)
TSS
Oil and Grease
PH
0.0000092              0.0000046
0.0000305              0.0000152
0.0000281              0.0000140
0.0000668              0.0000334
0.0000063              0.0000031
0.000104               0.0000518
0.0000019              0.0000010
0.0000261              0.0000131
0.0000242              0.0000218
0.000247               0.000102
0.000107               0.0000537
0.00363                0.00266
0.00242                0.00242
Within the range of 7.5 to 10
                               13

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(d)  Proposed Pretreatment Standards for Existing and New Sources
Pollutant or
Pollutant Property
Maximum for
Any One Day
 (kq/kkq)
  Maximum for
Monthly Average
   (kq/kkq)
Acenaphthene
2,4,6-trichlorophenol
Parachlorometacresol
Chloroform
Phenol
Butyl benzyl phthalate
Chrysene
Tetrachloroethylene
Lead
Zinc
Phenols (4AAP)
0.0000092
0.0000305
0.0000281
0.0000668
0.0000063
0.000104
0.0000019
0.0000261
0.0000242
0.000247
0.000107
0.0000046
0.0000152
0.0000140
0.0000334
0.0000031
0.0000518
0.0000010
0.0000131
0.0000218
0.000102
0.0000537
5.   Die Lube Operations

(a)  Proposed BPT Effluent Limitations

     No discharge of process wastewater pollutants to navigable
     waters.

(b)  Proposed BAT Effluent Limitations

     No discharge of process wastewater pollutants to navigable
     waters.

(c)  Proposed New Source Performance Standards

     No discharge of process wastewater pollutants to navigable
     waters.

(d)  Proposed Pretreatment Standards for Existing and New Sources

     No discharge of process wastewater pollutants to a
     POTW.
                                14

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B.   Copper Casting Subcategory
1.   Dust Collection Operations
(a)  Proposed BPT Effluent Limitations
     No discharge of process wastewater pollutants to navigable
     waters.
(b)  Proposed BAT Effluent Limitations
     No discharge of process wastewater pollutants to navigable
     waters.
(c)  Proposed New Source Performance Standards
     No discharge of process wastewater pollutants to navigable
     waters.                       .       .........    ,
(d)  Proposed Pretreatment Standards for  Existing and New  Sources
     No discharge of process wastewater pollutants to a
     POTW.
2.   Mold Cooling and Casting Quench Operations
     Quench Operations                          '  "~  '
(a)  Proposed BPT Effluent Limitations                   -
     No discharge of process wastewater pollutants to navi'gable
     waters.                        ;     i    *           •i--A.

(b)  Proposed BAT Effluent Limitations
     No discharge of process wastewater pollutants   to   navigable
     waters.                      .   .   .
(c)  Proposed New Source Performance Standards
     No discharge of process wastewater pollutants   to  •navigable
     waters.
(d)  Proposed Pretreatment, Standards for  Existing and New  Sources
     No discheirge of process wastewater pollutants to a  POTW.
                                15

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C.   Ferrous Casting Subcategory
1.   Dust Collection Operations
(a)  Proposed BPT Effluent Limitations
     No discharge of process wastewater pollutants  to  navigable
     waters.
(b)  Proposed BAT Effluent Limitations
     No discharge of process wastewater pollutants  to  navigable
     waters.
(c)  Proposed New Source Performance Standards
     No discharge of process wastewater pollutants  to  navigable
     waters.
(d)  Proposed Pretreatment Standards for Existing and New Sources
     No discharge of process wastewater pollutants to a POTW.
2.   Melting Furnace Scrubber Operations
(a)  Proposed BPT Effluent Limitations
     No discharge of process wastewater pollutants  to  navigable
     waters.
(b)  Proposed BAT Effluent Limitations
     No discharge of process wastewater pollutants  to  navigable
     waters.
(c)  Proposed New Source Performance Standards
     No discharge of process wastewater pollutants  to  navigable
     waters.
(d)  Proposed Pretreatment Standards for Existing and New Sources
     No discharge of process wastewater pollutants to a POTW.
                               16

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3.    Slag Quenching Operations
(a)  Proposed BPT Effluent Limitations
     No discharge of process wastewater pollutants  to  navigable
     waters.
(b)  Proposed BAT Effluent Limitations
     No discharge of process wastewater pollutants  to  navigable
     waters.
(c)  Proposed New Source Performance Standards
     No discharge of process wastewater pollutants  to  navigable
     waters.
(d)  Proposed Pretreatment Standards for Existing and New Sources
     No discharge of process wastewater pollutants to a POTW.
4.    Mold Cooling and Casting Quench Operations
(a)  Proposed BPT Effluent Limitations
     No discharge of process wastewater pollutants  to  navigable
     waters.
(b)  Proposed BAT Effluent Limitations
     No discharge of process wastewater pollutants  to  navigable
     waters.
(c)  Proposed New Source Performance,Standards
     No discharge of process wastewater pollutants  to  navigable
     waters.
(d)  Proposed  Pretreatmennt  Standards  for  Existing  and   New
     Sources
     No discharge of process wastewater pollutants to a POTW.
5.   Sand Washing Operations
(a)  Proposed BPT Effluent Limitations
     No discharge of process wastewater pollutants  to  navigable
     waters.
                               17

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 Cb)  Proposed BAT Effluent Limitations

     No discharge of process wastewater pollutants  to  navigable
     waters.

 (c)  Proposed New Source Performance Standards

     No discharge of process wastewater pollutants  to  navigable
     waters.

 (d)  Proposed Pretreatment Standards for Existing and New Sources

     No discharge of process wastewater pollutants to a POTW.


D.   Lead Casting Subcategory


 1 .   Continuous Strip Casting Operations

 (a)  Proposed New Source Performance Standards
Pollutant or
Pollutant Property
Maximum for
Any One Day
 (kg/kkg)
  Maximum for
Monthly Average
   (kq/kkq)
TSS
Oil and Grease
Lead
PH	
 0.00340                0.00250
 0.00227                0.00227
 0.0000227              0.0000204
 Within the range of 7.5 to 10
(b)  Proposed Pretreatment Standards for Existing and New Sources
Pollutant or
Pollutant Property
Maximum for
Any One Day
 (kq/kkq)
  Maximum for
Monthly Average
   (kq/kkq)
Lead
 0.0000227
   0.0000204
2.   Melting Furnace Scrubber Operations

(a)  Proposed BPT Effluent Limitations
                               18

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     No discharge of  process wastewater pollutants  to  navigable
     waters.
(b)   Proposed BAT Effluent Limitations
     No discharge of  process wastewater pollutants  to  navigable
     waters.
(c)   Proposed New Source Performance Standards
     No discharge of  process wastewater pollutants  to  navigable
     waters.
(d)   Proposed Pretreatment Standards for Existing and New Sources
     No discharge of  prdcess wastewater pollutants to a POTW.
3.   Grid Casting Operations

(a)   Proposed BPT Iffluent Limitations
     No discharge of  process wastewater pollutants  to  navigable
     waters.
(b)   Proposed BAT Effluent Limitations
     No discharge of  process wastewater pollutants  to  navigable
     waters.
(c)   Proposed New Source Performance Standards
     No discharge of processwastewater pollutants  to  navigable
     waters.
(d)   Proposed Pretreatment Standards for Existing and New Sources
     No discharge of process wastewater pollutants to a POTW.

E.   Magnesium Casting Subcategory
1.   Grinding Scrubber Operations
(a)   Proposed BPT Effluent Limitations
     No discharge of process wastewater pollutants  to  navigable
     waters.
                                19

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         (b)   Proposed BAT Effluent  Limitations
              No discharge of  process  wastewater  pollutants   to  navigable
              waters.
         (c)   Proposed New Source  Performance  Standards
              No discharge of  process  wastewater  pollutants   to  navigable
              waters.
         (d)   Proposed Pretreatment  Standards  for New  Sources
              No discharge of  process  wastewater  pollutants  to  a  POTW.
                                       20
_

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2.    Dust Collection Operations     .                    .''.>..-'•-
(a)  Proposed BPT Effluent Limitations
     No discharge of process wastewater  pollutants  to  navigable
     waters.   "•  .'••_/.' "'':,...  '~ ,  ". ..   .. "	•-"--,' 	••.. •'.-..-       .,  ;..
(b)  Proposed BAT Effluent Limitations                            •
     No discharge of process wastewater  pollutants  to  navigable
     waters. . .   ..  ..,  . •• . .  •.  .-.     . ,  ."• ;.. .-   ••• .o •   • :.n,..
(c)  Proposed New Source  Performance Standards
     No discharge of process wastewater  pollutants  to  navigable
     waters.
(d)  Proposed Pretreatment Standards for New Sources
     No discharge of process wastewater  pollutants to a POTW.

F.   Zinc Casting Subcategory
1.   Die Casting and Casting Quench  Operations
(a)  Proposed BPT Effluent Limitations                   r
     No discharge 6f process wastewater  pollutants  to  navigable
     waters.
(b)  Proposed BAT Effluent Limitations
     No discharge  of  process wastewater  pollutants  to  navigable
     waters.
(c)  Proposed New  Source  Performance Standards
     No discharge  of process wastewater pollutants  to  navigable
     waters.
(d)  Proposed Pretreatment Standards for Existing and New  Sources
     No discharge  of process wastewater pollutants to a POTW.

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2.   Melting Furnace Scrubber Operations.
(a)  Proposed BPT Effluent Limitations
Pollutant or
Pollutant Property
Zinc
Phenols (4AAP)
TSS
Oil and grease
PH
Maximum for
Any One Day
(kq/kkq)
0.00419
0.0315
0.129
0.0630
Within the range of
Maximum for
Monthly Average
(kq/kkq)
0.00176
0.0157
0.0630
0.0378
7.5 to 10
(b)  Proposed BAT Effuent Limitations
     No discharge of process wastewater pollutants  to  navigable
     waters.
(c)  Proposed New Source Performance Standards
     No discharge of process wastewater pollutants  to  navigable
     waters.
(d)  Proposed Pretreatment Standards for Existing and New Sources
     No discharge of process wastewater pollutants to a POTW.
                               22

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                           SECTION III

                          INTRODUCTION
LEGAL AUTHORITY

This report  is  a  technical  background  document  prepared  to
support  effluent  limitations  and  standards under authority of
Sections 301, 304,  306,  307,  and  501  of  the  Federal  Water.
Pollution  Control  Act,  as  amended (the Clean Water Act or the
Act)   These effluent limitations and standards  are  in  partial
fulfillment  of  the  Settlement  Agreement  in Natural Resources
Defense CounclL.  Inc^  v.  Train,  8  ERC  2120   (D.D.C.  1976X,
modified~~Ma7ch  9,  1979.   This  document  also  fulfills^ the
requirements of Sections 304(b) and 304(c)  of  the  Act.   These
sections  require  the  Administrator,  after  consultation  with
appropriate Federal  and  State  agencies  and  other  interested
persons,  to  issue  information on the processes, procedures, or
operating methods which result in the elimination  or reduction of
the discharge of pollutants through the application of  the  best
practicable  control  technology  currently  available (BPT), the
best available  technology  economically  achievable   (BAT),  and
through  the  implementation  of new source performance standards
(NSPS), and pretreatment standards for new and  existing  sources
(PSNS  and PSES) .

BACKGROUND - The Clean  Water  Act

The  Federal  Water  "Pollution  Control  Act  Amendments  of  1972
established  a comprehensive program to  restore and maintain  the
chemical,  physical,  and  biological   integrity   of the  Nation  s
waters.  By  July  1,  1977,  existing  industrial  dischargers  were
required   to   achieve   effluent    limitations    requiring  the
application  of  the  best practicable control  technology   currently
available  (BPT),  Section  301 (b) (1 ) (A);  and by July 1,  1984,  these
dischargers   were   required  to  achieve   effluent   limitations
requiring  the  application   of   the  best   available  technology.
economically achievable   (BAT),   Section  301 (b) (2) (A) .   BAT  will
result in  reasonable further  progress toward the  national goal  of
eliminating  the discharge of  all  pollutants.    New   industrial
direct  dischargers were required to comply with Section 306 new
source performance  standards   (NSPS),   based on   best  available
demonstrated  technology;  and  new   and  existing  so"rcef_^ich
 introduce  pollutants into publicly owned treatment works   POTWs)
were  subject  to  pretreatment standards under .Sections 307(b)  and
 (c)  of the Act.  While  the requirements  for direct  dischargers
were   to  be   incorporated   into National   Pollutant  Discharge
Elimination  System (NPDES) permits issued under   Section  402  of
 the  Act,  pretreatment  standards were made enforceable directly
                                23

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 against any owner or operator  of  any  source
 pollutants into POTWs (indirect dischargers).
which  introduces
 Although Section 402(a)(l) of the 1972 Act authorized the setting
 of  requirements  for direct dischargers on a case-by-case basis,
 Congress intended that,  for the most part,  control  requirements
 would be based on regulations promulgated by the Administrator of
 EPA.    Section  304(b)  of  the Act required the Administrator to
 promulgate  regulations    providing   guidelines   for   effluent
 limitations  setting  forth  the  degree  of  effluent  reduction
 attainable through the application of  BPT  and  BAT.    Moreover,
 Section  306  of the Act required promulgation of regulations for
 NSPS,   and  Sections  304(f),    307(b),    and   307(c)   required
 promulgation  of  regulations  for  pretreatment  standards.    In
 addition to these regulations for designated industry  categories,
 Section  307(a)   of  the  Act  required  the   Administrator    to
 promulgate  effluent  standards  applicable to all dischargers of
 toxic  pollutants.   Finally,  Section 501(a) of the Act   authorized
 the    Administrator   to  prescribe  any  additional   regulations
 necessary to carry out his functions under the Act.

 The EPA was unable to promulgate many of these regulations by the
 dates  contained  in the Act.   In 1976,  EPA  was  sued   by  several
 environmental  groups, and in  settlement of this lawsuit,  EPA and
 the  plaintiffs   executed   a  Settlement  Agreement,   which   was
 approved  by the Court.  This  Agreement  required EPA to  develop a
 program and adhere to a  schedule for promulgating  for  21  major
 industries  BAT  effluent limitations,  pretreatment standards,  and
 new source performance standards  for   65  toxic  pollutants   and
 classes  of pollutants.   (See Natural Resources Defense Council,
 Inc. v.  Train, 8  ERC  2120  (D.D.C.  1976),  modified March  9,  1979.)

 The Clean Water  Act amendments of  1977   incorporated   several   of
 the  basic  elements   of  the   Settlement  Agreement   program  for
 priority    pollutant   control.     Sections   301(b)(2)(A)     and
 301(b)(2)(C)  of   the Act now require the achievement by  July 1,
 1984, of  effluent  limitations  requiring  application  of  BAT   for
 toxic   pollutants,  including  the  65  toxic pollutants  and  classes
 of pollutants which Congress declared  toxic under  Section   307(a)
 of  the Act.  Likewise,  EPA's  programs for new source  performance
 standards  and pretreatment standards are  now  aimed principally  at
 toxic pollutant  control.   Moreover,  to  strengthen  the  toxic
pollutant   control  program, Congress added Section 304(e)  to  the
Act,  authorizing the  Administrator  to prescribe   best  management
practices   (BMPs)  to  prevent  the release of toxic and  hazardous
pollutants  from plant site runoff, spillage or leaks,   sludge   or
waste disposal, and drainage from raw material storage associated
with,  or ancillary to, the manufacturing  or treatment process.
                               24

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GENERAL DESCRIPTION OF THE METAL MOLDING AND CASTING INDUSTRY

The  unique  feature  of  the  foundry industry is the pouring or
injection of molten metal into a mold, with  the  cavity  of  the
mold  representing, within close tolerances, the final dimensions
of the product.  One of the major advantages of this  process  is
that  intricate  metal shapes, which are not easily obtainable by
any other  method  of  fabrication,  can  be  produced.   Another
advantage  is  the rapid translation of a projected design into a
finished article.   New  articles  are  easily  standardized  and
duplicated by the casting method.

The   foundry    industry  ranks  fifth  among  all  manufacturing
industries based on "Value added  by  Manufacture"  according  to
data  issued  by the United States Department of Commerce in 1970
(Survey of Memufacturers, SIC 29-30).  As  of  1978,  there  were
over  3,600  commercial  foundries in the United States employing
approximately 300,000  workers  and  producing  over  17  million
metric tons/year (19 million tons/year) of cast products.  In the
estimated  number  of  foundries  the  Agency  does not count art
studios,  trade  schools,   coinage   mints,   and   other   such
establishments as commercial foundries.

The  product  flow  of  the typical foundry operation is shown in
Figure III-l.  In all  types  of  foundries,  raw  materials  are
assembled  and stored  in various material bins.  From these bins,
a  "furnace charge" is  selected by using various  amounts  of  the
desired  materials.    This  material  is  "charged" into a melting
furnace and  through a  heating process, the metal is made  molten.
Simultaneously-,  molds  are  prepared.    This  process  begins by
forming a pattern  (usually of  wood)  to  the  approximate  final
shape of the product.  This pattern  is usually .made  in two pieces
that  will   eventually match  to  form   a single piece, although
patterns may consist of 3 or; more  pieces.   Each  part  of  the
pattern  is  used  to form a cavity in a moist sand media, and the
two portions of  the mold  (called  "cope" and  "drag")   are  matched
together  to  form  a  complete   cavity   in   the  sand media.  An
entrance hole  (called  a  "sprue")  provides   the  proper  path  of
molten  metal   introduction   into  the  cavity.  The  mold  is  then
ready to receive the molten metal.   In die  casting operations the
mold  cavity  is  formed  in metallic die  blocks  which   are   locked
together to  make a complete  cavity.

The molten metal is now  "tapped"  from the furnace  into  the  ladle.
The   ladle and molds are moved  to a  pouring  area and the metal  is
poured  into  the  molds.   The  molds are then   moved   to  a   cooling
area  where   the  molten  metal   solidifies  into the shape  of the
pattern.  When sufficiently  cooled,  the   sand  is   removed   by   a
process  known  as  "shake   out."  By  violent   shaking,  the  sand
                                25

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 surrounding the metal is loosened,  falls away,  and is returned to
 the sand storage area.

 The cast metal object (casting)  is  further processed by  removing
 excess  metal,  and  cleaned by  various methods that complete the
 removal  of the sand  from  its  surface.    In  the  case  of  die
 casting,   where  no sand is used,  the cast object is removed from
 the die  casting machine after cooling sufficiently to retain  its
 shape.    The  casting is either  further cooled  by a water bath or
 is allowed to air cool  on a runout  or cooling  table.   Depending
 on  the   final  use  of  the  casting,  further  processing by heat
 treatment,     quenching,     machining,     chemical     treatment,
 electroplating,   painting,   or coating  may take place.   Following
 inspection,  the casting is  ready for  shipment.

 Foundry  Metal Description

 Many of  the  cast metals have unique  properties  which   influence
 the  way  they are melted and processed and,  subsequently,  affect
 the process  wastewater  characteristics.   A brief  description  of
 these metals,   foundry  equipment, and processes is presented to
 identify  sources of process wastewaters.

 Aluminum

 Aluminum  is  a light silver-white metal   2.7  times  denser  than
 water.   It is soft but  possesses good tensile strength.   It melts
 at   660°C (1200°F)  and  is easily cast,  extruded,  and pressed.   An
 aluminum  structure weighs half as much  as a   steel  structure  of
 comparable strength.  Until  1886 aluminum was a rarity.   Then the
 economic  Hall process  was  developed  to extract metallic  aluminum
 from its  oxide  "alumina".   Today aluminum is   the  second  most
 widely used  metal  after  iron.  Table  III-l  indicates that in 1977
 over 0.9  million  metric   tons)   (1  million   tons of  aluminum
 castings  were shipped in  the  United States.   Aluminum may be cast
 in  a variety of  ways.  A  drawing depicting the  process and   water
 flow in  a  typical  aluminum  investment operation is presented in
 Figure III-2.  Figure III-3 shows   the  process  arrangement  and
 water   flow  schematic  for  a typical  aluminum  die   casting
 operation.

 Copper

 Copper is  a  red,   ductile   nonferrous   metal,    second   only   to
 aluminum  in  importance of nonferrous metals.    It  melts at  1083°C
 (1982°F)  and  has excellent corrosion  resistance.   It  is the  metal
which heralded the Bronze Age  (3,000 B.C.)  and   is   occasionally
 found in a metallic  state in nature.  Brass and bronze, which  are
mixtures  of  copper,  tin,    lead,  and zinc,  are  two of  the most
                               26

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important copper alloys.  Other,copper alloys include  manganese,
nickel,  silicon,  and  beryllium.  Tafafe III-T provides a recent
history of copper shipment tonnages^  Copper and its  alloys  may
also  be  cast  in a variety of ways as depicted in Figure IIIr-4.
Figure II1-4 also shows the process and'process  wastewater  flow
schematic typical of a copper casting operation.

Ferrous

Iron  is  the  world's most widely used metal.  When alloyed with
carbon, it has a wide range  of  useful  engineering  properties.
Alloys  of  iron  include:  gray,  ductile, malleable, and steel.
Tonnages shipped are presented  in  Table  III-l.   Figure  II1-5
displays  typical processes and process wastewater flow schematic
for ferrous foundries.

Gray Iron  is  the  most  popular  of  the  cast  irons.   It  is
characterized  by the presence of most of the contained carbon as
flakes of free graphite  in  the  as-cast  iron.   Gray  iron  is
classified into ten classes based on the minimum tensile strength
of a cast bar:.  The tensile strength is affected by the amount of
free   graphite   present   as  well  as  the  size,  shape,  and
distribution of the graphite  flakes.   Flake  size,  shape,  and
distribution  are strongly influenced by metallurgical factors in
the melting of the iron and its subsequent treatment while molten
and by solidification rates and cooling in the mold.

Ductile Iron  (also known as nodular iron, spherulitic iron, etc.)
is similar to gray iron with respect to carbon, silicon and  iron
content,   and   in  the  type  of  melting  equipment,  handling
temperatures, and general metallurgy.  The  important  difference
between  ductile  and gray iron is that the graphite separates as
spheroids or nodules (instead of flakes as in  gray  iron)  under
the  influence  of  a few hundredths of a percent of magnesium in
the composition.  The presence of minute  quantities  of  sulfur,
lead, titanium, arid aluminum can interfere with, and prevent, the
nodulizing  effect  of  magnesium.   Molten  ductile iron must be
purer than molten gray iron, however; a small quantity of  cerium
added  with  the  magnesium  minimizes  the effects of impurities
which inhibit nodule formation and make it  possible  to  produce
ductile iron from the same raw materials used for high grade gray
iron manufacture.

The  general  procedure for manufacturing ductile iron is similar
to  that  of  gray  iron,  but  with  more  precise  control   of
composition and pouring temperature.  Prior to pouring metal into
the  molds  (and  in  some  cases  during  pouring), the metal is
innoculated with the correct percent of magnesium, usually  in  a
                          ..•	  27

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carrier  alloy,   to  promote   the   development   of   spheroids   of
graphite on  cooling.

While the development of ductile iron dates  back to   the   1920's,
only  within the last  20  years  has   it   become   an important
engineering  material.  This can be  noted  from Table   III-l  which
shows its increasing use.
Malleable   Iron   is  produced
ranges of composition:
          Carbon
          Silicon
          Manganese
          Sulfur
          Phosphorus
          Boron
          Aluminum
from  base  metal in the following
                                   Percent
2.00
1 .00
0.20
0.02
0.01
0.0005
0.0005
to
to
to
to
to
to
to
               ,00
                80
               ,50
                17
                10
                0050
              0.0150
Low tonnage foundries use batch-type furnaces  (e.g., electric arc
induction, or reverberatory).  The  tapping  temperature  of  the
iron is 1500°C-1600°C (2,700 - 2,900°F) depending on the fluidity
required.   In large tonnage shops needing a continuous supply of
molten malleable iron, electric furnaces or duplexing systems are
employed.  Cupola furnaces are common in  some  malleable  shops,
especially  for  the production of pipe fittings.  After the iron
casting solidifies, the metal is a brittle white iron.  Malleable
iron castings are produced from this white iron by heat  treating
processes  which  convert  the  as-cast  structure  to  a "temper
carbon" grain structure in a  matrix  of  ferrite.   This  is  an
annealing   process  requiring  proper  furnace  temperature/time
cycles and a controlled atmosphere.

Steel - The making and pouring of  steel  for  sand  castings  is
similar   to  the  casting  of  steel  into  ingots.   One  major
difference  from  steel  mill  practice  is  the  higher  tapping
temperature  needed to attain the correct fluidity needed to pour
the steel into molds.  The  melting  furnaces  in  foundries  are
generally  of  the  same  type  as  those for steel mills but are
smaller.  Only a thoroughly "killed" steel is  used  for  foundry
products.   Molding  practices  are similar to those of gray iron
operations, however, precautions  are  required  for  the  higher
pouring  temperatures  1800°C (3,200°F).  Mold coatings or washes
are used to give a better finish and are generally made  of  more
refractory-like materials to resist metal penetration.
                               23

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Lead

Lead  is  a  heavy,  gray,  soft  metal  of  low tensile strength
weighing 11,340 kg/cu m (710 Ib/ft3).  The melting point for lead
is 327.4°C (621°F).  Its softness and  ductility  makes  lead  of
little  use  as  a  load  bearing metal, however, its outstanding
resistance to corrosion warrants its use in many applications.

Most lead production results from the  remelting  of  the  metal.
Lead  is  cast  into  grids  used in the manufacture of lead acid
storage batteries.  For battery manufacture, lead is  cast  in  a
grid casting machine or by the continuous strip casting method.

Magnesium                                                  ;   ?

Magnesium  is  a  silver-white  metal  weighing 1751 kg/cu m  (108
lbs/ft3).  On an equal weight basis, magnesium  is  equal  to  or
stronger  than  any  other common metal.  It can be melted in the
same types of furnaces used for aluminum or zinc.   However,  due
to  the  nature  of  molten  magnesium, care must be exercised in
selecting refractories and other materials which the molten metal
may contact.                            ;

Magnesium furnaces are  usually  of  the  stationary  or  tilting
crucible  type  and  heated  by  gas,  oi-1,  or coreless electric
induction units.  The crucibles are made of low carbon steel with
nickel and copper contents  below  0.10  percent.   Magnesium  is
usually  alloyed  with  aluminum,  zinc, manganese, or rare earth
metals for foundry work..

Most magnesium is cast in sand  molds.   The  practice  for  sand
casting of magnesium alloys differs from most other metals in the
precautionary  measures required to prevent metal-mold reactions.
Inhibitors such as sulfur, bpric  acid,  potassium  fluoroborate,
and  ammonium  fluorosilicate  are mixed with the sand to prevent
these reactions.  Molding sands for magnesium  alloys  must  have
high  permeability  to  permit the free flow of mold gases to the
atmosphere.

Table III-l  indicates the growth of magnesium foundry production.
A general process schematic is presented in Figure  II1-6.

Zinc

Zinc, which  is less dense than iron,  is a bluish-white metal with
a hexagonal  close-spaced  crystal^structure.  Zinc melts at  420°G
(788°F)  and boils  at a temperature  of 907°C  (1665°F).   Its  low
melting  temperature, very small grain  size  and adequate  strength
makes  zinc  and   zinc  alloys  well  suited for die casting.  Die
                                29

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 casting  is  the  process  most  often  used  to   shape   zinc   products.
 Zinc  alloy  compositions consist  of 0.25  percent copper,  4  percent
 aluminum,   0.005   to  0.08   percent magnesium  and  traces of  lead,
 cadmium,  tin, and  iron.   Furnaces  used  in   melting  and  alloying
 zinc  are  usually the  pot  type,   although   immersion tube  and
 induction furnaces are  also  used.   A furnace should  hold five   to
 seven times  the   amount used  in  one  hour.  Good temperature
 control  is  a necessity  for both  melting  and  holding   furnaces.
 Table III-l indicates  the decreasing shipments of zinc  castings.
 A zinc casting  process  schematic is presented  in Figure  II1-7.

 PLANT DATA  COLLECTION

 A preliminary review of the  data which existed at  the   start   of
 this  study  indicated the need  for  more extensive plant data.   The
 needed data were collected through the use of  a mail survey  and a
 sampling  program.

 Development of  the Data Collection Portfolio

 After  the  review and  analysis   of existing data, a draft data
 collection  portfolio was developed.   The portfolio was  designed
 to collect  information  about all types of  plants engaged in metal
 molding and casting.  Information  was solicited about plant size,
 age,   historical   production,    number   of   employees,   land
 availability, water usage, manufacturing processes, raw  material
 and  process  chemical   usage,   air   pollution control techniques
 which  result   in   a  process  wastewater,  wastewater   treatment
 technologies,   the known or believed  presence  or absence of toxic
 pollutants  in the  plant's raw  and   treated process  wastewaters,
 and other pertinent factors.

 During the  review  of the existing  data,  15 trade associations  and
 interest    groups   associated  with   metal  molding  and  casting
 activities  were identified.  Representatives of these  15  groups
were  invited   to  meet   with  EPA,   to  review  the  draft  data
 collection  portfolio,  and to offer comments.

Comments received  from  these   groups  were reviewed  and,  where
 appropriate,  were incorporated   into   the final  data collection
portfolio.   In  addition  to  this   input,    EPA   remained    in
 communication  with many of the  trade associations throughout  the
entire study in order   to  utilize their   knowledge  of   foundry
practices.

Survey Design

The  Penton  "Metal Casting Industry Directory", which identifies
4,400 metal molding and  casting activity operations,  was used  as
                               30

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the  primary  basis  for  the survey.  Initially, a survey of all
4,400 plants was considered.   However,  the  Penton  information
provided  sufficient detail (e:.g.,  metal cast and employee group)
to design a statistically based survey.  After reviewing existing
treatment process and in-process control trends, 71 companies and
corporations with 269 plants were selected to  receive  the  data
collection portfolio (DCP).

In  order  to  collect  data  from  a wide variety of plants, the
Penton information was partitioned into 36 cells (a matrix  of  9
metal  types by 4 employee groups), as shown in Table III-2.  The
9 metal types are:  ductile  iron,   gray  iron,  malleable  iron,
steel,  brass  and bronze, aluminum, magnesium, zinc, and a final
group designated as "other metals".   The  employee  groups  are:
under  10 employees, 10 to 49 employees, 50 to 249 employees, and
250  or  more  employees.   This  survey  provided  a  basis  for
assessing  the potential economic impacts of effluent limitations
and standards on plants in each employee group.

After reviewing  information  available  in  the  Penton  casting.
industry directory and other data,  it was considered necessary to
solicit data from 1,000 additional plants.  Therefore, a total of
1269 plants were surveyed via DCP questionnaire  (approximately 29
percent  of  the  total plant population identified in the Penton
census).

To ensure that those plants, which appear to be relatively few in
number (i.e., cell  populations  no  larger  than  70  individual
plants),  were  not  missed  in the random selection process, 394
plants, falling into cells with populations no greater  than  70,
were selected from the sampling frame of 1,000 plants.

Using  a  computer,  606  plants   (the  remainder of the group of
1,000) were randomly selected from the Penton file.  Table  II1-3
displays the distribution by metal type and employee group of the
plants  selected  to  receive  a survey questionnaire.  The total
number of entries on Table  III-3 exceeds 1,000, since entries for
plants which cast more than one metal type appear once  for  each
type of metal cast.

Randomly   selected  plants  had  equal  probabilities  of  being
selected for inclusion in the survey.   The  probability  that  a
plant  would  be  selected  was  calculated  using  the following
equation.

     P = (1000 - L) /  (4404 - K - L)

where L = number of plants  occupying cells with populations
           no larger than 70
                                31

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      K = number of specific plants surveyed due
           to the need for specific technical  information
Therefore  P =  (1000 - 394) /  (4404 -  269

            P = 0.162
394)
The weight assigned to each plant surveyed with  P  =  0.162  was
therefore,  1/P  or 6.17.  In estimating plant populations, based
upon the survey design, plants surveyed with  "p" probability  are
designated  as  "P" plants.  Likewise, plants surveyed due to the
need for technical information are designated as "K" plants while
plants surveyed with corresponding  cell  populations  no  larger
than  70  are designated as "L" plants.  In addition to weighting
the survey responses, corrections to the weighting  factors  were
made to account for plants which failed to respond to the survey.
Since  it  was  anticipated that plants with more employees would
have a different response ratio (the number of  survey  responses
vs.  the  number  of  surveys  mailed)  than  plants  with  fewer
employees, the correction for  non-response  was  made  for  each
specific  employee group.  Therefore, four different non-response
correction factors were developed.

Distribution of the Plant Survey

Using a mailing list of plants developed according to  the  plant
selection process described above, information requests were sent
to the selected recipients.

In addition to the distribution of plant surveys described above,
Metal  Molding  and  Casting  DCPs were mailed to another type of
plant.  These plants were identified from  the  preliminary  data
review as being engaged in the casting of lead.  These plants are
primarily  involved  in  battery  manufacture.  All of the plants
identified  as  casting  lead  were  mailed  DCPs.    Two  hundred
twenty-six surveys were sent to companies believed to have plants
engaged in the casting of lead.

Processing of Survey Responses

Upon  receipt  of  the  survey responses, the data were reviewed,
organized and prepared for computer entry.   Tables II1-4  through
111-21  provide  summaries of the plant survey data.  Also, Table
111-22 identifies the operating modes and control  and  treatment
technologies  applicable to wastewaters from this industry.  That
table gives the key to symbols appearing on Tables II1-4  through
111-21.    In  determining  recycle  and discharge rates,  all data
(block diagrams and various data entries) in the DCP were used to
confirm the information  provided  in  the  summary  tables.    In
                               32

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several  instances, state environmental offices were contacted to
confirm information presented in the DCPs for certain plants.

Additional Information Collected

The plant survey information also  provided  the  identity  of  a
number  of engineering firms which design and install foundry air
and water pollution  control  equipment  which  operate  with  no
process  wastewater  discharges.   These firms provided operation
and maintenance information on  these  systems  and  installation
lists  of user foundries.  Thirty-six foundries were subsequently
contacted by phone, and information pertinent  to  the  operation
and maintenance of this complete recycle equipment was obtained,

PROFILE OF PLANT DATA

The  DCP  survey data were used to develop a technical profile of
the plants within the foundry point source category.  The profile
data provide information such as  plant  frequency  distribution,
the  types  of  metals  cast,  employee  groupings, manufacturing
processes, air pollution sources, and water use.  A discussion of
the profile development follows.

Industry Profile Development

Based upon the data received, each plant was classified as either
"wet", "dry", "not a foundry" or "non-deliverable".  "Wet" plants
generate process  wastewaters  from  metal  molding  and  casting
operations  or  from  air pollution control facilities associated
with these operations.  "Dry"  plants  do  not  generate  process
wastewaters   from   the  operations  described  above,  although
noncontact cooling waters may be used  at  these  plants.   Those
respondents  which  indicated  that  the company was no longer in
business, the casting manufacturing facility no  longer  existed,
or  that  the company was not engaged in commercial metal molding
and casting operations were identified as "not a  foundry".   The
data  request  was  identified as "non-deliverable" if the Postal
Service could not deliver thje material at the indicated address.

Realizing  that  the  plant ^survey  was   statistically   based,
estimates  (based upon the design of the survey and the responses
received) were  made  for  the  total  plant  population.   These
estimates  were  determined  in  the  following  manner.  A 9 x 4
matrix (9 metal types by 4 employee  groups)  was  developed  for
each  of  the  four classifications noted above., DCP information
about the metal cast and the number  of  employees  was  compared
with  the Penton information and, where necessary, adjustments in
cell populations were made to reflect the  plant  DCP  data.   An
additional   fifth  matrix  was  developed  which  presented  the
                               33

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frequency distribution of plants which   had  not   responded   even
after a second data solicitation was mailed.

Each  of  the  five  matrices was then  further broken down into  3
discrete subparts which  identified plants within   the  matrix by
the   way   in  which  the  plants  were surveyed   (i.e.,  plants
previously  designated as either K, L, or P plants).

At this level of detail, the appropriate statistical weights  and
correction  factors  for  nonresponse   plants  could  be applied.
Nonresponse correction factors were determined for  each  employee
group.   Estimates  were  then made of  the total number of plants
generating  a metal molding and casting  process  wastewater,  the
total number of plants which do not generate process wastewaters,
and  the  total number of plants not engaged in metal molding and
casting.    The  statistical  weights  were  further applied   to
determine plant populations in each process segment and discharge
mode   (i.e.,   direct   or  POTW),  and  to  determine  industry
productions and wastewater volumes.

For the  lead  casting  subcategory,  technical  information  was
obtained  concurrently  with  the battery manufacturing technical
data solication.  A survey of the entire lead casting subcategory
was conducted.


DESCRIPTION OF METAL MOLDING AND CASTING INDUSTRY PROCESSES

After reviewing the data provided in the  responses  to  the  DCP
questionnaires,  the Agency developed a list of the metal molding
and  casting   industry   operations   which   generate   process
wastewaters.   The  data  presented in  the plant survey responses
indicate that the major sources  of  wastewaters  and  wastewater
pollutants   are  the  air  pollution   control  devices  used in
conjunction with metal molding and casting processes.   Following
are descriptions of the wastewater generating operations noted in
the plant survey data base.

Melting Equipment

Scrubbers   are  used to remove the fumes, gases, and particulates
from melting furnace emmissions.  As a  result,  these  scrubbers
generate  process  wastewaters  which  are  contaminated with the
pollutants  carried  by  the  furnace  emissions.   The  following
melting  equipment  descriptions  are  provided  as  a  basis for
discussion of the various types  of  scrubbers  used  in  melting
furnace operations.
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Cupola Furnace

The  cupola  furnace  is a vertical shaft furnace consisting of a
cylindrical steel shell, lined  with  refractories  and  equipped
with a wind box and tuyeres for the admission of air.  A charging
opening  is  provided  at  an upper level for the introduction of
melting stock and fuel.  Holes and  spouts  for  the  removal  of
molten metal and slag are located near the bottom of the furnace.

Air  for  combustion  is  forced  into the cupola through tuyeres
located above the slag well.  The products of  combustion,  i.e.,
particles  of  coke, ash, metal, sulfur dioxide, carbon monoxide,
carbon dioxide, etc., and smoke comprise  the  cupola  emissions.
Air  pollution emission standards require that these emissions be
controlled.  Wastewaters are  generated  in  this  process  as  a
result of using water as the medium for scrubbing furnace gases.

The  cupola  has been the standard melting furnace for gray iron.
Figures III-8 and III-9 illustrate cupola furnace systems.

Electric Arc Furnaces

An electric arc furnace is essentially a refractory lined  hearth
in  which material can be melted by heat from electric arcs.  The
molten metal has a large surface area in relation to  its  depth,
permitting  bulky  charge  material  to  be  handled.  This large
surface area to  depth  ratio  is  effective  in  slag  to  metal
reactions as the slag and metal are at the same temperature.  Arc
furnaces are not generally used for nonferrous metals as the high
operational  temperatures  of  the arc tend to vaporize the lower
melting temperature metals.  Arc furnaces are .operated in a batch
fashion with tap-to-tap times of. 1-1/2 to 2 hours.  Power, in the
range of 551-662 kwh/metric ton (500-600 kwh/ton), is  introduced
through  three  carbon electrodes^  These electrodes are consumed
in the process of passing the electric current through the  scrap
and  metal into the molten batch.  They oxidize at a rate of 5 to
8 kg per metric ton of hot metal (10.5 to 17 Ibs/ton).

The waste products from  the; process  are  smoke,  slag,  carbon
monoxide  and  dioxide  gases,  and  oxides  of  iron  emitted as
submicron fumes.  Dry type air pollution control  equipment  such
as  baghouses  are generally used to control electric arc furnace
emissions.

Induction Furnaces

Induction melting furnaces have  been  used  for  many  years  to
produce  nonferrous metals.  Innovations in the power application
area during the last 20 years have enabled these furnaces  to  be
                               35

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competitive  with  cupolas  and  arc  furnaces  in gray  iron  and  steel
production.    This  type   of   furnace   has   some  very   desirable
features.  There  is  little or  no contamination of the metal  bath,
no  electrodes are   necessary,  composition  can   be  accurately
controlled, good stirring  is inherent,  and   while   no  combustion
occurs, the temperature obtainable is  theoretically unlimited.

There  are  two  types  of induction  furnaces:   (a) coreless,  in
which a simple crucible is surrounded  by  a  water-cooled  copper
coil  carrying alternating  current,  and  (b)  core  or channel,  in
which the  molten  metal   is   channeled through  one  leg   of  a
transformer  core.    The   induction furnace provides good furnace
atmosphere,  control,  since  no  fuel   is   introduced  into   the
crucible.   As long  as clean materials  such as castings  and  clean
metal scrap are used,  no  air  pollution   control   equipment   is
necessary.   If  contaminated  scrap   is  charged or magnesium .is
added to manufacture ductile iron, air  pollution control  devices
are required to collect the fumes  that  are  generated.

Reverberatory  Furnace

A  reverberatory   furnace  operates  by radiating  heat from the
burner flame,  roof,  and walls onto the  material  to  be  heated.
This  type  of  furnace  was  developed particularly for melting
solids and for refining and heating the resulting liquids.   It  is
generally one  of the least expensive methods of melting since the
flames come into direct contact with the solids and molten metal.
A reverberatory furnace usually consists of a  shallow refractory-
lined hearth for holding the charged metal.   It  is enclosed   by
vertical  side  and  end walls,  and covered  with a low arched roof
of refractories.   Combustion of fuel occurs  directly  above  the
charge  and the molten bath.  The  wall  and  roof receive heat from
the flame and  combustion products  and radiate  heat  to the  molten
bath.   The  transfer  of heat occurs almost solely by radiation.
There are many shapes of reverberatory  furnaces,  with  the  most
common   type   being   the  open  hearth   style  used  in  steel
manufacture.   However, the cost of pollution  control  equipment,
as well as inefficiencies  in handling the metal, have caused this
type  of  furnace  to  become  obsolete  in steel  and gray iron
manufacture.    Reverberatory  furnaces   are  widely   used    in
nonferrous production.

The  products  of  combustion  from  reverberatory  furnaces  are
conducted  to  a   stack  and   exhausted    to   the   atmosphere.
Contaminants  such   as smoke,  carbon monoxide  and dioxide, sulfur
dioxide,  and metal oxides must be  removed from the  exhaust gases,
These become process wastewater  pollutants  when   scrubbers  are
used to clean the  combustion gases.
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Crucible Furnace

Crucible  furnaces,  which are*%sed to^melt metals having melting
points below 1900°C (2,500°F);, are constructed  of  a  refractory
material  such as a clay-graphite mixture or silicon carbide, and
are made in various shapes and sizes.  The crucible is set  on  a
pedestal  and  surrounded by a refractory shell with a combustion
chamber between the crucible and  the  shell.   The  crucible  is
usually  sealed  or  shielded  from  the  burner gases to prevent
contamination of the molten metal.

There are three general types of crucible furnaces; tilting, pit,
and stationary.  All have one or more gas or oil burners  mounted
near the bottom of the unit.  The crucible is heated by radiation
and  contact  with the hot gases.  The exhaust gases contain only
products  of  hydrocarbon  combustion  and  generally   are   not
controlled.

Fume Scrubbing Equipment

The  preceding  discussion  on the various types of melting units
used in the remelting of metal describes the source of the fumes,
particulates, smoke, and other waste products that are the  major
contaminants  of  process  wastewater  when scrubbers are used to
control the furnace emissions.  Generally, venturi scrubbers  are
used to clean these furnace emissions but other methods are used.

The   methods  of  cleaning  the  wastewaters  produced  will  be
described in later sections pf this report.

Fabric Media (Baghouse)

The collection of particulate matter is achieved by entrapment of
the particles in the fabric of a  filter  cloth  that  is  placed
across  a  flowing  gas stream.  These dust particles are removed
from the cloth by shaking or back flushing the fabric  with  air.
Filtration  does not remove gaseous contaminants from the furnace
exhaust.  These gaseous contaminants includes   carbon  monoxide,
phenols,  carbon  dioxide, hydrogen, chloride, hydrogen, sulfide,
nitrogen and its oxides, ammonia, hydrogen, and water vapor.  The
quantities of these contaminants depend  on  the   type  of  fuel,
furnace  efficiency, and infiltration of air into  the gas stream.
Baghouse particulate removal methods have  been  developed  to  a
high  degree  of efficiency (97-99 percent removal of particulate
matter).  These methods, coupled with the  recuperation  of  heat
and .  the  ignition  of  the; combustible  gases,  have  received
considerable attention from industry.
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The cloth filter media  (baghouse)  has  a  temperature  limit  of
approximately  121°C  (250°F).  These gases can be cooled to this
temperature by long runs of duct work between the furnace and the
baghouse.  The ductwork acts as a radiator  to  cool  the  gases.
These systems are dry operations and, as such, produce no process
wastewaters.

Other  installations  have  quench towers between the furnace and
the baghouses or  electrostatic  precipitator.   This  method  of
operation  cools  the hot gases by evaporating water sprayed into
the quench tower prior to  their  entry  into  the  baghouses  or
precipitators.   This  quench  chamber  usually  is  arranged  to
provide a sharp.reversal in the direction of the gas stream and a
sudden reduction in flow velocity.  These features, coupled  with
the  cooling  effect  achieved  by  the evaporation of the water,
cause the larger dust particles to be deposited at the bottom  of
the  chamber.   The  gases  then flow to the filter chamber.  The
deposited dust is removed periodically.
In addition to a gas  temperature  reduction,  this  water
absorbs many of the gaseous contaminants listed above.

Wet Scrubbers
spray
Washing  Coolers:  Several general designs of washing coolers are
used,  however,  all  provide  some  means  of  securing  a  long
retention  time  to  keep the gases in contact with the scrubbing
liquor.  In general, these units consist of a  large  cylindrical
vessel  with  the  gases  entering tangentially at the bottom and
exiting through the top center.  Several levels of  sprays  bring
the  scrubbing  liquor  into  contact with the rising gases.  The
bottom is usually conical with a large pipe outlet to return  the
dirty liquor to a settling area.

Another  type of scrubber known as the bulk bed washer, or packed
tower, contains water sprayed gravel beds.  The gases enter in  a
downward  or  tangential direction which results in a preliminary
dust removal capability (due to inertia).  The  gases  then  flow
upward through a wetted gravel bed.  At the upper surface of this
bed,  the gas velocity creates a turbulent water zone that brings
the finest dust particles  into  contact  with  the  water.   The
scrubbing liquid is sprayed above this gravel bed and continually
washes  it.   The  liquid  is  then  removed at the bottom and is
recirculated and/or discharged.   Above  the  spray  heads  is  a
droplet  catcher  that  removes  the droplets from the rising gas
stream.  This scrubbing  method  requires  approximately  10  in.
(water)  of  pressure  drop  and  is  not  effective on particles
smaller than 1 micron.
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Figure III-8 illustrates this method, as  well  as  a  method  of
recovering some of the heat from the gas stream.

Wet  Cap:   The  "wet  cap"  method  is  an attempt to reduce the
particulate emissions by passing the waste gases through a  water
stream  or  water  curtain.   This  method,  operated  with a low
pressure drop, could be added to existing cupolas with only minor
changes to equipment and operations.  Figure III-9  depicts  this
method.

Venturi  Scrubber:  This scrubber consists primarily of a Venturi
tube fitted with spray nozzles at  the  throat.   The  dust-laden
gases  flow axially into the throat where they are accelerated to
61 m/sec (200 ft/sec).  Water is sprayed into this  throat  by  a
ring  of nozzles.  This produces a dense mist-like water curtain.
The  water  droplets  in   this  curtain  combine  with  the  dust
particles.    In  the subsequent diffuser, the velocity is reduced
and inertia is used to separate the droplets from the gas stream.
Venturi scrubbers require  15-100 in.   (water)  of  pressure  drop
across  the   gas  stream.  They are very effective on particulate
matter in the range of 1 micron and readily adsorb  many  furnace
gases, thus adding many pollutants to  the process wastewaters.

Venturi  scrubbers are operated in conjunction with sedimentation
and recirculation systems.

Dust Scrubbing Equipment

Foundries that use sand as a molding media have   the  problem  of
collecting  and   controlling  the  dusts produced in  handling  and
using  this  sand.  Sand, as used in foundry molding,  is mixed with
one or more materials that coat the  sand .grains   and act  as  a
binder  to  hold  the  sand   into the  form of  the pattern.  These
binders  are a major  source  of  organic   pollutants   in   foundry
operations.   Fumes and odors result  from the  pouring  of hot metal
into molds, while the cleaning of the  casting to  remove traces of
sand,  gates,  runners,   heads,  mold  flashings and mismatch  also
produces dust and fumes which are removed  from the   work  place.
Many   of   these  dusts   are  collected on   fabric   media  in  a
 "baghouse." In many  instances,  it   is   more   economical  or   more
efficient  to remove these  airborne particles by entrapping  them
 in a  spray  or mist.   These types  of  "wet  collectors"  will   be
examined as they  are currently  used in the foundry industry.

Spray  Chambers

 The  simplest  type   of   wet scrubber  is  a chamber in which  spray
 nozzles  are placed.   The  gas  stream  velocity  decreases   as  it
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 enters  the  chamber where the particles are wetted by the spray,
 settle,  and are collected at the bottom of the chamber.

 Cyclone-Type Scrubbers

 Cyclone-type  scrubbers  feature  a   tangential   inlet   to   a
 cylindrical  body.   Water is injected through spray nozzles which
 break (the water into many droplets.   These droplets  contact  the
 particles and increase their inertial action with the result that
 the  particulates  impinge  on  the  vessel  sides where they are
 flushed  to the bottom.   The clean gases then exit through the top
 of the scrubber.   Baffles in this exit collect  and  aid  in  the
 removal  of the water droplets from the gas stream.

 Orifice-Type Scrubbers

 Orifice-type  scrubbers utilize the velocity of  the gas  stream to
 provide  liquid contact.   The flow of gases through  a restricted
 passage   partially  filled with water causes the  dispersion of the
 water into many droplets that  intimately   contact  and   wet  the
 airborne  dusts  and  absorb  some  of  the gaseous contaminants.
 While the amount  of water in motion  is large,  most of the  water
 can be recirculated without pumps.

 Mechanical-Centrifugal  Scrubbers

 A   spray  of  water  at   the inlet of a fan becomes a mechanical-
 centrifugal  collector.   The collection efficiency is enhanced  by
 the   entrapment    of  dusts  on   the  droplet  surface   and  the
 impingement  of the  droplets on the rotating  blades.   The  spray
 also  flushes   the   blades  of the  collected dusts.   However,  this
 spray can substantially  increase  corrosion and wear on the fan.

 Another  type of mechanical  collector  uses  a rotating  element  to
 generate  a  spray of  water  droplets  into a dust  laden gas  stream.
 The wetted particles  flush  to the  collection pan  where  they  can
 settle while the water  is recirculated.

 Venturi  Scrubbers

 Venturi   scrubbers  have been described in the section on  melting
 furnace   scrubbers.   They   are  also   used   in   dust  collection
 systems.    In  some   cases  there is a  single large  Venturi  in  the
 dust  laden air stream  with   low  pressure   water   added   at   the
Venturi   throat.   The extreme turbulence  breaks  the water  into a
 fine  spray where it impacts  and wets  the dust particles.

Other applications are similar to orifice-type scrubbers but with
the Venture's shape replacing  the orifices.  These Venturi's  are
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located  at the water line and, consequently, water is drawn into
the Venturi throat where it is broken into a fine- spray  by  the
turbulent air.  The spray droplets wet the dust particles and are
impinged against baffle plates where they drain to the reservoir.

Packed Towers

This  device  is  similar to the bulk bed washer described in the
melting scrubber section.  The dust laden gases  pass  through  a
bed  of  granular  or fibrous collection material while liquid is
flushed over the surface of the collection material  to  keep  it
wet  and  clean,  and to prevent re-entrainment of the particles.
Collection efficiency depends on  the  length  of  time- the  gas
stream   is   in  contact  with  the  collecting  surfaces.   The
collecting material should have a large ratio of area  to  weight
and be of a shape that resists close packing.  Coke, broken rock,
glass spheres, rashig rings, and tellirets are materials that are
often used as tower packing materials.

A cone-shaped bottom aids in>removing settled dust particles from
the liquid, while mist eliminators  located in the exit gas-stream
reduce  the   loss  of  the flushing liquor.  Recirculation of the
liquor is usually practiced.

Wet Filters

A wet filter  consists   of  a  spray  chamber  with  filter  pads
composed  of  glass  fibers,   knitted wire mesh, or other  fibrous
materials.  The dust is  collected on the  spray pads by virtue  ot
the  dust  laden  gas stream being drawn through  the pads.  Sprays
directed against  the pads'wash the  dusts  away.   The water  drains
to  a  reservoir  where   it   is  settled  or clarified  and then
recirculated  or discharged.

Casting Methods

Foundries  use several methods  of casting  molten   metal   into   its
final  shape.   None  of  these  methods  involve intimate  contact
between  the molten metal  and  water  as   the  explosive  forces,
developed  by the rapid  generation  of steam  when water  comes  into
contact with  molten  metal,  cannot be  controlled.

Sand  Casting

Green Sand Castings:    This  is   the  most   widely  used  molding
method.    it  utilizes  a  mold  made of  compressed,  moist  sand.   Tne
term  "green"  denotes the presence of  moisture  in the  molding  sand
and that  the  mold is not dried or baked.   This method is  usually
                                41

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          the  most  expedient,
          very heavy castings.
but is generally not suitable for large or
          Dry Sand Casting:   Most large and very heavy castings are made in
          dry sand molds.   The mold surfaces are given a refractory coatinq
          and are dried before  the  mold  is  closed  for  pouring.   This
          hardens  the  mold and provides the necessary strength to contain
          large amounts of metal.   Molds which  are  hardened  by  the  CO
          process  may also be considered in this category.   Such molds are
          not dried,  but are made from an essentially  moisture  free  sand
          mixture  which  contains  sodium  silicate.    The  mold is rapidly
          hardened by the  reaction of carbon dioxide gas with the silicate
          The  process  can   also  be  used  for  making  cores.     It   is
          advantageous in  reducing manufacturing time,  but is not practical
          for some types of  work.

          Shell   Mold  Castings:    This method is of recent  development and
          utilizes the unique process  of  making  molds  by  forming  thin
          shells  of a resin-bonded sand over a hot pattern.   It is suitable
          for small and some medium-sized castings.   Shell molding provides
          improved accuracy  and   surface  finish,   thus  allowing greater
          detail  and  less  drift  than  would normally be  acceptable in  green
          sand   molding.    Metal   patterns  of   special   construction  are
          necessary.   The  process is   of  particular   advantage  when  it
          provides  savings   in machining and finishing.   The  shell  process
          has  also  been  very effectively  applied  in making cores  which  may
          be  used  with  any of  the  molding methods.

          Core  Mold  Casting:  Castings  of  unusual  complexity  (such  as the
          thin and  deep  fins of  an   air-cooled   engine  cylinder)  may  be
         produced  in   a  mold  made of  the  type of sand commonly  used for
          cores.  This sand  has almost  free-flowing properties  when   it  is
         packed  around  the  pattern,   and   it  will  fill  crevices   and
         reproduce detail.  After baking, the mold becomes  strong   enough
         to  resist  the  forces of flowing molten metal.  Core  sand  molds
         may be used when complexity requires more than one  parting   line
         in  a  casting.  Core sand sections may be used to form a complex
         external portion of a casting in either a green or dry  sand mold
         }ust as cores are used to form  internal surfaces.

         Permanent Mold Castings:  Iron  castings,  within  limits  as  to
         size,  complexity,   and  properties,  can  be  produced  in large
         numbers from mechanically operated permanent  iron  molds.   This
         mechanized,   high-production  process is mainly used for castings
         of suitable  shape,  of less than 11.4 kg {25  pounds)  in  weight,
         and  with  0.48  cm  (3/16")  minimum  wall thickness.  Cores are
         formed with  conventional sand or shell cores.
                                       42
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Ceramic  Mold  Casting!   Certain  highly  specialized   castings
requiring  an  unusually  fine  finish, precise detail, and close
tolerances are produced in molds made of fired ceramics.  This is
comparable  to  the  plaster-mold  process  which  is  used   for
nonferrous   alloys.    Pattern   equipment  is  generally  of  a
"core-box" type, and may be made of metal or  plaster.   In  some
applications,  backdraft  or, undercuts are allowed by making part
of the pattern of a flexible material.   When  the  mold  can  be
assembled  from  a  number of pieces, castings of several hundred
pounds in weight and several feet in a  major  dimension  can  be
made to relatively close tolerances.

Centrifugal Casting Operations

Centrifugal   casting   utilizes   the   force  of  gravity,  but
centrifugal force may be used.  True  centrifugal  casting  is  a
means  for producing a cavity in the"casting without the use of a
core.  The production of pipe by this process is well known,  but
the  method  is  also  used  for  making  many  other cylindrical
castings from engine cylinder liners to large process rolls.

Investment Casting Operations

Investment casting uses a mold that  is produced by surrounding an
expendable pattern with a ceramic slurry which  hardens  at  room
temperature.  The pattern is usually wax or plastic and is melted
or  burned  out  leaving a cavity, with very close tolerances, in
the refractory material.  Investment casting is also known as the
"lost wax" or "precision casting" process.

In sand casting, the pattern  is usually wood  or  metal,  and  it
makes  an  impression  or  cavity   in  the  sand.   In  investment
casting, a metal die is used  to produce the wax patterns.  These,
in turn, produce the ceramic  mold.    Ceramic  cores,   which  are
expendable, are used when needed.

The  wax   is  melted   out  and all moisture in the ceramic backup
material eliminated  in an  autoclave  where  temperature  can  be
closely  controlled.   Metal  is poured into the molds  and allowed
to cool.   The mold  is  then pushed   from   its  container and  the
ceramic  is  broken  away.    Final   cleaning, a source  of process
wastewater,  is  accomplished by high  pressure  water,  jets   in   a
hydroblast  cabinet.   The  casting  is then sent  to the finishing
department where heads and gates are removed.

Die  Casting

In most die  casting operations the  major  sources   of   wastewaters
are   the   die casting  machine hydraulic  oil  leakage,  mold  cooling
                               - 43

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         water leakage, casting quenches, and mold  lubricant spray.  These
         wastewaters collect around the machine base and are  contaminated
         by dirt, and oil and grease from various fittings.

         In  some  operations  (see Figure  II1-3) where the casting quench
         tank is located beneath the machine, these waters drain  into  the
         quench  tank.   Other  plants  segregate their process wastewater
         streams.

         Die Lubes

         In die casting, the application of lubricants to the  die  cavity
         is  a necessary and often critical process.  Lubricants prevent a
         casting from sticking to the  die,  and  also  provide  a  better
         finish  to  the casting.   The correct lubricant will permit metal
         to flow into cavities that will not otherwise fill  properly.    A
         secondary function of a lubricant is the cooling of the die.

         Selection of a lubricant  is based upon the melting temperature of
         the  metal,   operating  temperature  of  the die surface, and the
         alloy being  cast.   No single lubricant will be suitable  for   all
         die  casting  applications.    In  fact,   two  or  three different
         lubricants   are    sometimes   needed   to   achieve    increased
         productivity.

         When   molten  metal  contacts   an oil  type lubricant,  some of  the
         lubricant  decomposes   and  leaves  a  powder    of   carbonaceous
         materials  on   the  die surface.   This  can be removed from the  die
         surface with an air jet.   When the  correct  lubricant   is used,
         enough  of   it  remains   on  the die for  the production  of several
         more  castings.

         Moving die parts, such as  ejectors  and   cores,   must  be   treated
         with  a  high   temperature  lubricant   to  prevent  seizure.   Oil
         suspensions  of graphite  are  usually   used.   Many   of  these
         compounds  are  carefully  developed  for  specific  machines  and
         represent a  considerable expense.   The  placement,   recovery   and
         reclamation  of these materials  is an  important phase  of the  die
         casting operation.  Several plants  have   segregated  their waste
         streams and  employ  die lubricant  recovery processes.

         Casting Quenches

         In some instances certain metal grain structures,  obtainable only
         through  sudden  thermal  changes,  are desired in a casting.  In
         these cases,  the operator will quench  the  casting  in   a water
         f!#«    This  water  bath  maV  be  plain water or may contain an
         additive to promote some special condition.  The  additive- is  a
         very minor part of the bath.
                                       44
_

-------
Non-ferrous  foundries quench their castings more frequently than
ferrous froundries.  This is due to a desire to cool and solidify
the casting quickly  more  than  to  promote  a  grain  structure
change.   Nonferrous  foundries are predominantly die casters.  A
quench operation immediately after ejection of a die  cast  part,
will  solidify  the metal quickly, reduce the machine cycle time,
and increase production.  Many aluminum die casting  plants  have
replaced the quench with a runout table on which the castings air
cool.   Depending upon the configuration of the casting, zinc die
cast material may sag and not retain the  desired  specifications
if  air  cooled.  Therefore,' the trend to eliminate quenching and
its associated water pollution problems has not been as prevalent
in zinc die casting operations as it has in aluminum die  casting
operations.

Mold Cooling

Where  permanent  molds  are  used  in the casting process, it  is
often necessary to force cool the molds  with  water  sprayed   or
flushed  over  the mold.  This water becomes a process wastewater
and contains contaminating materials picked up  from  the. molds.
The  centrifugal   casting  of pipe is an example of mold cooling.
Only large foundries  are  engaged  in  this  casting  method   as
indicated by Table 111-23.


Slag Quench

Most  melting  operations  produce  a  slag  or  dross.   This  is
generally  is mixture of non-metallic fluxes  introduced  with  the
"charge"   to act as a scavenger  to remove  the  impurities  from the
molten metal.  This slag is removed from   the  molten  metal  and
cooled   for  disposal   or  for   reclamation of metal.   In ferrous
foundries  the  amount of slag  produced  requires   disposal  on   a
large scale.   Where the slag  is  continuously produced  (i.e.,  in a
cupola   operation),  the  slag   is  quenched  in a  water stream  to
rapidly  cool   and  fragmentize   it  to  an  easily  handled   bulk
material.  The quench water  is  a process wastewater.

In  nonferrous  foundries   the   slags  generated are considerably
smaller  in volume  and  mass   than  those   generated  in   ferrous
foundries  and  are  handled without producing  a  process  wastewater.

Sand Washing                .      .                      .

In  the  many   plants   which   use sand   as   a molding media,  the
reclaiming and reuse of the  sand is   a  major  operation.    Three
methods  of   reclaiming sand  are   in  general use;  dry,  wet,  and
thermal.
                                45

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 The dry method has several sub-methods  which  generally  include
 screening,  lump  breaking,  and  cooling  before  reuse.   These
 processes usually produce a dust from the handling of  the  sand,
 but  no process wastewaters result unless a wet dust collecter is
 used.

 The wet method has several variations.  Generally,  a  slurry  is
 made'of sand and water.   Agitating or stirring this slurry causes
 the  sand  grains  to  scrub  against  each  other and remove the
 particles of burnt clay,  chemical  binders,  sugar,  wood  fiber,
 etc.,  which may adhere to the sand grains.  The slurry is pumped
 to a classifier for separation of the fine materials.   The  sand
 is then dried.

 The  thermal  method  involves  heating  the  sand  to  649-816°C
 (1200-1500°F)  in air to  remove carbonaceous material.  Some  clay
 may also be removed by abrasion of the sand grains as they travel
 through  the  process.    The thermal  reclamation process does not
 produce a process wastewater.

 The wash water  used  in   wet  reclamation  contains  considerable
 contaminants  in  the form of  fine silicate material, spent clay,
 and other pollutants.  To economize on water use,  this water  can
 be  clarified   and  returned to the sand washing system.   Several
 examples of water reclamation  from wet sand reclamation processes
 are found in the plant survey  response.
Magnesium Grinding  Scrubbers

Finely divided particles of magnesium  can  react  violently  in  air.
It is mandatory that magnesium dusts be wetted   to  prevent   this
reaction.   Therefore,  all  dusts  produced  in  cleaning,  sawing,
grinding or machining of magnesium are collected in  a  scrubber.
The  water  spray   coats  the  dust laden  gas stream and wets the
magnesium particles eliminating the fire hazard.

Scrubbers on grinding or sawing dusts  can  be of  several types as
previously  described.   Where  practicable,  the dusts from  such
metal working operations can be salvaged and remelted.

ANTICIPATED INDUSTRY GROWTH

During 1956  through  1976,  annual  castings  production  ranged
primarily  between  13.6  and 18.1 million metric tons (15 and 20
million tons).  Ferrous castings  have  accounted  for  about  90
percent  of  the  total tonnage produced annually since 1956, and
nonferrous casting production has remained close to  10  percent.
                               46

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Table  III-l  presents  information  on  foundry shipments in the
United States.

Contrasting trends, however, are evident among  the  ferrous  and
nonferrous  metal  types  (as can be seen in Figure -III-l °> *^f
presents production at 5-year intervals over the 1956-76  P^iod
For  example,  within  the  ferrous  castings group, the trend of
ductile iron production has been sharply upward, while production
for gray iron, malleable iron, and steel in 1976 was  lower  than
20  years   earlier.   Similarly,  among  the  nonferrous  metals,
aluminum has registered a significant  long-term gain, whereas the
trends for  the others are relatively mixed.

Figure III-TI shows that the number of smaller  iron foundries has
decreased   dramatically,  while  large  and  medium   size   iron
foundries   have   increased  in  number.  In addition, as noted in
Table III-l,  and as  observed  from  conversations  with  plant
personnel,   there is  a  trend toward a decreasing percentage of
zinc casting  shipments compared to total foundry shipments and to
aluminum shipments.   It appears that zinc casting  Product^nmw^^
decrease in favor of  the production of  lighter weight  aluminum
castings.    However,  zinc casting plants will  remain  in  operation
for some time.

PROFILE OF  PLANTS IN  THE METAL MOLDING AND  CASTING POINT  SOURCE
CATEGORY

The  profile of  the Metal Molding and Casting Industry is  based
upon the technical data  furnished  to  the Agency by plants  engaged
 in metal molding and  casting  operations.  Regulations  applicable
 to  plants   casting   nickel,   tin,  and   titanium   are  not  being
proposed   because  these operations   do   not  generate   process
wastewaters.

 The  profile of  the industry is organized  into the  following  seven
 topics (the discussion of  each topic  follows):
 1 .
Wet and dry plant frequency distribution and analysis
 2.   Process wastewater flow profile

 3.   Production profile

 4.   Process wastewater discharge mode profile

 5.   Frequency distribution profile of toxic pollutants

 6.   Production equipment age vs. treatment equipment age
                                 47

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 7.   Analysis of  the  land  available  for  treatment  equipment
      installation

 Wet and Dry Frequency Distribution and Analysis

 Analysis  of the survey data reflective of 1976 indicated that an
 estimated 3600 plants manufactured castings  applicable  to  this
 point  source  category.    One  thousand  nineteen  (1019), or 28
 percent, operated manufacturing processes which resulted  in  the
 generation of a process wastewater.  Based upon the update survey
 the  agency conducted in 1981,  it is estimated that of those 1Q19
 plants,  965 are currently producing a process wastewater.    These
 plants  are  considered  to  be  wet  plants.  Some plants either
 closed  or  changed  manufacturing  processes  or  air  pollution
 control   devices  from  those  with  process wastewaters to other
 equipment which did not produce a process wastewater.   Of  the 965
 plants with process wastewaters,   287  plants  discharge  process
 wastewaters  to  navigable  waters,  327 plants introduce  process
 wastewaters into Publicly Owned Treatment Works (POTWs), and  351
 plants do not discharge process wastewaters.

 The distribution of plants by major metal  cast  and employee group
 is presented in Table II1-24.   Following is  a summary  of the data
 presented in this table.
   Type  of
Metal Cast
 Percent of the Plants Casting This
Metal That Have a Process Wastewater*
Aluminum
Copper
Iron and Steel
Lead
Magnesium
Zinc
*    Based upon  1980 operations.
               11 .6
               11.0
               47.1
                7.1
               58.3
               21 .7
Table  II1-24 also indicates that 72 percent of the plants in the
category do not generate process wastewaters, while 28 percent of
the plants generate process wastewaters  as  a  result  of  metal
molding and casting activities.

Table  II1-25 presents the percentage of "wet" operations in each
employee group in each subcategory.  This  table  indicates  that
smaller  foundry  operations,  as  distinguished by the number of
employees,  usually do not generate a  process  wastewater.   This
trend is illustrated below.

                               Percent of Active Plants,  in
                               48

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      Employee Group
         10-49
         50-249
        >250
Each Group that are Dry

          98.7
          84.0
          51.4
          22.5
The  main  reason  for the trend noted above is the different air
pollution requirements for plants of various  sizes.   The. small
foundries  still in operation are generally job shops that do not
require large capacity production equipment.  As  a  result,  the
air  pollution impact from these shops is much smaller than large
production foundries, and for  economic  reasons,  baghouses  (as
opposed  to  scrubbers  which generate wastewaters) are preferred
for emission control.  In addition, most sand handling activities
in small shops are performed by hand,  and  subsequently  do  not
produce  the large volume of dust associated with mechanical sand
handling equipment.  Therefore, many of the small foundries  have
not  installed  wet  air pollution control devices to control air
emissions for sand handling operations.  These factors  have  led
to the predominance of dry operations for small metal molding and
casting operations.


Process Wastewater Flow Profile

An  estimated 420 billion liters (111 billion gallons) of process
wastewater is generated each year in the manufacture of castings.
Approximately  279  billion  liters  (73.6  billion  gallons)  of
process  wastewater  or  66  percent  is recycled to some extent.
Approximately 94.9 billion liters (25.1, billion gallons)  of  the
total  process  wastewater flow is discharged to navigable waters
while 8.5 billion liters (2.2  billion  gallons)  are  introduced
into  POTWs.  Of the 279 billion liters (73.6 billion gallons) of
process wastewater recycled each year, 168 billion  liters  (44.3
billion  gallons)  are  recycled  in  operations  which  have  no
discharge.

The  subcategories   (ranked  in  decreasing  volume  of   process
wastewater)  are:  ferrous casting, zinc casting, copper casting,
aluminum casting, lead casting, and magnesium  casting.   Process,
wastewaters discharged to navigable waters from plants engaged in
the  molding and casting of iron and steel account for 98 percent
of the total direct discharge volume for the category.  Likewise,
91 percent of the total volume of process wastewaters  introduced
into  POTWs  results  from  the  casting of ferrous metals.  More
specific details of  the  process  wastewater  flow  profile  are
presented in Section V.
                                49

-------
 Production Profile

 For the purposes of  this document,  the term production is used to
 express the amount of metal  poured  and not the weight of finished
 castings  produced  by,   or  shipped from,  those plants within the
 Metal  Molding  and Casting Point  Source Category.

 An  estimated 55.2 million metric tons  (60.8   million  tons)  of
 metal   are  poured  annually  in plants which generate a process
 wastewater  in  their metal  molding   and  casting    processes.
 Approximately   29.7   million  metric  tons (32.8  million tons)  of
 metal   are  poured  annually  in   plants    discharging   process
 wastewaters directly to navigable  waters.   Ten  million metric
 tons  (11 million tons) of metal  are poured annually  in  plants
 which   introduce  process wastewaters  into POTWs.   An estimated
 15.4 million metric  tons (17.0 million tons) of metal are  poured
 in  plants  which do not  discharge   process wastewaters (or  28
 percent  of the  total   annual  amount of metal  poured).    In
 determining the estimate for  "no discharge" operations,  only the
 weight of  metal  poured at plants which do  not   discharge  process
 wastewaters from any   metal  molding and casting   process was
 considered.  For example,  the  weight of metal  poured  at  a plant
 with  one   process  which did  not have a wastewater discharge and
 one process discharging  to a POTW was  included in  the  estimate
 for the  POTW discharge group.

 In  addition,  for  those plants   with a  process wastewater,  65
 percent  of  all the metal  melted  is  poured  in 25   percent   of  the
 plants.    Ninety-seven   percent  of  the metal  poured  in these wet
 operations  is  ferrous metal, and gray  iron  represents 70   percent
 of  the  total weight of  all ferrous metal  poured.  More  specific
 information about  the production profile is presented in   Section
 V of this  document.

 Process Wastewater Discharge Mode Profile

As  discussed  earlier,   an  estimated  965  operations   generate
process wastewaters  in the metal molding  and  casting   industry.
Of  this  total,   287  (or   30%) of  these operations  discharge  to
navigable waters, while  327  (or 34%) of the  total  discharge   to
POTWs.   In  351 out of the 965 (or  36%) metal molding and  casting
processes,   no process wastewaters are discharged.  More   specific
discharge  mode   information   is  presented  in Section V  of  this
document.

Production Equipment Age Versus Treatment Equipment Age

The age of a foundry has  no  bearing  on  the  applicability  of
installing  water  pollution  control equipment at that facility.
                               50

-------
Some foundries, which have operated at the same location for over
100 years, replaced melting furnaces .as recently  as  five  years
ago  and  sand  handling  systems  as  recently as ten years ago.
Process wastewater treatment'equipment  age  varies  from  thirty
years for some equipment items to less than one year for the more
recent  system  installations  or  additions  to  older treatment
systems.

A review of the Industry survey data indicates that about half of
the plants in the industry summary data  base  installed  process
wastewater  treatment  equipment  five  or  more  years after the
installation of  the  oldest  melting  furnace.   _In  fact,  nine
percent  of  the  ferrous  foundries  in  the data base installed
process wastewater treatment equipment as long as 30 years  after
the installation of the oldest melting furnace.
Land  Availability
Equipment
for  the Installation of Wastewater Treatment
In the survey  questionnaires,  the  Agency  requested  that  the
plants  provide  information  on the amount of land available for
the  installation  of  wastewater   treatment   equipment.    The
information  provided  by the industry was used to identify those
plants which may have a  shortage  of  land  on  which  to  erect
treatment facilities.

Approximately  10  percent of all the respondents to this segment
of the data collection portfolio reported that they had a limited
amount of land available  adjacent  to  the  plant  on  which  to
install treatment facilities.  This concern was expressed through
their   response  to  the  information  sought  and  through  the
description of the physical circumstances  which  may  limit  the
installation of treatment equipment.

Review  of  the  plant  data  from  the   10 percent of the plants
expressing  concern  over  the  limited   availability   of   land
indicates  that these plants already have some process wastewater
equipment in-place  equivalent  to  the   BPT  and  BAT  treatment
equipment  identified in this document.   These plants employ some
form of settling technology and recycle.  Thirty-three percent of
those plants  (those plants with   information  expressing  concern
over  land  availability)  with,  settling  and recycle technology
already installed  reported  that  no  process  wastewaters  were
discharged  from  their  plants.   In  these cases, no additional
treatment equipment  is needed.  The  remaining  plants  generally
employ extensive recycle.

Based upon the technical findings, the installation of additional
treatment  equipment  or  the   elimination  of process wastewater
                                51

-------
 discharges would not be hindered by the limited  availability  of
 land  reported  by  plants responding to the  information request.
 In addition, though many plants use settling  ponds or lagoons for
 solids removal, the more  space-efficient  clarifiers  have  been
 included as part of the BPT and BAT model treatment systems.

 ADDITIONAL DATA COLLECTION ACTIVITIES

 Initially,  all existing information on metal molding and casting
 was collected  from  previous  EPA  foundry   studies,  literature
 sources,   trade  journals,  inquiries  to  EPA regional and state
 environmental authorities, and from raw  material  and  equipment
 manufacturers  and suppliers.   These sources provided information
 on  industry  practices  and  wastewater  generation,  and   gave
 direction to the effort of collecting additional data.

 Previous  studies - Previous federal government contracted studies
 of  the  foundry  category  were  examined.    These  studies were
 prepared  by Cyrus Wm.  Rice  Division  of  NUS  Corporation  under
 Contract   No.   68-01-1507  and  A.  T. Kearney and Company,  Inc.  for
 the National  Technical  Information Service,   U.S.   Department  of
 Commerce,   PB-207  148.  These studies provided data on the types
 of   metals   cast,   plant   size,   geographic    distribution,
 manufacturing  processes,  waste treatment  technology,  and raw and
 treated process wastewater characteristics  at specific plants.

 Literature Study -  Published literature  in  the form of handbooks,
 engineering  and  technical  texts,  reports,    trade   journals,
 technical   papers,  periodicals,   and  promotional  materials were
 examined.   Those sources used  to   provide   information  for   this
 study are  listed in Section XIV.   As previously noted,  the  "Metal
 Casting   Industry  Directory"   (a   Penton  Publication)   provided
 information on  the number,  size,   and   distribution   of  foundry
 operations  in   addition   to   other factors   pertaining  to  plant
 characteristics.

 Regional and State Data  - EPA regional  offices  and  state en-
 vironmental   agencies   were   contacted  to   obtain   permit and
 monitoring  data  on specific plants.  The EPA's Water   Enforcement
 Division s   Permits  Compliance  System"  was used   as  another
 mechanism   to   identify 'and   gather  additional  information  on
 foundries.

Raw  Material  Manufacturers   and   Suppliers   - Manufacturers and
suppliers of foundry raw materials  and process  chemicals, such as
 core  binders  and  mold  release   agents,  were  contacted   for
 information  about  the  chemical compositions of their products.
Since many of these materials  are considered proprietary  by  the
vendor,   only  generic  information  was  obtained  about  these
                               52

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products.  From this information, predictions were made as to the
possible introduction of toxicw=pollutants  into  foundry  process
wastewaters due to the presence of these materials in the foundry
work area.

Equipment   Manufacturers   and  Suppliers  -  Manufacturers  and
suppliers of foundry process ,and pollution control equipment were
contacted to  obtain  engineering  specifications  and  technical
information  on -foundry manufacturing processes and air and water
pollution control practices.

In addition to utilizing existing data (including  data  from  19
ferrous  foundries  sampled  in  1974)  and  plant  supplied data
(submitted in the survey questionaire), a  sampling  program  was
carried  out  at  23  additional  plants.   Five aluminum casting
plants; five copper casting plants; ten iron  and  steel  casting
plants;  one lead casting plant; one magnesium casting plant; and
four zinc casting plants  were  sampled.   At  two  plants,  both
aluminum  and  zinc casting analytical data were obtained.  These
two plants are counted twice in the above distribution; once  for
aluminum casting and once for zinc casting.

Upon  completion of the sampling and analysis efforts, all of the
data obtained  were  analyzed  to  determine  process  wastewater
characteristics  and mass discharge rates for each sampled plant.
In addition to  evaluating  pollutant  generation  and  discharge
rates .for  the  sampled  plants,  the  industry survey data were
examined  to  determine  the  range  of  control  and   treatment
technologies  existing  within  the  foundry  category.   Special
attention was paid to in-process technology such as  the  recycle
of  process  wastewater,  the  segregation  of characteristically
different process wastewaters and the minimization of water  use.
An  industry  update  survey was conducted in mid-1981 to confirm
and to update the wastewater treatment data for the industry.
                                53

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-------
                                        TABLE III-2

                             PENTON FOUNDRY CENSUS INFORMATION
Ductile Iron

Gray Iron

Malleable Iron

Steel

Brass & Bronze
  (Copper Alloy)

Aluminum

Magnesium

Zinc

Other Metals
 Less  than
10 Employees

    28

    149

    11

    45

    533


    843

    30

    225

    150
  10-49
Employees

     127

     489

     20

     177

     714


     1,016

     50

     289

     158
  50-249
Employees

    283

    579

    42

    337

    277


    450

    42

    175

    59
Greater  than
250 Employees

    98

    156

    37

    97

    37


    75

    8

    39

    9
                                          55

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        TABLE  III-3

DISTRIBUTION OF ADDITIONAL
1000 FOUNDRY PLANT SURVEYS
Ductile Iron
Gray Iron
Malleable Iron
Steel
Brass & Bronze
(Copper Alloy)
Aluminum
Magnesium
Zinc
Other Metals
Less than
10 Employees
25
54
11
41
119
167
28
50
32
10-49
Employees
26
104
18
30
144
200
46
65
24
50-249
Employees
60
103
36
56
69
98
36
43
50
Greater than
250 Employees
69
79
22
33
28
52
4
25
8
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                       TABLE 111-22

          OPERATING MODES,  CONTROL AND TREATMENT
            TECHNOLOGIES AND DISPOSAL METHODS

                         Symbols
Operating Modes

1.   OT

2.   Rt,s,n
                    Once-Through

                    Recycle, where t = type waste
                                   s = stream recycled
                                   n = % recycled

                                   t:  U = Untreated
                                       T = Treated
     P       Process Wastewater % of raw waste flow

3.   REt,n          Reuse, where t = type
                                 n = % of raw waste flow

                                 t:  U = before treatment
                                     T = after treatment

4.   IR             Internal Recycle

5.   BDn            Slowdown, where n = discharge as % of
                                        raw waste flow

Control Technology

10.  DI             Deionization

                    Spray/Fog Rinse
11.  SR

12.  DR

Disposal Methods

20.  H

21.  DW

22.  EME
                    Drag'-out Recovery



                    Haul Off-Site

                    Deep Well Injection

                    Evaporation, Multiple Effect
                            93

-------
TABLE 111-22
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 2          	:	
C.      Disposal Methods (cont.)

        23.  ES             Evaporation on Slag

        24.  EVC            Evaporation, Vapor Compression Distillation

D.      Treatment Technology
        30.  SC

        31.  E

        32.  Scr

        33.  OB

        34.  SS

        35.  PSP

        36.  SSP

        37.  EB

        38.  A

        39.  AO

        40.  GF

        41.  M

        42.  Nt
         43.  FLt
Segregated Collection

Equalization/Blending

Screening

Oil Collecting Baffle

Surface Skimming (oil, etc.)

Primary Scale Pit

Secondary Scale Pit

Emulsion Breaking

Acidification

Air Oxidation

Gas Flotation

Mixing

Neutralization, where  t =  type
                                                   t:   L = Lime
                                                       C ~ Caustic
                                                       A = Acid
                                                       W = Wastes
                                                       0 = Other, footnote
 Flocculation, where  t  = type
                                    94
                                                   t:  L = Lime
                                                       A = Alum
                                                       P = Polymer
                                                       M = Magnetic
                                                      FC = Ferric Chloride
                                                       0 = Other, footnote

-------
TABLE 111-22
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE_3	„____	i	
D.      Treatment: technology  (cont.)

        44.  CY             Cyclone/Centrifuge/Classifier
        45.  DT  ;

        46.  CL

        47.  T

        48.  TP

        49.   SLn


         50.   VF


         51.   Ft,m,h
              Drag Tank

              Clarifier

              Thickener

              Tube/Plate Settler,

              Settling ;Lagoon, where n  = days  of  retention
                                         time

              Vacuum Filtration  (of, e.g.,  CL,  T, or TP
                                  underflows)

              Filtration,  where  t * type
                                 m =* media
                                 h * head
                                   m
              D ™ Deep Bed
              F == Flat Bed
         52.  CLt
         53.

         54.
CO

BOt
          55.

          56.
CR

CT
                  S = Sand
                  0 = Other,
                      footnote
                  G = Gravity
                  P =» Pressure
Chlorination, where t = type

                    t:  A a Alkaline
                        B = Breakpoint

Chemical Oxidation (other than CLA or CLB)

Biologicai 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)

 Cooling Tower
                                       95

-------
TABLE 111-22
OPERATING MODES, CONTROL AND TREATMENT
TECHNOLOGIES AND DISPOSAL METHODS
PAGE 4
D.
Treatment Technology (cont.)
        57.  ACt
        58.  IX
        59.  RO
        60.
        61.  AA1
        62.  OZ
        63.  UV
        64.  CNTt,n
        65.  On
        66.  SB

        67.  AE
        68.  PS
        69.  OS
                    Activated Carbon, where t = type
                                                            Powdered
                                                            Granular
                    Ion Exchange
                    Reverse Osmosis
                    Distillation
                    Activated Alumina
                    Ozonation
                    Ultraviolet Radiation
                    Central Treatment, where t a type
                                                     n = process flow as
                                                         % of total flow

                                                     t:  1 = Same Subcats.
                                                         2 = Similar Subcats.
                                                         3 3 Synergistic Subcats.
                                                         4 = Cooling Water
                                                         5 = Incompatible Subcats.
                    Other, where n =" Footnote number
                    Settling Basin
                    Aeration
                    Precipitation with Sulfide

                    Oil Separator
                                       96

-------
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-------
                                        TABLE _III-25
                           PERCENTAGE OF ACTIVE "WET" OPERATIONS
                                 WITHIN EACH EMPLOYEE GROUP
                               .METALS CASTING INDUSTRY
Subcategory

Aluminum Casting
Copper Casting
Ferrous Casting
Magnesium Casting
Zinc Casting
  Less than
10 Employees

     0
     4.0%
     0
     0
     0
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Employees

  12.3%
  3.8%
  24.6%
  40.0%
  26.6%
  50-249
Employees

  29.8%
  39.3%
  57.6%
  83.3%
  26.3%
 More than
250 Employees

    77.8%
    100%
    78.0%

    41.7%
                                            99

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                          FIGURE 3E-IO


     CAST ME-TALS PRODUCTION (THOUSANDS  OF TONS)
             AT 5-YEAR INTERVALS 1956-1976
20,000
 10,000 —

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 2,000
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SOURCE'- Deportment of Commerce
                                                  GRAY IRON
                                                DUCTILE IRON,,


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                                              MALLEABLE JRON   —
                           w


                                                   ALUMINUM __~
                                                      ZINC

                                                      •—••^^
                                                COPPER ALLOY
                                 1966
                                               1971
                                                             1976
                                109

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                                 FIGURE m - II

         FERROUS  FOUNDRY  TRENDS IN  THE UNITED STATES
    1800
   1600
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   1200
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   2OO
                                SMALLER FERROUS FOUNDRIES
                                    (100 or Less Employees)
                               LAR6ER  FERROUS FOUNDRIES
                                   (500 or More Employees)
                                    MEDIUM FERROUS FOUNDRIES
                                        {100-500 Employees)
1
)60 1961
1 1 1 1 1 1
'963 1965 1967 1969 1971 |973 |9
SOURCE: A.T. Kearny
                                  110

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                           SECTION IV

                   INDUSTRY SUBCATEGORIZATION

INTRODUCTION

The metal molding and casting  (foundry)  point  source  category
includes  a  large  number of plants which use a variety of metal
molding and casting techniques  to  cast  the  different  metals.
Foundries  employ different manfacturing processes (some of which
require air  pollution  control  devices)  which  create  process
wastewaters.    These   wastewaters   have   unique   raw   waste
characteristics and  require  various  wastewater  treatment  and
control technologies.  The metal molding and casting point source
category  is, therefore, not amenable to a single set of effluent
limitations and standards applicable to all foundries.

This category is, however, amenable to a subcategorization scheme
which provides for the grouping of foundries which: cas-t  similar
metals,  employ  similar  manufacturing  processes,  have similar
sources of air pollution which require control, and, as a result,
generate  wastewaters   with   similar   basic   characteristics.
Appropriate  subcategorization ensures that plants grouped into  a
subcategory and process group are  sufficiently  similar.   As   a
result,   a  reasonable  comparison  of  like  plants  and  their
treatment performances can be  made.   This  segmentation  scheme
allows   the  application of  a uniform set of effluent  limitations
and standards of performance for  each process segment.

SELECTED SUBCATEGORIBS

Based on the findings detailed  in this  section and   supported  by
the  discussions   in Sections  III, V,  and VII,  the  subcategones
and subcategory  segments  established   for  the development  of
effluent limitations and  standards of performance are:

A.   Auminum Casting
      1.   Investment  Casting  Operations
      2.  Melting Furnace  Scrubber Operations
      3.  Casting Quench Operations
      4.  Die Casting Operations
      5.  Die Lube  Operations

B.    Copper Casting
      1.   Dust  Collection  Scrubber Operations
      2.   Mold  Cooling  and Casting Quench Operations
                                111.

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 C.    Ferrous Casting
      1.   Dust Collection Scrubber Operations
      2.   Melting Furnace Scrubber Operations
      3.   Slag Quenching Operations
      4.   Mold Cooling and Casting Quench Operations
      5.   Sand Washing Operations

 D. '   Lead Casting

      1.    Continuous Strip Casting Operations
      2.    Melting Furnace Scrubber Operations
      3.'   Grid Casting Scrubber  Operations

 E.    Magnesium Casting
      1.   Grinding Scrubber Operations
      2.   Dust Collection Scrubber  Operations

 F.    Zinc Casting
      1.   Die  Casting and Casting Quench  Operations
      2.   Melting  Furnace Scrubber  Operations

 SDBCATEGORY DEFINITIONS

 Metal molding  and casting  is defined as  the  remelting of a metal,
 or  metal  alloy,  to  form  a cast intermediate or final product by
pouring or forcing the   molten  metal  into  a  mold  except  for
 ingots,  pigs,  or  other  cast  shapes  related to primary metal
smelting.  The  category  includes the aluminum,  copper,  ferrous,
 lead,   magnesium,    and   zinc    casting    subcategories.    The
manufacturing processes  associated with  the  casting of each metal
and which generate process wastewaters are:

Aluminum Casting

     1.   Investment Casting Operations - The casting of aluminum
     or  aluminum  alloys  by   investment   casting   techniques
     involves:  mold backup, hydroblast cleaning of castings, and
     the collection of dusts resulting from the hydroblasting  of
     castings  and the handling of the investment material.   This
     operation is also known as the lost wax, lost  pattern,   hot
     investment, or precision casting process.

     2.    Melting  Furnace  Scrubber  Operations  -   Those    air
     pollution  control  operations  which  clean dusts and  fumes
     from melting furnace operations through the use of water  or
     process  wastewater as a cleaning medium.

     3.    Casting Quench Operations - Those operations in which  a
     casting  at elevated temperature is immersed in a liquid  bath
                              112

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     for  the purpose of rapidly decreasing the temperature of the
     casting.

     4.    Die Casting Operations -  Those  operations  associated
     with  die  casting  in  which  the  various  related process
     wastewaters  are  collected  in  a  common  container.   The
     sources  of  these  wastewaters include:  die surface cooling
     sprays, hydraulic fluid leakage,  splash  over  from  casting
     quench,  and  leakage from non contact cooling water systems
     associated with the die casting equipment which subsequently
     becomes contaminated due to common collection  with  process
     wastewaters.               ,

     5.    Die Lube Operations - Those operations associated  with
     die   casting   which  involve  the  spraying  of  a  liquid
     containing mold release agents onto the die surface  or  die
     head and the subsequent segregated collection of the liquid.

Copper Casting

     1.    Dust  Collection  Scrubber  Operations  -   Those   air
     pollution  control  operations  which  clean dusts resulting
     from: sand preparation, sand molding processes, core  making
     processes,  sand handling transfer processes, the removal of
     sand from the casting, and other sand related  dust  sources
     through the use of water or process wastewater as a cleaning
     medium.

     2    Mold Cooling and  Casting  Quench  Operations  -  Those
     operations  in  which  contact  cooling  water is applied to
     metallic molds and those operations in which  a  casting  is
     immersed  in  a   liquid  bath  for  the  purpose  of  rapidly
     decreasing :the temperature of the casting.

Ferrous Casting

     1.   Dust  Collection  Scrubber  Operations  -   Those   air
     pollution   control  operations  which  clean dusts resulting
     from:  sand preparation, sand molding processes, core  making
     processes,  sand handling and transfer processes, the  removal
     of   sand  from  the   casting   (including shot blasting), and
     other  sand  related dust sources, and pouring floor,   pouring
     ladle,  and   transfer  ladle  fumes when collected  in an air
     duct system common with sand dusts  through the use of water
     or process  wastewater  as a cleaning medium.

     2.   Melting   Furnace  Scrubber  Operations  -   Those   air
     pollution   control  operations  which  clean dusts  and  fumes
     from:  melting  furnace  operations  pouring   floor   fumes,
                                113

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     pouring   ladle  or   transfer   ladle  dusts,   and   fumes  when
     collected in  a air  duct  system common with   the   melting  or
     holding   furnace.    These   scrubbers   use water   or  process
     wastewater as a cleaning medium.

     3.    Slag Quench Operations  -  Those  operations  in which
     furnace   slag  is   cooled   or  sluiced with  water or  process
     wastewater.

     4.    Mold Cooling and  Casting  Quench Operations - Those
     operations   requiring   the  application  of  cooling water
     directly  on the casting  mold  and those operations in  which a
     casting is immersed in a liquid  bath  for   the   purpose  of
     rapidly   decreasing the  temperature  of the casting or for
     imparting desired metallurgical properties.

     5.    Sand Washing Operations  -  Those  operations  in which
     spent  sand   is reclaimed  for reuse by  washing  the  sand to
     remove impurities.
Lead Casting

     1.   Continuous Strip Casting Operations - Those  operations
          requiring  the application of cooling water directly on
          the lead strip for the purpose  of  rapidly  decreasing
          the temperature of the lead strip.

     2.   Melting  Furnace  Scrubber  Operations  -   Those   air
          pollution control operations which use water or process
          wastewater to clean the dusts and fumes from melting or
          holding furnace exhaust gases.

     3.   Grid Casting Scrubber Operations - Those air  pollution
          control   operations   which   use   water  or  process
          wastewater to clean dusts and fumes resulting from grid
          casting operations.

Magnesium Casting

     1.    Grinding Scurbber  Operations  -  Those  air  pollution
     control  and  fire retardant operations which clean and trap
     magnesium dusts resulting from the  cleaning,  abrading,  or
     grinding  of the casting following its removal from the mold
     medium.

     2.    Dust  Collection  Scrubber  Operations  -   Those   air
     pollution  control  operations  which  clean dusts resulting
     from sand preparation,  sand molding processes,  core  making
     processes,  sand handling and transfer processes,  the removal
                               114

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     of  sand  from  the  casting,  and  other  sand related dust
     sources through the use of water or process wastewater as  a
     cleaning medium.
Zinc Casting

     1.   Die Casting  and  Casting  Quench  Operations  -  Those
     operations  in  which  castings at elevated temperatures are
     immersed in  a  liquid  bath  for  the  purpose  of  rapidly
     decreasing the temperature of the casting.

     2.   Melting  Furnace  Scrubber  Operations  -   Those   air
     pollution control operations which clean the dusts and fumes
     from  melting  or holding furnace operations with the use of
     water or process wastewater as a cleaning medium.

SUBCATEGORIZ ATION BASIS

In identifying the subcategories and subcategory process segments
for the metal molding and  casting  point  source  category,  the
following factors were considered:

 1.  Type of metal cast
 2.  Manufacturing process
 3.  Air pollution sources
 4.  Water use
 5.  Process wastewater characteristics
 6.  Raw materials
 7.  Process chemicals
 8.  Wastewater treatability
 9.  Plant size
10.  Plant age
11.  Geographic location

The  type  of  metal  cast arid the manufacturing process form the
basic  framework for the  selected  subcategories.   Many  of  the
other    factors    provided    additional    support   for   the
subcategorization scheme.  These other factors, including process
wastewater  characteristics,  helped  to  delineate   the   final
subcategories   and   are  reflected  in  the  subcategories  and
subcategory process segments developed.

Rationale for Subcateqorization - Factors Considered
Type of Metal Cast

The  type  of  metal   cast  forms
subcategorization of  the  category.
chemical properties.
the   principal   basis   for
Metals differ in physical and
                               115

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 The  inherent differences in the physical  and chemical  properties
 of  the various types of metals cast  result  in  a  diversity  of
 manufacturing  processes,   process  chemical   use,  sources of air
 pollution,  water use,  and process wastewater  characteristics.   As
 seen  in the technical  findings of this  study,  the type   of  metal
 cast   affects  the  kinds and quantities of toxic metal and toxic
 organic pollutants present in foundry process  wastewaters.    The
 different   casting  techniques  used with  the various cast metals
 require the use of different process chemicals.   The binders,   or
 chemical additives  used  in  sand  casting,   are  substantially
 different from those  process  chemicals   used  as  mold  release
 agents in die casting  operations.

 Examination  of the analytical data indicated that differences in
 alloys of the same base metal were not  of  sufficient magnitude to
 subcategorize by alloy.   This is most  apparent   in the  ferrous
 casting    subcategory,     where    variations   in  raw    waste
 characteristics,   manufacturing  processes,   process   chemicals,
 etc.,   among   gray  iron,  malleable,  ductile,  and steel foundries
 were  not significant   enough  to  support subcategorization   by
 alloy.

 Subcategorization   based   upon   waste   characteristics    was
 considered.   However,  a review of  each  of  the  remaining  factors
 reveals that  the type of metal  cast,  the manufacturing process,
 and the subsequent air  pollution  control   device or  process
 chemical  used,  affects the process wastewater characteristics of
 plants in the foundry  category.   Subcategorization  by metal  type,
 therefore,     inherently     considers      process      wastewater
 characteristics  and other  pertinent factors.

 In  those   instances where a plant  casts more  than  one  metal,  the
 manufacturing  processes, equipment,   and   pollutant  sources   are
 usually segregated by  metal  type.  A specific  melting furnace,
 for example,  melts  only  one metal  to  avoid  cross   contamination
 with    another  metal.   Manufacturing  processes   are   generally
 designed to handle  only  one metal  type  without extensive overhaul
 or  rebuilding.    Many   of   these   manufacturing  processes   (die
 casting  for example) require  the use  of special process  chemicals
 designed for  very  specific  applications.

 As  would  be  expected,  there  is a  close relationship between  the
 type of metal  cast  (and  the  subcategories  derived from  them)   and
 factors  such  as manufacturing processes,  process  chemicals,  raw
materials,  process  wastewater  characteristics, and air   pollution
sources as described below.
                               116

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Manufacturing Process

The  subcategories  developed;  on  the  basis  of metal type were
further  segmented  to   allow   for   dissimilar   manufacturing
processes.   This segmentation takes into account the differences
in   water   use   and   the   dissimilar   process    wastewater
characteristics.

Many  manufacturing  processes  are  unique  to the type of metal
cast.  The data indicate that slag quenching is  only  associated
with  the  melting  of  ferrous  metals.  The other manufacturing
operations depend on the type of metal being processed.  A cupola
furnace is a unique source of air pollution  with  characteristic
emissions  generally  controlled  by  wet  air  pollution control
devices.  Casting techniques also differ depending on the  metal.
Aluminum and zinc castings are frequently produced by die casting
methods while ferrous metals are not.

Not  all  manufacturing  processes generate a process wastewater.
Consideration of  manufacturing  process  helped  to  distinguish
between  those  processes which generate a process wastewater and
those which do not.  Examination  of  the  data  reveals  that  a
manufacturing  process  may generate process wastewater in one of
two ways: water which  is  used  directly  in  the  manufacturing
process,  or  water  which  is  used  in an air pollution control
device associated with the manufacturing process.   The  industry
survey  data  indicate  that  approximately  80%  of  all foundry
wastewaters are generated by air pollution control devices.

Manufacturing Processes                     ..,   ,

The manufacturing processes which generate a  process  wastewater
directly  are:  1) for aluminum casting - the  investment casting,
casting quench, die casting,  and  die  lube  processes;  2)  for
copper  casting -the mold cooling and casting quench process; 3)
for ferrous casting - the slag quenching, casting quench and mold
cooling, and sand washing processes; and 4) for  zinc  casting
the die casting and casting quench process.

Though   some   manufacturing   processes   exhibit   significant
differences  depending  upon ' the  type  of  metal  cast,   other
manufacturing  processes,  similar   in  design  and function, are
associated with the casting of different  metals.   For  example,
aluminum  and  zinc  castings may be formed through a similar die
casting   process.    Where   similar   manufacturing   processes
associated   with  different  metals  were  encountered,  process
chemical  usage  and  process  wastewater  characteristics,   were
examined  to  identify  any  additional  basis  of  support for a
                              -117

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subcategorization scheme based upon the type of  metal  cast
the manufacturing process.
and
The  consideration  of  the type of metal cast and the associated
manufacturing processes helped to identify the sources of process
wastewaters and to group the data, by manufacturing process,  for
further  analysis.  In instances where process wastewater streams
are not generated as  the  result  of  direct  contact  with  the
manufacturing process and where different metals are processed on
similar manufacturing units, other factors were considered.

Air Pollution Sources

Certain manufacturing processes are characteristic sources of air
pollution.   Where  required,  air pollution control devices have
been  installed   to   control   air   emissions   from   various
manufacturing  processes.   The  design  of  these devices may be
either of the "dry" or "wet" type.  An example of  a  "dry"  type
control device is a bag house.  Such dry devices are discussed in
Section III.  "Wet" air pollution control devices are referred to
as scrubbers, and these devices produce process wastewater.

Those manufacturing processes which generate a process wastewater
from  scrubbers  are:   for aluminum casting; the melting furnace
scrubber  process,  for  copper  casting;  the  dust   collection
scrubber  process,  for  ferrous  casting; 1) the dust collection
scrubber process, and 2) the melting  furnace  scrubber  process;
for lead; 1) the melting furnace scrubber process and 2) the grid
casting  scrubber  process,  for  magnesium  casting; 1) the dust
collection scrubber, and 2) the grinding scrubber  process;  and,
for zinc casting; 1) the melting furnace scrubber process.

Since  wet  air  pollution control equipment is unique to certain
manufacturing processes, these operations are differentiated from
other manufacturing operations and from other process  wastewater
sources  as previously described.   Consideration of air pollution
sources and the associated  control  devices  helped  to  further
substantiate   the   manufacturing   process  segments  for  each
subcategory.

Process Water Usage

The decision to use water as part of a manufacturing  process  or
as  an air pollution control medium depends on many factors.  The
volume  of  water  used   is   primarily   dependent   upon   the
manufacturing process, air pollution control device,  the cost and
availability  of  water,  and  most  significantly,  plant  water
management practices.   Manufacturing processes and air  pollution
control are implicitly reflected in the subcategories and process
                               118

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segments  developed.   Plant water management practices vary from
plant to plant, therefore, process water usage was not considered
to be an appropriate basis for subcategorization or segmentation.
However,  process  water  usage  is  an  integral  part  of   the
wastewater treatment models and limitations developed.

Process Wastewater Characteristics

In  addition  to  supporting  subcategorization  by  metal  type,
consideration   of   wastewater   characteristics    helped    to
differentiate  between  similar  manufacturing operations used to
cast different metals.  The analytical data  for  the  wastewater
samples  indicate that the type and quantity of pollutants differ
among similar manufacturing processes.  While aluminum  and  zinc
are  cast  on  similar  die  cast equipment, zinc was found at 40
times the concentration in zinc  casting  quench  solutions  than
aluminum casting .quench solutions.  More toxic organic pollutants
were  detected  in aluminum casting quench solutions than in zinc
casting quench solutions.

Raw Materials

Raw material composition was  found  to  significantly  influence
wastewater  characteristics.  This effect is primarily the result
of the type of metal  being  cast.   The  production  of  a  zinc
casting  for example, initially begins with the use of, a zinc raw
material in the charge to the melting furnace.

Because of this, raw material usage is implicitly considered in a
subcategorization scheme based on the type of metal cast.

Process Chemicals

The major process chemicals used in the manufacture  of  castings
fall  into  two  general  classes;  those  associated  with  sand
casting, and those associated with die casting.  This distinction
helped to further substantiate the subcategorization scheme.  The
process chemicals associated with sand casting techniques include
sand and core binders and related chemical additives.  Several of
these process chemicals contain  toxic  pollutants  or  chemicals
which  when  exposed  to hot metal temperatures may break down to
toxic pollutant materials.

Analysis of plant data indicates the use of  a  wide  variety  of
sand  casting materials.  At least 14 different chemical types of
sand additives are commercially  available.   On-site  visits  to
many plants indicated that more than one type of sand additive is
often  used  simultaneously within the plant, and that changes in
the use of the various products occur periodically.
                               119

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The process chemicals associated with  die  casting  include  die
lubricants,  die coatings and quench solution additives.  Twenty-
eight manufacturers or suppliers of these process chemicals  have
been  identified.   These  materials are used to prevent castings
from adhering to the die and to provide a casting  with  improved
surface  characteristics.  Many different products are frequently
tried until a satisfactory lubricant  or  coating  is  found.   A
correctly chosen lubricant will allow metal to flow into cavities
that otherwise may not be filled.

Due  to  the  wide  variety of process chemicals and the frequent
changeover of these products, the type of process  chemical  used
was  not  found  to  be  a  primary  basis for subcategorization.
However, the type of  process  chemical  used  was  a  supportive
factor   in   the   subcategorization   and  segmentation  scheme
developed.

Process Wastewater Treatability

Treatment  systems  are  designed  to  treat  specific  types  of
pollutants   which   are   characteristic   of   various  process
wastewaters.  Some process wastewaters will be predominantly oily
in nature, while other process wastewater streams will be free of
oil but will contain toxic metals.   The  treatment  applications
identified  at  plants  during  the  development  of  this report
encompass  systems  ranging  from  no  treatment  to   relatively
extensive treatment.  The wastewater treatment systems range from
once-through systems discharging to POTWs or navigable waters, to
100   percent   recycle   systems.    Since   process  wastewater
characteristics  differ  among   waste   streams   from   various
manufacturing   processes,
the   different   process   segments
implicitly  consider  the  various  treatment  technologies   and
capabilities   involved   in   handling   the  different  process
wastewaters.  Thus, wastewater treatability does not substantiate
the need for further segmentation.

Plant Size

Plant size  can  be  evaluated  by  several  methods:  number  of
employees, production, or process wastewater flow.  Evaluation of
the  production  and  employee  group  information  confirmed  an
expected trend.  Larger  foundries  (based  upon  the  number  of
employees)  generally  had  greater  productions.   However, this
trend did not have any effect on the subcategorization scheme for
the industry.

No identifiable relationship between size and process  wastewater
characteristics  was  found.   Nor did the number of employees or
production have a quantifiable relationship with  the  volume  of
                               120

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process  wastewaters  produced.   No discernable pattern appeared
when plant water usage rates were compared with plant  production
rates  and  the employee groups.  However, the employee groupings
have been retained and used as a means  of  providing  convenient
BPT, BAT, and PSES model sizes for further economic evaluation.

Plant Age

Referring to the Plant Summary data presented in Sections III and
V  it  can be seen that the provision of wastewater treatment, up
to complete recycle, is not related to plant age.  As an example,
plants which have been in operation for over 30  years  installed
treatment  and  recycle  facilities as recently as six years ago.
In other instances, treatment and recycle facilities have been in
use at some plants for over 35 years.  The Agency has, therefore,
concluded that age  is  not  an  appropriate  basis  for  further
subcategorization or subdivision.

Geographic Location

Plants engaged in metal molding and casting are located in all of
the  industrial  regions  of  the  United  States.   None  of the
available data indicate that,the location of a plant affects  the
type  of metal cast, the manufacturing process employed, or other
process wastewater characteristics.  The only pattern noticed  is
that  the  plants are generally located near the areas which will
use their products, whether they  are  used  by  other  corporate
entities  or  are  sold  to the end users.  Therefore, geographic
location  is  not  cpnsidered  as  an   appropriate   factor   in
establishing subcategories.

Summary

The  primary  factor  affecting the wastewater characteristics of
plants is the type of metal cast.  An additional important factor
is the type of manufacturing process used  to  form  the  desired
casting.   These two factors form the basis for subcategorization
of.the metal molding  and  casting  point  source  category.   In
addition,  other  factors  such as process chemical usage and air
pollution  sources,  helped  to  support  the   subcategorization
scheme.

PRODUCTION NORMALIZING.PARAMETER

Having  selected  the  appropriate  subcategorization scheme, the
next step involved the development of a quantitative parameter on
which  to  base  limitations  and  standards.   Since   pollutant
measurements,  are expressed as mg/'l, concentration is the obvious
first  consideration  for  limitations.    However,   while   the
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 concentration   of   a  pollutant  is   an  intensive  property  of  the
 wastewater,  it  is  not  an   intensive   property   of   pollution.    A
 plant   which dilutes   its  wastewater would have  an  advantage in
 meeting concentration   limitations   over  plants   which   conserve
 water.    Thus,   a   plant   with   good water conservation  practices
 might be penalized by  a concentration based limitation.   In order
 to preclude  the possibility  of   dilution,   the  concentration   of
 pollutants   in   the discharge must be multiplied by the  discharge
 flow rate to provide a mass  discharge level for each pollutant.
 Since   the mass discharge  relates to the level  of  production,  the
 mass discharge  level requires still  another parameter to account
 for  differences  in  the  actual production levels from plant to
 plant.   Such a  parameter must   establish  an  effluent  discharge
 rate  relationship  that   changes  in proportion  to  the level of
 production activity.   The  following   discussions   deal  with  the
 selection of   this production normalizing  parameter   and  the
 application  of  this parameter to effluent  limitations.

 Selection of Production Normalizing  Parameter

 The level of production activity in   a   plant   can be  expressed
 quantitatively   as  the amount of   metal  poured, the  amount of
 process  chemicals  consumed,  the weight of   castings  shipped,   or
 the  number  of employees.   In  addition,  in those  instances  where
 sand is  used as the mold medium, the amount of  sand used can   be
 an indicator of production activity.

 The  technical   findings   indicate that  the use of two production
 normalizing  parameters  is  appropriate.   These two  parameters   are
 the  weight  of  metal poured, and the weight of  sand used in  molds
 and cores.   These  two production normalizing parameters  are  more
 closely  associated with the  level of production activity relative
 to  pollutant   load than  any   other  parameters   which could be
 considered.

An  outline  of  the  rationale used  in   selecting   these    two
parameters,  as  well   as  in   eliminating  other  parameters from
 consideration follows.

Weight of Metal  Poured

The weight of metal poured readily lends itself as  a  reasonable
production   normalizing  parameter   for many of the subcategories
and subcategory  segments.

 In those  instances  where a furnace scrubber is  used   to  control
furnace  emissions, the pollutants become waterborne contaminants
during the furnace  emission  cleaning  process.    The   emissions
result  from  the   melting and  heating of the raw materials which
                               122

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make up the furnace charge.  On  first  consideration,  it  would
appear  to  be  appropriate  to  base  the production normalizing
parameter on furnace charge.  However,  the  composition  of  the
furnace  charge varies from plant to plant.  This is particularly
prevalent in the ferrous  casting  subcategory.   The  ratios  of
coke,  scrap,  iron,  limestone,  etc.,  vary widely among plants
which produce the same quantity of iron or steel.  Therefore,  it
would  be impractical to apply a production normalizing parameter
on such a variable basis as furnace charge.

The use of the weight of metal poured provides a  consistent  and
uniform  parameter  for  applying  effluent limitations to a wide
variety of plants.  In addition to  its  application  to  furnace
scrubbers,  its  use with all the other manufacturing subcategory
segments (except for those segments associated with  sand  usage)
is  technically  reasonable  and  provides  a  uniform  basis for
applying limitations.

Weight of Sand

In those instances  where  sand  is  used  as  the  mold  medium,
consideration  of the mechanisms by which pollutants are conveyed
from the manufacturing process to the process wastewater leads to
the selection of the weight of sand as a  production  normalizing
parameter.    Those   subcategories  are:  copper  casting;  dust
collection scrubber process, ferrous casting; dust collection and
sand washing processes and, magnesium  casting;  dust  collection
scrubber process.

The  processes  associated with sand usage, such as mold and core
making, casting shakeout, and sand handling  equipment,  generate
dusts  and  fumes.  The contaminated air is cleaned by scrubbers.
Therefore, contaminants in the air are transferred to the  water.
The  volume  of  air  passing  through the scrubbers remains at a
constant rate, while the mass of pollutant material  in  the  air
stream  changes with varying levels of production activity (i.e.,
the amount of sand in use).  To  account  for  these  changes  in
production  activity,  the  amount  of  sand  used  leads  to the
selection of the weight  of  sand  as  a  production  normalizing
parameter for dust collection scrubber processes.

In sand washing operations, sand comes into intimate contact with
water,   and,   as  a  result  the  water  is  contaminated  with
pollutants.  The  amount  of  sand  washed  affects  the  process
wastewater  Characteristics  and  leads  to  the selection of the
weight of sand washed as a production normalizing  parameter  for
the sand washing subcategory segment.
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Surface Area  of  Casting

Surface   area was  considered  as  a possible production  normalizing
parameter for those manufacturing processes  involving   quenching,
since  pollutants  enter  the quench water  through  intimate  contact
with the  casting.  However,   surface  area   of  a   casting  is   a
randomly  changing  variable dependent upon the shape and design of
the,castings  being manufactured.  Therefore, surface area  was not
selected  as a practical  production normalizing parameter.

Number of Employees

As  previously   indicated,  the  number   of  employees  does  not
necessarily reflect the  production rate at any plant.   For .these
reasons,   the   number  of   employees  does  not   constitute  an
appropriate production normalizing parameter.

Weight of Final  Product

The weight of final product is   a  readily   available   production
record, but its  application as a production  normalizing parameter
has a significant  drawback.

The  weight   of  the  casting  in  final  product   form may vary
substantially from the casting's initial  weight.  Casting  weight
is  at  a maximum when  the  casting  is   first   formed  (i.e.,
immediately after  the pouring of the molten metal into the mold).
At this point, the casting has   the  gates,  sprues,   and  risers
attached,  and   the total weight of all the  castings produced per
unit time closely  equates with the total  amount of  metal  poured
during that unit of time

The  major reduction in weight occurs after  the metal  molding and
casting and supportive process steps (sand preparation,  mold  and
core  making,  sand  washing,  etc.)  have occurred.   This weight
reduction is due to the removal  of the gates, sprues,  and  risers.
Weight loss can  be as little as  5  percent  or  as  much  as  70
percent   of   the initial total casting weight, depending upon the
type of metal cast, the casting  shape,   and  the  volume   of  the
gates,   sprues,   and risers in the mold required to  allow adequate
flow of the molten metal into the mold.

Additional weight  changes can occur when metal is removed  during
the  machining  of  the  casting  or, for example, when weight is
added during the electroplating or the painting of  the  casting.

For the reasons stated above, the weight of the final product was
not found to be a  suitable production normalizing parameter.
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Process Chemicals Consumed

For  the  reasons  stated  in  the  discussion  of  the   factors
considered  for  subcategorization,  the  variability  of process
chemicals consumed diminishes its usefulness  as  an  appropriate
production normalizing parameter.
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                   v: :    .  'SECTION V

              WATER USE AND WASTE CHARACTERIZATION
INTRODUCTION
This  section  presents  data  which  characterize the wastewater
streams originating  in  the  various  foundry  operations.   The
wastewater  characterizations  are  based upon the field sampling
programs conducted in .association with this study (1977-1978) and
a previous study (1974).
Process water usage plays a major role in  the  determination  of
pollutant loads and, in turn, the estimation of pollutant removal
costs.  The Agency evaluated published information, DCP responses
and  the  sampled plant analytical data to evaluate process water
use; to estimate pollutant  loads;  to  obtain  total  wastewater
volumes; and to identify the, treatment technologies in use in the
foundry industry.

The  water  use  rates  pertain only to metal molding and casting
process and air pollution control equipment wastewaters  and  not
to  nonprocess  or noncontact cooling waters.  Process wastewater
is  defined  as  that  water  which,  during   manufacturing   or
processing,   comes  into  direct  contact  with  the  processes,
products, exit gases, raw materials,  or  by-products  associated
with   foundry   operations.    The  process  wastewaters  become
contaminated with the various pollutants  characteristic  of  the
manufacturing   process  orwet  air  pollution  control  device
(scrubber)  associated  with  a  manufacturing  process.    Thus,
process  wastewaters  from  metal  molding and casting operations
would include those  wastes  generated  during;   the  melting  or
remelting  of  the cast metal; the preparation of cores and molds
and related activities such as sand transfer, sandwashing,  etc.;
the  pouring or injection of metal into molds; the removal of the
casting from the mold; the removal or cleaning of the mold medium
from the mold; and the removal of gates, sprues,  and risers  from
the casting.  For example, casting quench process wastewaters are
considered   to   be   foundry   related  wastewaters.   However,
wastewaters generated during the plating of  these  castings  are
non-foundry  process  wastewaters.   Noncontact   cooling water  is
defined as that cooling water which does  not  come  into  direct
contact   with ,  the  processes,  products,  by-products  or  raw
materials.  Non-process water is defined as  that  water  which   is
used  in non-process operations, such as for  utility requirements.
However,  when noncontact cooling or non-process  waters are mixed
with process wastewaters, either  by  design  or   through  leaks,
spills,  etc., the  total volume of the discharge  is considered  to
be  process wastewater.
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 INFORMATION COLLECTION

 EPA  collected  information  describing  the  metal  molding  and
 casting   industry from a number of sources.   Some information was
 found within existing  Agency  data  from  a  previous  study  of
 ferrous   foundry  operations  performed  by EPA,  and from foundry
 permits  for operations which discharge to  surface  waters.    The
 Agency  also  reviewed  published  literature  for the purpose of
 obtaining as much pertinent information as possible.   In addition
 to  the data provided  in the information requests  sent to a number
 of   foundries  and to  several  chemical  suppliers,    technical
 information  was  provided   by industry representatives and trade
 associations throughout the course of this study.    The  sampling
 program   provided  the  greatest  amount  of  specific  plant and
 process  data.   Finally,  further  comments  and  information  were
 provided by plants commenting on the  Contractor's Draft Technical
 Report (EPA 440/1-80/070a).

 A previous  Agency study of  ferrous casting operations  was used to
 supplement    the  plant  information   and  analytical   data  base
 developed for  this study.   Although this earlier   study  was  not
 published,   it  presented   treatment   and  analytical  data from a
 number of  ferrous casting  operations.    This   information  was
 incorporated  with the ferrous foundry treatment capability and
 analytical  data  bases  developed during this  current study.

 National  Pollutant Discharge  Elimination System   (NPDES)   permits
 for  metal   molding and casting plants  having a  direct discharge
 were obtained  from the appropriate Regional  EPA or state offices.
 In many  cases, these permits  covered  other wastewater  streams and
 noncontact  cooling waters in  addition to the foundry wastewaters.
 In some  instances  these permits  did  not  specify   the  point  of
 origin   of   the  discharge  streams,   and  it  was  not  possible  to
 determine if noncontact cooling  waters or other wastewaters   were
mixed  with  foundry   wastewaters   prior to  discharge.   For  these
 reasons,   only  minimal   use   (other  than  confirming   some   other
observations)  of this  analytical  data was made during  this study.

The  Agency  conducted  a   literature search  to   obtain as  much
pertinent published information   as   possible.    Information  was
gathered  on:  the  processes  employed   in  the metal  molding and
casting  industry;  the purpose and  theory  of   each  process;  the
chemicals  used;   the  methods of  reducing water consumption; and
the methods of treating foundry  industry  wastewaters.   Some  of
this information is presented in  this  section  and  in Sections III
and VII.

Industry    and   trade   association   representatives   provided
information throughout the  course  of   this   study.   Wastewater
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treatment  system  capabilities,  new industry developments which
may impact regulatory  decisions  and  options,  and  many  other
industry  aspects  and  topics were provided to or discussed with
the Agency.

In addition to the data  requests  sent  to  a  large  number  of
foundry  operations,  product data was requested from some of the
chemical suppliers.  The data provided by the chemical  suppliers
pertains  to  proprietary  products.   It  is  considered  to  be
confidential and does not appear in this document.  However, this
data was used by the  Agency  as  a  guide  in  predicting  which
pollutants  could  be  expected  to  be  found in foundry process
wastewaters.   The  requested  company  data  is  presented   and
discussed  later  in  this section.  The sampling program is also
described later in this section.

Comments  on  the  Contractor's  Draft  Technical   Report   were
incorporated  in  this  report  where applicable.  These comments
covered topics ranging from general  manufacturing  processes  to,
the  problems involved in wastewater treatment and their relation
to foundry operations.

PRODUCTION PROFILE

Table V-l presents for each subcategory; the estimated weight  of
metal poured annually, the weight of metal poured in plants which
discharge  their  process  wastewater  to  navigable  waters, the
weight of metal poured in plants which  discharge  their  process
wastewater  to  POTWs,  and  the  weight  of  metal poured in wet
process plants which do not discharge process wastewaters.

PROCESS WASTEWATER FLOW

Estimates, by process segment andemployee  group  of  the  total
annual  process  wastewater  flows  within  the metal molding and
casting point source category are presented in Tables V-2 through
V-7.  These estimates are based upon the process wastewater flows
reported by plants responding to the data  collection  survey  in
conjunction  with  the  statistical  weights  (the relationship of
each plant to the  industry as a whole;) of the  respondents. ,  The
"Applied Flow" column indicates the volume of process wastewaters
flowing  through  or associated with the manufacturing processes,
or through the air pollution control devices associated with  the
manufacturing processes.  The "Recycle Flow" column  indicates the
volume  of  process  wastewater  which  is  recycled  back to the
process, while the column marked "Flow at  100  percent  Recycle"
indicates  the  volume of process wastewater which is recycled in
those operations with no process wastewater discharges.
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 Table  y-8  summarizes  by  subcategory  the distribution  of  foundry
 operations  according to  discharge  mode,  i.e.,  direct discharge,
 indirect discharge  to POTW's,  or  zero  discharge.

 SELECTION  OF PLANTS FOR  SAMPLING

 In order to   characterize   foundry   process   wastewaters,   assess
 treatment  capabilities,   develop model   treatment   systems,  and
 develop the  proposed  limitations  and standards,  it was  necessary
 to   visit   selected   foundries.     At   these   sites,  detailed
 operational  data  (including treatment  costs   and  water  use   and
 wastewater   generation  rates)   were   obtained,  and wastewater
 samples were collected.  The information presented   in  the DCPs
 served  as the primary basis for  selecting plants for engineering
 and sampling visits.  The  specific criteria used  to  select  these
 plants included:

     1.    The metal cast
     2.    The foundry processes which  generate wastewaters
     3.    The type  of air  pollution  control  devices installed,
           i.e.,  scrubbers or  "dry"  type collectors such  as  bag
           houses
     4.    The type  of process wastewater treatment   equipment   in
           place
     5.    The in-process control  technologies  which   reduce   the
           volume of process wastewaters
     6.    The degree  to which process  wastewater  is   recycled   or
           reused.


Sampling Program and  Pollutant Analysis

During  this study, sampling programs  were conducted  at  23  plants
for the purpose of obtaining samples on which analyses   would   be
performed    for   conventional,   nonconventional,    and   toxic
pollutants.  Prior to any  plant visit,  all available  data,  i.e.,
plant  layout,  production  sequence,  and  wastewater   treatment
facilities in use were reviewed.  This  information   was  usually
furnished  with  the  plant's DCP.   However, in some  instances,  it
was necessary to solicit additional details.   Following  is  a list
of the plants sampled  during  this  phase  (1977-1979)  of  this
study.
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                         SAMPLED PLANTS
Aluminum Casting

04704
10308*
12040*
17p89
18139*
20147
                     Copper Casting

                         04736
                         06809
                         09094
                         19872
                       Ferrous Casting
00001
00002
06956
07170.
07929
15520
15654
20009
50315
51026
51 1 15
51473
52491
52881
53219
53642
54321
55122
55217
56123
56771
56789
57100
57775
58589
59101
59212
Lead Casting

10145
Magnesium Casting

    08146
Zinc Casting

  04622
  10308*
  12040*
  18139*
*These plants cast both aluminum and zinc.

Generally,  two  separate  visits  were  made  by the EPA project
officer and the contractor to each plant selected as  a  sampling
site.   During  the  first  visit,  an engineering reconnaissance
visit,  sample  point  locations  which  represented   the   most
appropriate  flow  measurement locations were identified, and any
questions about plant  operations  were  resolved,  so  that  the
sampling  team leader could become sufficiently familiar with the
plant to  conduct  a  technically  sound  sampling  survey.   The
information   collected  during  the  engineering  reconnaissance
visit, together with the previously  obtained  information  about
the plant, was organized into a detailed sampling plan.
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During  the  second  visit  to  the plant,  the actual sampling was
conducted.   In addition  to  the  wastewater  sampling  and  flow
measurement  tasks performed during the sampling visits, specific
technical  information was also  obtained for each  sampled  plant.
This  technical   information included production and raw material
usage, during the period of  sampling,  and  routine  maintenance
procedures   and  equipment.   Also,  during  the sampling visits,
existing  or  potential  problems  and   preventive   maintenance
procedures   associated  with the use of extensive recycle systems
were discussed with plant personnel.

Additional engineering visits (no samples  were  collected  during
these  visits)  were  made  at  three  plants  for the purpose of
obtaining technical information.  During a previous EPA study  of
the  foundry  industry,  samples  were collected at 19 foundries.
Therefore, the total number of  foundries visited is  forty-three,
of which forty were sampled.

Analyses  of  the  samples  collected  at  the visited plants were
performed in accordance with EPA protocols.  These protocols  are
detailed  in  "Screening and Analysis Procedures for Screening of
Industrial Effluents for Priority Pollutants," March 1977 revised
April 1977, U.S. EPA (short form of title: "Screening Protocol").

A major goal of this study was  the  characterization  of  foundry
process  wastewaters  with  respect  to  toxic pollutants.  These
efforts  were  conducted  in  response  to the  1976  Settlement
Agreement.  A complete list of  the toxic pollutants, as developed
from  the  Settlement  Agreement  and  in  the Clean Water Act, is
presented in Table V-9.   Analyses  were   also  performed  for  a
number  of  other  pollutants,  some of which result from foundry
processes.   These  pollutants  are  identified  on  Table  V-10.
Analyses  for  several  of  these pollutants, i.e., total solids,
temperature, calcium hardness,  alkalinity, acidity, and pH,  were
performed   so   that   Langelier  Saturation  Indices  could  be
determined for various high recycle rate systems.  The  Langelier
Saturation   Index  provided  data  which   were used to assess the
scaling  or  corrosion  problems  that  can  be  associated  with
wastewater recycle systems.

In a two-phase sampling and analysis program, EPA checked for the
presence  and  quantities  in   foundry  wastewaters  of the toxic
pollutants designated in the Clean Water Act.  In addition to the
129 toxic pollutants, EPA sampled for several other  conventional
and  nonconventional  pollutants (such as  total suspended solids,
oil  and  grease,  pH,   iron,    ammonia,  cyanide,  and   nontoxic
phenols).
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EPA  derived  data  in  a  field  sampling  program  designed  to
determine   the   concentrations   of  „ pollutants   in   foundry
wastewaters.   Sampled  plants"were selected to be representative
of the manufacturing processes,  the prevalent mix  of  production
among  plants,  and  the in-place treatment technologies found in
the  industry.   EPA  obtained  and  analyzed  samples  from   40
facilities.   Before  visiting  a  plant,  EPA reviewed available
plant specific data on  manufacturing  processes  and  wastewater
treatment.   The  Agency selected representative points to sample
the raw wastewater  leaving  the  manufacturing  process  or  air
pollution  control  device  prior  to treatment and to sample the
final treated  effluent.   The  Agency  prepared,  reviewed,  and
approved  a  detailed  sampling  plan showing the selected sample
points and the overall sampling procedure.

Under the sampling plan, the Agency conducted the sampling in the
following  manner:  sampling  visits  were  made   during   three
consecutive days of plant operation.  Raw wastewater samples were
collected   before  treatment.   Treated  effluent  samples  were
collected   following   application   of    in—place    treatment
technologies.   EPA  also sampled plant  intake water to determine
the  presence   of   pollutants   prior   to   contamination   by
manufacturing processes.

This  first phase of the sampling program detected and quantified
waste constituents included in the list  of 129 toxic  pollutants.
Wherever possible, each sample of an individual raw waste stream,
or  a treated effluent was collected by  an automatic, time-series
compositor over three consecutive  8  to  24  hour  sampling  and
operational   periods.    Where  automatic  compositing  was  not
possible, grab samples were collected  and  composited  manually.
The  second  phase of the sampling program confirmed the presence
and further quantified the concentrations and waste  loadings  of
the toxic pollutants found during the"first phase"of the program.

Metals  analyses were performed by the flame and flameless atomic
adsorption methods.  The flameless method was  used  for  mercury
analyses.    ... .          	

Analyses  for  cyanide  and cyanide amenable to chlorination were
performed using methods promulgated by the Agency  under  Section
304(h) of the Act  (304(h)"methods).

Analysis  for  asbestos  fibers  included  transmission  electron
microscopy, with selected area diffraction.  Analysis results were
reported  as chrysotile fiber count.
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 Analyses  for  conventional   pollutants  (TSS,   pH,   and  oil   and
 grease)   and  nonconventional   pollutants (ammonia,  fluoride,  and
 iron,  etc.)  were performed  by  304(h)  methods.

 EPA  employed   the  analytical  methods  for   the  toxic   organic
 pollutants   that  are  described  in   the sampling  and analytical
 protocol.  This protocol  is set forth in "Sampling   and  Analysis
 Procedures   for  Screening   of  Industrial Effluents for  Priority
 Pollutants", revised April,  1977.
Analysis    for    total    phenols    was
4-aminoantipyrine (4AAP)  method.
performed   using
the
During  both  phases  of  this  study,  all  samples were  analyzed  for
all  toxic  organic   pollutants,  while   Phase  II  toxic  metals
analyses were done selectively  depending on  the screening  results
of  Phase   I.   Screening visits were conducted first  to  generally
characterize the wastewater quality  of foundry  operations.    For
these visits, analyses were performed for all toxic metals (refer
to Table V-9).  After evaluating  the screening program analytical
data  and the data presented  in Tables V-ll  and V-12, those  toxic
metal pollutants found below  the  level of treatability   or  below
quantifiable    levels   in  a  particular foundry  process  were
eliminated  from further  analytical or regulatory  consideration.
There  are  no  data  presented  in   Tables  V-ll and  V-12  for  the
casting quench  and mold  cooling process  segment  of   the  ferrous
subcategory,  because no  toxic  metal  pollutants were  found, or
believed to be  present,   in   significant  concentrations.    Table
V-ll presents a summary  of the  plant assessments (as  noted in  the
DCP  responses)  of   the known  or   believed  presence  of  toxic
pollutants  in each subcategory.   Table V-12  presents  a summary of
the toxic pollutants  expected,  on the basis of  an  engineering
assessment,   to   be   present  in   each subcategory's  process
wastewaters.  Refer to Section  VI for a  discussion of the  factors
used to evaluate the  environmental significance  of   the  various
pollutants.

After  the  data  gathered  during   the   screening  program  were
evaluated, subsequent analyses  were   performed  for   those  toxic
metals  which warranted  further verification in each  subcategory.
The toxic metal pollutants selected  for  verification  analyses are
presented in Table V-13.

As a number of  toxic  organic  pollutants  were  suspected  to  be
present or detected (refer to the above  data) in each of the four
analytical classes of toxic organic  pollutants,  it was determined
that  it  would be more  practical, from  an analytical standpoint,
to perform analyses   for  all   toxic  organics  for  all   samples
                               134

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collected    Published information pertinent to raw materials and
process chemicals used in  the  casting  manufacturing  processes
indicated  that many toxic organic pollutants could be present in
these materials.  Table V-14 presents a  summary  of  the  annual
conlumpUon  of  process  chemicals  in  the form of additives or
binders, as noted in the plant DCP responses.  Information on the
raw materials used in the metal molding and casting processes  is
presented in the glossary.


WATER USE AND WASTE CHARACTERISTICS

Incoming Water Analysis

Incoming  water samples were collected for each sampled plant and
analyzed  for  various  pollutants   as   previously   discussed.
Overall, these analyses revealed  few pollutants at  concentrations
above   the  minimum quantifiable  limit of the specific analytical
method  or at concentration  levels significant  enough  to  street
the  anticipated  design  of   a   waste  treatment   system.   Where
incoming   (i.e.,  makeup)   water  concentrations    of   regulated
pollutants  are  of a significant level,  the environmental impact
will be assessed  on  a   case-by-case  level  by   the  respective
regulatory  authorities.

Raw Waste Analysis

The  analytical  data   base generated  as  a  result  of .the  sampling
effort  is  presented  in  Supplement B to the  Technical   Development
Document.   After.reviewing the  analytical  data,  those pollutants
which  could be considered for  regulation  in each  subcategory were
 identified.   Upon a  further review  (detailed in   Section   VI)   of
 the  information obtained as a  result of  this evaluation,  lists  of
 those  pollutants to  be  considered for  regulation  for  each process
 were   developed.  The  sampled  plant analytical  data  both raw and
 treated  wastewater)   presented   in  this  section  (Tables, V-15
 through  V-31)  refer   to these  selected pollutants.   Tables^V-32
 through V-37  present profiles  of the  raw  wastewater  analytical
 data   obtained  as   a  result   of  the  sampling  programs in each
 subcategory.    For   definitions   of  the  various   control    and
 treatment  technology  codes  used  in  Tables V-15 through  V-31,
 refer  to Table 111-21.

 Effluent Analysis

 Samples of the final plant effluents were taken for every day  of
 sampling.   Since  a  number  of .plants had. two or more effluent
 discharges, samples were  taken  of  each  effluent.    For  those
 sampled plants which did not have an effluent discharge (i.e.,  no
                                135

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 discharge  of  process  wastewater  to  a  surface  water or to a
 municipal  treatment  plant),   samples   of   treated   recycled
 wastewater  were  collected.   Where sampled plants had more than
 one completely recycled stream, each recycle stream was sampled.

 Aluminum Foundries

 An estimated  3.94  billion  liters  (1.04  billion  gallons)  of
 process  wastewater  are  generated  each  year in the casting of
 aluminum.  Fifty-six percent  of  this  wastewater  is  recycled
 while 38 percent is discharged to navigable waters,  and 6 percent
 is discharged to POTWs
 Investment Casting Process

 An  estimated  45.32  million  liters  (11.97 million gallons)  of
 process wastewater are generated each year  by investment  casting
 processes.    This  represents  1.2  percent   of the total process
 wastewater  flow  at   plants   within   the   aluminum   casting
 subcategory.    Twenty-nine  percent of this  flow is discharged  to
 navigable waters,  while 71  percent is discharged to POTWs.   Plant
 S2rX«y  responses indicated applied flow rates ranging from a  low
 of 20,400 1/kkg (4,900 gal/ton)  to a high of 53,290 1/kkg (12,800
 gal/ton/.

 A   general  process   and  water   flow diagram of a  representative
 aluminum  investment  casting operation is  presented  in Figure III-
 4.   The process wastewater  in this operation results  from several
 processes.    The  processes  are   mold backup,   hydroblast    (of
 castings),    and  dust  collection  (used   in  conjunction   with
 hydroblasting and  the  handling of   the investment  material  and
 castings).    The major impact on the  waste loads results  from the
 use  of  the  investment  material.  The  type of   wax   used   in   mold
 formation   and   the  hydroblast  process  also  impact wastewater
 quality.

 A  review   of   the   three   respondents  employing   this   process
 indicated   that  in  two  of  the  plants, the  process wastewaters
 receive treatment via  settling (the other  plant's  discharge  is
 untreated).   The  three plants discharge all  process wastewaters
 to either a POTW or  to  navigable   waters  without   recycle    The
most  extensive  treatment system  was  installed  in  1977, and  this
plant was visited and  analytical data  was  obtained.   Treatment
components at this plant include polymer addition to promote floe
formation with a subsequent settling stage for solids removal
                              136

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Plant
are
       04704, Figure V-l ,  generates process wastewaters from mold
         hydroblSst casting cleaning, and dust collection   which.
     co-treated.   Polymer  is added to aid settling in a Lamella
      sector .  The Lamella sludge is filtered through^  paper
filter,  with  the  filtrate  being  returned  to the head_of the
treatment system.  The treated  effluent  is.  discharged  to  the
river.      '..,.  ,  " ''•  . .' "  ,":  ' ~     •' '"     "'".'".

Table   V-l 5   presents   the  raw  waste  and  treated  effluent
concentrations and waste  loads from this plant.
Melting Furnace Scrubber Process

An estimated 1254 million liters  (331 million gallons)  of  Process
wastewater are generated annually  by  melting   furnace scrubber
operaUons.   This  represents  31.8 percent of  the  total  process
wastewater  flow  at   plants   within    the   aluminum   casting
subcaTSgory.   Approximately,60 percent  of  this  flow is recycled,
while 40 percent  is discharged to  navigable waters.   Plant survey
responses  indicated a  range  of  applied   flow  rates  from  2,194
1/kkg   (527  gal/ton)  to 55,290  1/kkg  (13,280 gal/ton).   Recycle
rates varied from 37 percent to a  high of 97.5 percent.

A general  process and  water  flow  diagram of   a  representative
aluminum   foundry melting   operation  and its scrubber system is
presented  in Figure  111-5.,           • •      *       :  _

The  Quality and   cleanliness  of   the  material   charged  in  the
furnace"  influences   the  emissions  from the  furnace.  Generally,
aluminum  fCrnaces which melt high quality material do not  require
 "wet" air  pollution -control  ..devices  (e.g.,   after bur nexrs  may  be
used).    However, when   dirty,   oily   scrap  Is  .used, the  furnace-
emissions  are  often  controlled through  the use of scrubbers.  The
process  wastewater   from   these   scrubbers   may   be   either
recirculated    within   the   scrubber   equipment  package   (which
 includes   a   settling  chamber)   or   discharged  to ^an  external
 treatment system and then recycled back to the scrubber.

 A  review  of   the   five  respondents  using  melting  furnace gas
 scrubbing  equipment  indicates  that  process  wastewaters_  are
 handled  in a variety of ways, although they are generated in the
 same manner.   Table II1-4 describes the  treatment  systems^ used
 with this process.   All of the surveyed plants employ  some degree
 of  process  wastewater  recycle,  however some systems employ;an
 "internal" (within the scrubber equipment package)  recycle, while
 other plants recycle their process wastewaters  externally  after
 passing  through  various  treatment  stages.   Two of the plants
                                137 :

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  employ  internal  recycle   systems,   with   the  blowdowns  of  each
  system   being   introduced  untreated  to  a POTW.   These two plants
  are among  the  three  plants  with  the  highest  recycle   rates   (95
  percent  and   97.5   percent).    The  process wastewater treatment
  systems  used at  the  three remaining plants provide  for recycle  of
  externally treated process  wastewaters,  with the  blowdown being
  discharged to  a  receiving stream.   The treatment  systems  at these
  £j?h on0in?°rE°rate.^aSically   some  tyPe of  settling operation,
  with one plant providing  more extensive  treatment.
quench
 Plant 17089, Figure V-2, produces die casting and casting
 P^?S gss  wastewaters which are skimmed of oil and fchen C2
 with melting furnace scrubber process wastewaters.  At  the  time
 ?L.4.samp:4ng'  the  treatment  consisted  of  alum  and  polymer
 additions in a flash mix tank followed by clarification, pressure
 JjJ^1?"' reCy^le' and discharge.  The clarifier underflow  was
 thickened  and  dewatered in a centrifuge before being dried in a
 basin.   Sixty-five percent of the treated process wastewater  was
 reused  in  the  plant,  while  the  remainder  was discharged to
 navigable waters.   Since the completion  of  the  sampling  vist,
 this plant has added an activated carbon adsorption system.
 v     -18139,:u Fi9ure  V-3,   generates  process wastewater from a
 Venturi  scrubber on the aluminum melting furnaces.    The  process
 £a?!:ewater .1?.  ^circulated  through  a settling tank.   Overflow
 from the settling tank is mixed with process wastewaters from the
 zinc melting furnace and aluminum and zinc casting  quenches.   The
 mixed process wastewater passes through a settling  basin,  an   oil
 separator and storage tanks  before, discharge.

 Table   V-16  summarizes  the  raw  waste  and  treated   effluent
 concentrations and  waste loads  observed  during   the   sampling
Casting Quench Process

An  estimated  104.57  million  liters  (27.63 million  gallons) of
process wastewater are generated  each  year  by  casting  quench
operations.   This  represents  2.66 percent of the total process
SbS?;™*  fl°?  at  -PiantS   Withi"   the   aluminum   Casting
subcategory.   Forty-eight  percent  of this flow is recycled, 10
percent is discharged to navigable  waters,  and  42   percent  is
discharged to POTWs.  Plant survey responses indicated a range of
a?Pi^?V?5? r^es from 6.05 1/kkg (1<45 gal/ton) to 28/590 J/kk
16,866 gal/ton).   Recycle rates varied from 0 to 100 percent   In
some  instances  no  applied flow could be assigned to a process,
since the castings were quenched in a tank with no  discharge  or
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only  very  infrequent dumps.  In these instances, the operations,
were considered to be TOO percent recycle, since the same  quench,
solution is continuously reused.

A  general  process  and  water  flow diagram of a representative
aluminum foundry casting quench operation is presented in , Figure
III-5.   The  process  wastewaters considered in association with
this operation are those wastewaters which  are  discharged  from
the  casting  quench  tanks.   Raw waste loads will depend on the
duration of the quenching cycle, the degree  of  quench  recycle,
the  quench solution additives used, and the contamination of the
quench solutions with wastes from other  sources   (hydraulic  oil
leaks,  etc.).  The major impact on the raw waste  loads, however,
is  due  to  the  nature  of  the  quenching  solution  and   the
contamination  of  the  quench  solutions  with wastes from other
sources.

A review of  the  twelve  plant  responses  with   casting  quench.
operations  indicates  that  all process wastewaters are generated
in the same manner, although they are handled   in- a  variety  of
ways.   The  treatment schemes  range from untreated discharges to
POTWs to complete recycle systems.   Refer  to  Table  II1-5  for
descriptions  of  the  treatment schemes  used in  this subcategory
segment.  All plants use some form of settling, even  if  this  is
only  accomplished  in  the  quench  tank   itself.   However, the
quantity  of  castings  quenched,  the  process  wastewater  flow
through  the  quench  tank,  and  the size  of the quench tank are
factors which may necessitate the need  for  a   separate--settling
stage to remove solids.

Of   the twelve plants with  casting quench operations  indicated in
their responses,  two plants  employed  TOO  percent  recycle and  two
plants  employed  a  90 percent recycle rate.   The  blowdowns  of^the
two  90 percent recycle plants as well as  the  discharges  of  four
other plants  (with  no recycle)  are  introduced untreated  to  POTWs.
Of   the   three  direct  discharge plants, one has treatment  via  a
settling  lagoon,  and  the other  two  provide  no  treatment.   The
process   wastewaters  of   one   plant  are  removed  by  a  contract
hauler.   Settling is  indicated  as  the only  treatment provided  for
casting quench process wastewaters.

Plant 10308,   Figure  V-4,   generates   zinc  die   casting   quench
wastes,  aluminum  die  casting quench  wastes, cutting and machining
coolant  wastes,  and impregnating wastes which are co-treated in.a
batch-type system.   The  zinc casting  quench waste is actually  the
effluent   from  a  system  which recycles the quench tank contents
 through  a settling and  skimming operation and back to the  quench
 tanks.   The zinc  casting quench wastes  represent  approximately 25
percent  of  the   total   treatment . volume.   After  undergoing  a
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 sulfuric  acid   and   alum   emulsion   break,   neutralization,
 flocculation  and  solids  separation,  the  treated  effluent is
 discharged to a land locked swamp.

 Plant 17089, Figure V-2, produces die casting and casting  quench
 process  wastewaters which are skimmed of oil and then co-treated
 with  melting  scrubber  process  wastewaters.     The   treatment
 consists  of  alum  and  polymer  additions  in  a flash mix tank
 followed by  clarification,  pressure  filtration,  recycle,  and
 discharge.   Clarifier  underflow is thickened and dewatered in a
 centrifuge before being dried in a basin.   Sixty-seven percent of
 the treated water is reused in the plant,  and  the  remainder  is
 discharged.

 Plant 18139,  Figure V-3,  has a number of die casting machines and
 associated  quench  tanks which are emptied on  a scheduled basis.
 The schedule results in the emptying of  one  1135.5  liter  (300
 gallon)   quench  tank  each operational day.   Each quench tank is
 emptied  approximately once a month.   The  quench  tank  discharge
 mixes with   melting  furnace  scrubber  discharges,  zinc casting
 quench tank  flows,  and other non-foundry flows  prior to  settling
 and  skimming.   The treated process  wastewaters are discharged to
 a  POTW.

 Table V-17   summarizes  the  raw waste  and  treated   effluent
 concentrations   and  waste  loads observed  at  these two plants
 during the sampling program.
Die Casting Process

An estimated 2.52  billion   liters   (0.665  billion   gallons)  of
process  wastewater  are  generated  each  year  by   die  casting
operations.  This represents 64.0 percent of  the  total  process
wastewater   flow   at   plants   within   the  aluminum  casting
subcategory.  An estimated 56.4 percent of this flow  is recycled,
while 37.5 percent is discharged to  navigable  waters,  and  6.1
percent is discharged to POTWs.  Plant survey responses indicated
a  range  of  applied  flow  rates  varying  from 371 1/kkg (88.9
gal/ton) to 60,358 1/kkg (14,464 gal/ton).  Recycle rates  varied
from 0 to 90 percent.

A  general  process  and  water  flow diagram of a representative
aluminum foundry die casting operation is depicted in Figure III-
5.  The  various  sources  of  wastewaters  in  the  die  casting
operations  are  contact  mold cooling water,  die surface cooling
sprays,  casting machine hydraulic cooling  systems  using  water,
and  leakage  from  various  noncontact cooling systems which are
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subsequently contaminated with hydraulic oils,  lubricants/  etc.
Depending upon the degree of maintenance performed on the various
die  casting  systems,  the  major  source of process wastewa-ters
could vary from surface cooling sprays, in the  case  of  a  well
maintained  operation,  to  contaminated  leakages in the case of
systems  which  receive  only  cursory  maintenance.   Preventive
maintenance can affect the volume and contaminants of die pasting
process  wastewater.  Refer to Table III-6 for process wastewater
source and treatment information,                         ;


Of the ten plants with die casting operations identified in their
responses, five recycle systems, at 37%, 79%, 80%, 90%, and  95%,
are  indicated.  Six of these ten plants discharge to POTWs.  One
of these plants employs emulsion breaking, skimming,  alum  feed,
flotation  and  additional  skimming.  Of the remaining five POTW
dischargers,,  three  plants   provide   no   process   wastewater
treatment, and two plants provide only, settling.

The  four  plants  discharging  to  navigable waters provide more
extensive treatment than the POTW dischargers.            ;

Of the seven plants employing some  type  of  process  wastewater
treatment system, the following technologies are  used:

a.   Settling and skimming  (7 plants): Primary solids  and  tramp
     oil removal is achieved with settling and skimming.   In some
     instances, recycle follows.

b.   Emulsion breaking  (5 plants):/  Using alum or sulfuric  acid
     or  both, the emulsified oils are broken out of the emulsion
     and are then removed as scum.

c.   pH adjustment, flocculation and   clarification   (4  plants):
     Lime,  polymer,  alum  and other chemicals are used to adjust
     waste pH and promote floe formation, after which  the  floe  is
     allowed to settle  in a clarifier.  This  step  provides  for
     metals  removal,   some  oil  removal,  and   enhanced , solids
     removal compared to settling tanks.

d.   Filtration  (2 plants): Two plants  use   filters   to  provide
     additional TSS and particulate pollutant removal.

Plant   17089, Figure  V-2, produces die  casting and  casting quench
wastes which are skimmed of oil and then  co-treated with   melting
scrubber wastewaters.   The  treatment consists of  alum  and polymer
additions  in a flash  mix tank followed by clarification, pressure
filtration,  recycle,   and  discharge.    Clarifier  underflow   is
thickened  and dewatered in  a "centrifuge before being  dried   in   a
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 basin.   Sixty-five percent of the treated water is reused in the
 plant, and the remainder is discharged.

 Plant 12040,  Figure V-5, produces aluminum and zinc  die  casting
 process  wastewaters which are co-treated.  After collection in a
 receiving tank where oil is skimmed,  they are  batch  treated  by
 emulsion  breaking,  flocculation  and settling before discharge.
 The released  oil is returned to the receiving tank for  skimming,
 and the settled wastes are vacuum filtered and dried before being
 land filled.   Filtrate water is returned to the receiving tank.

 Table   V-18   summarizes  the  raw  waste  and  treated  effluent
 concentrations and  waste  loads  observed  during  the  sampling
 program.
 Die  Lube  Process

 An   estimated   14.62   million   liters   (3.86   million  gallons)  of
 process   wastewater   are   generated  each   year    in    die    lube
 operations.    This  represents   0.37 percent  of  the total process
 wastewater   flow  at    plants    within   the   aluminum  casting
 subcategory.    Fifty-two   percent  of this  flow is  recycled, while
 14.5 percent is discharged to navigable  waters,  and 33 percent  is
 discharged to  POTWs.   Plant survey responses  indicated a range  of
 applied flow rates varying from a  low of 36.3  1/kkg (8.7 gal/ton)
 to a high of 270  1/kkg (71.  Plant survey  responses indicated the
 use of either  complete or  no recycle.

 A general process and  water flow diagram of a  representative  die
 casting  operation  employing   a  die lube system  is presented  in
 Figure III-5.

 The die lube operation involves  the  spraying  of  a   lubricating
 solution  onto  the die surface prior to  casting.   These solutions
 are emulsions which  contain  certain  "casting  release"  agents
 which  permit the casting  to fall  away or  be removed readily from
 the dies.

 A review of the four plants with die lube  operations   identified
 in  their  survey responses  indicate that  the process  wastewaters
 are  generated  in  the  same  manner,    although   the   process
wastewaters  are  treated  in distinctly  different  ways.  Refer  to
Table III-7 for descriptions of  the various treatment  systems.  A
 100 percent recycle system  is in operation at one  plant  and  was
observed  during  a  sampling visit,  while the other three plants
discharged all  die lube process wastewaters.  The  more  extensive
treatment systems were  installed after 1971.
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a.
b.
Of  the  three  foundries with process wastewater discharges, one
plant provided no treatment prior to its  discharge ^to  a  POTW,
another  plant  discharged  the  permeate from an ultrafiltration
unit to a POTW, and the remaining plant provided treatment  in  a
central  facility  prior  to  a  direct  discharge.  This central
facility (die lube flow  represented  only  7  percent  of  total
central   treatment  facility  flow)  provided  various  chemical
additions, biological  treatment,  and  clarification.   The  100
percent  recycle  plant used skimming, cyclonic separation, and a
paper filter to treat  its  process  wastewater  and  recover, die
lubricants.

The  various technologies in use at the three plants with process
wastewater treatment systems are as follows:

     Ultrafiltration Unit:  hydraulic pressure  is  used  to  drive
     the  aqueous  phase  of  the die lube  wastes  through a semi-
     permeable membrane.  Higher molecular  weight  organics remain
     behind that membrane.  Some lower molecular weight  organics
     pass through with the aqueous phase.

     Cyclonic  Separator, Skimming, Paper  Filter:   This system  is
     used   in  conjunction  with  a complete  recycle  operation  to
     provide for suspended solids removal,  tramp oil  removal, and
     recovery  of process chemicals.

     Flotation,  skimming, addition of ferric  chloride and   lime,
     lagoon,   trickling  filter, activated  sludge,  and clarifier.
     Note:  Die  lube  flow  is  only  seven  percent   of the   total
     plant  process  wastewater flow  to  the treatment system.

 Plant   20147,   Figure V-6,  indicated  that the sources of  die lube
 process wastewaters are:   1)  excess  die lube  sprayed on  the  dies
 for additional   cooling,  2)  leakage  from die cooling (noncontact
 cooling water  which becomes  mixed  with   process  wastewater),  3)
 leakage  from   hydraulic system cooling water (noncontact cooling
 water  which passes  through  a,heat  exchanger to cool the  hydraulic
 oil and becomes mixed with  process wastewater), and 4)   hydraulic
 oil leakage.

 Process  wastewater   is controlled in three ways.   On each shift,
 maintenance personnel inspect each die casting machine for'leaks.
 Where  necessary, repairs are made during the shift to reduce  the
 process  wastewater   flow.    Under the die of each machine,  a pan
 collects excess die lube which drips from the  die.   A  portable
 pump  and  tank  is   wheeled to each machine during each shift to
 collect the die lube  collected in the pans.  In addition, on  the
 floor around each die casting machine,  a dam contains the process
 wastewater  from  various  leaks.    Die  lubricant which does not
c.
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 collect  in  the pan  is  also  contained  by   the   dam.   The   process
 wastewater  collected   in   this  manner   flows  to  storaqe  tanks
 through  a floor drain.

 Stratification of the  process wastewater  into  three layers occurs
 in the storage tanks.   Tramp oil floats to the top and  is  removed
 by a belt collector.   The tramp oil   is   collected,  stored   and
 removed  by  a  contractor.   The  middle layer, comprised of die
 lubricant,  is removed  to a second tank.   From  this  second   tank
 the  die  lubricant  passes  through  a cyclonic filter.  The die
 lubricant removed through the top of  the  cyclone passes through a
 paper filter and then  is stored, until it is reused  on  the  die
 casting  machines.   The  material removed from the bottom of the
 cyclone is stored, until it is removed by a contract hauler.

 Die lubricants collected in the pans beneath the dies are removed
 to the reconstruction area of  the  plant,  where  the  used  die
 lubricant  passes  through  a  paper  filter,   is  mixed with new
 lubricant and  water to bring  it  up  to  specification,  and  is
 stored until needed on the die casting machines.

 Table   V-19  summarizes  the  raw  waste  and  treated  effluent
 concentrations and  waste  loads  observed  during  the  sampling
 program.

 Copper Foundries

 An estimated   7.20   billion  liters   (1.90  billion   gallons)  of
 process  wastewater result each  year  by the casting  of  copper   and
 copper   alloys.    Approximately   98.2   percent  of  this water  is
 recycled, while 1.4  percent  is  discharged   to   navigable waters
 and   0.4  percent   is  discharged  to  POTWs.  Complete  recycle  is
 practiced at plants  which generate 74.3 percent of  the  wastewater
 in this  subcategory.  Three  manufacturing  processes use water  in
 the copper casting subcategory.

 Dust  Collection Process

 An  estimated 814 million  liters  (215  million gallons)  of process
 wastewater result each  year by dust collection  operations     This
 represents   11.3  percent of the total process  wastewater flow at
 plants within the copper  casting  subcategory.   Of  this  total
 flow,   97.0  percent  is  recycled, while 3.0 percent is discharged
 to navigable waters.  None of the DCP  respondents indicated   that
process  wastewaters  from this process were discharged  to POTWs
Plant survey data indicate a range of applied flow rates  varying
from 63 1/kkg (15.1 gal/ton) to 8,440  1/kkg (2,027 gal/ton).  The
recycle rates indicated  in the plant survey data were either 0 or
 100 percent.
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A  general  process  and  water  flow diagram of a typical copper
foundry dust collection system is presented in Figure III-6.

Copper foundry dust collection operations use scrubbers to remove
airborne  participates.   The  dust  collection   systems   under
consideration  herein are used to remove the airborn particulates
generated as a result of molding sand handling  operations,  mold
making and casting shake out.  The major pollutant load from this
process  results from the casting sand itself and the binders and
process chemicals used in the molding and casting processes.

A  review  of  the  six  plant  responses  with  dust  collection
operations  indicates  that all process wastewaters are generated
in the same manner and are handled in the same manner, i.e.,  all
of  the  treatment  systems  employ  some  type of settling step.
Refer to Table II1-8 for descriptions of  the  treatment   systems
employed  in  this  subcategory segment.  Of the six plants using
this process, four plants employ  100 percent recycle systems, and.
two discharge all dust collector  process wastewaters.  Of  the TOO
percent recycle plants, three have   "internal"  recycle   systems,
while  one  plant recycles all dust  collector process wastewaters
through  a  settling   lagoon.   The  internal   recycle    systems
recirculate  process   wastewater  within  the  scrubber equipment
package as designed by the scrubber  manufacturer.  The two plants
with discharges provide settling  prior to the  discharge   of  all
dust collector process wastewaters to receiving streams.

Settling   to  achieve solids  removal   is  the  only  treatment
technology  identified  in  the  survey  responses.   Plant  19872,
Figure V-7, was observed during the  sampling program.  This plant
uses  a   dust  collector scrubber  with an  internal recycle rate  of
 100 percent.   Settled  sludge is removed by   a   dragout  mechanism
for   disposal.    Specific,   representative  raw  wastewater  and
treated effluent  samples  could not be obtained  at this plant.

Plant  09094,  Figure V-8,  produces process wastewater   from  three
 internal   recycle  dust   collectors. The process wastewaters are
 collected and treated  in  a  series of three   lagoons   to   provide
 solids   removal.    The  lagoon   effluent   is recycled back to the
 scrubbers.   Discharge  from  the  ponds was  eliminated in  1977  when
 the  ponds were dammed.  Additional  water  from the  lagoons is used
 to  sluice  the  sludge   from  the  settling  chambers  of  the three
 scrubbers to the  first pond. ,

 Table  V-20  summarizes   the  raw  waste   and  treated   effluent
 concentrations  and  waste   loads  observed  during  the sampling
 program.
                                145'

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 Mold Cooling and Casting Quench Process

 An estimated  6.39  billion  liters   (1.69  billion  gallons)  of
 process  wastewater  are  generated each year by mold cooling and
 casting quench operations.  This represents 88.7 percent  of  the
 total process wastewater flow at plants within the copper casting
 subcategory.    Approximately   98.3  percent  of  this  flow  is
 recycled, while 1.18 percent is discharged  to  navigable  waters
 and  0.48 percent is discharged to POTWs.  Plant survey responses
 indicated a range of applied flow rates varying  from  583  1/kka
 (140  gal/ton)  to  110,200  1/kkg (26,470 gal/ton).  All plants,
 except one, had discharge rates of 100  percent  of  the  applied
 flow.   The exception,  which had the largest applied flow rate (at
 least  eleven  times  greater  than  the next lowest applied flow
 rate),  had a recycle rate of 99.5 percent.

 A general process and  water  flow  diagram  of  a  representative
 copper  foundry dust collection system is presented in Figure III-
 O *

 Copper  casting foundries generate process wastewaters as a result
 o±   cooling  operations requiring contact cooling water  for  molds
 and quenches  for   castings  as   they  are  formed.    The  major
 pollutant  load   from  these operations is the  particles  of copper
 and alloying materials  which are  represented as  suspended  solids.
 These particles  settle  primarily  in  the cooling  and quench tanks,
 where periodically  the  solids  are  removed and  reclaimed.

 Review  of  the  responses of  the surveyed plants with mold   cooling
 and  casting    quench   operations   indicates  that  all   process
 wastewaters  are  generated  in the same  manner,  although the wastes
 are handled  in a variety of  ways.   Refer   to  Table I I 1-9   for
 descriptions  of  the treatment systems  employed  at these  plants
 Process  wastewater  handling  schemes   varied    from  untreated
              ?2JnS t0  Settlin9 an<* cooling.  Settling operations
               I
Of the six plants identified in the survey with this process, two
plants  discharge  all  of  their mold cooling and casting quench
process wastewaters untreated  to  POTWs,  three  plants  provide
settling   prior  to  the  discharge  of  all  of  their  process
wastewaters to a receiving stream, and the process wastewaters of
one plant are discharged to a POTW following  extensive  recycle
The recycle plant installed cooling towers in its recycle loops.'
   =4-     *-plantfu using  some  type  of  Process  wastewater
treatment  system,  the  various  technologies  employed  are  as
JLOX JLOWS •
                                146

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a.   Settling:  To provide solids removal.

b.   Settling, Recycle and Cooling Tower:  Settling  is  used  in
     the  system  with  a  high  recycle  rate  to provide solids
     removal.  Cooling is needed  to  maintain  the  proper  heat
     removal capabilities in the system.

Plant  04736,  Figure V-9, uses a mold cooling and casting quench
operation.   This  process  operates  with  a  higher  degree  of
recycle,  with  make-up via a float valve.  An auxilliary holding
tank is installed to maintain a water balance in this system.

Plant 06809, Figure V-10, recycles its mold cooling  and  casting
quench wastewaters through a cooling tower.  An overflow from the
hot  wells  serves  as a blowdown from this recycle system.  This
blowdown undergoes treatment (sedimentation and  skimming)  in  a
central  treatment  system.   The mold cooling and casting quench
wastewaters comprise 3 percent of the total flow to  the  central
lagoon.

Table   V-21  summarizes  the  raw  waste  and  treated  effluent
concentrations and  waste  loads  observed  during  the  sampling
program.

Iron and Steel (Ferrous) Foundries;

An  estimated  399.1  billion  liters   (105.4 billion gallons) of
process wastewater is generated  each  year  by  the  casting  of
ferrous  metals.   Seventy-five percent  is recycled, 23.3 percent
is discharged to navigable waters, and  1.9 percent is  discharged
to  POTWs.  An estimated 39.2 percent of  this flow is recycled at
100 percent.
Dust Collection Process

An estimated 208.9  billion   liters   (55.2  billion  gallons)  of
process  wastewater  is  generated  each  year  in dust  collection
operations.  This represents  approximately  52.3  percent  of   the
total  process  wastewater  flow  at  plants  within  the ferrous
casting subcategory.  Approximately 78.7 percent of this  process
segment's  flow  is recycled, while 20.1 percent  is introduced  into
navigable  waters  and   1.2   percent  is discharged to  POTWs.  An
estimated  45 percent of  this ;flow is  recycled  at  100 percent.
Plant  survey   responses  indicated a range of  applied  flow rates
varying from 171 1/kkg   (27   gal/ton)  to   96,200. 1/kkg   (16,840
gal/ton).  Recycle rates varied from  0 to,  100 percent.
                               147

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 Figure III-7 presents a general process and water flow diagram of
 a representative ferrous foundry dust collection operation.

 Ferrous  foundry dust collection systems use the various types of
 scrubbers,  described in Section III,  to remove airborne gases and
 particulates.   These dust collection  systems are used  to  remove
 the  airborne contaminants generated  as a result of sand handling
 operations,  mold and core making,  and mold and casting  shakeout.
 The major pollutant load results from the casting sand itself and
 the binders  and process chemicals  used in the molding and casting
 processes.    Test data from dust collection systems were obtained
 during the  sampling programs conducted during 1974 and 1978.

 A  review  of   the  147  plant   responses  with  dust  collection
 operations   indicates  that all process wastewaters are generated
 in the same  manner  and  are treated  in  essentially  the   same
 manner,   i.e.,   all  treatment   systems  are  primarily  settling
 operations.  Refer  to  Table  111-10  for  descriptions  of   the
 treatment systems used in this process.   Recycle rates vary  from
 0 to 100  percent.    Recycle systems  involved  both  "internal"
 (within   the  scrubber equipment package)  and "external" (through
 separate  waste treatment)  recycle  of  the process wastewaters.

 Of the 147 responses indicating the presence of  dust  collection
 scrubbers,   73   plants  indicated  that 100 percent of the process
 wastewaters  associated with their  dust collection  operation   are
 recycled.    Of   these  73  plants,  47  plants indicated 100 percent
 "internal" recycle within  the scrubber equipment package,  and  26
 plants indicated   100 percent  recycle of  process wastewater  with
 external  treatment provided.

 Seventy-four  plants  recycle   the    dust   collection   process
 wastewater at  less  than TOO  percent.   Thirty-five of  these plants
 discharge the  recycle overflow  untreated;  24  untreated  discharges
 go   to POTWs, and  11  untreated  discharges  go  to navigable waters.
 Of  the 39 other plants  discharging treated process   wastewaters,
 11  discharge to POTWS,  and  28 discharge  to navigable  waters.

 Sixteen  plants discharge  all of their process  wastewater  without
 any  recycle.  Nine   plants   provide   treatment   prior   to  direct
 discharge, and one plant discharges untreated process wastewaters
 to   navigable  waters.   Two  plants  provide   treatment  prior to
 discharge to POTWs,  and  4   plants  discharge   untreated   process
wastewaters to POTWs.
The
are:
various  treatment  technologies indicated in the plant data
                               148

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a.   "Internal" Recycle:  Settling for solids removal is.provided
     within a manufacturer's scrubber equipment package.   Sludge
     is  removed via an endless chain conveyor fitted with scoops
     to  move  the  sludge  from  the  settling  chamber  to   an
     appropriate receptor outside the scrubber.

b.   Settling With or Without  Chemical  Addition  and  Skimming:
     Solids  removal is accomplished in a variety of ways.  These
     methods include  lagoons,  clari-fiers,  tanks,  and  dragout
     chambers.   Polymer  or  other  chemicals  may  be  added to
     enhance solids removal •. \ Skimming is  'provided  for  surface
     scum removal.

Plant  55122,  Figure  V-l 1, was sampled during the 1974,sampling
program.   Dust  collector  process  wastewaters   from   casting
cooling,   core   room/  molding  and  cleaning  departments  are
collected and recirculated from a central sump.   Ninety  percent
of  the  process  wastewater is recirculated, while 10 percent is
discharged to a receiving stream.  A sidestream treatment  system
consists  of  a. cyclone  separator,  with  the  underflow screen
dewatered and solids  disposed  to- landfill,  while  the  screen
drains  to  the  central  sump.   The  cyclone overflow goes to a
thickener where polymer is added.   The  thickener  underflow  is
vacuum  filtered,  the  solids are disposed of at a landfill, and
the filtrate is returned to the thickener.

Plant 59101, Figure V-12, has a series of 12 bulk bed washer type
scrubbers in the foundry for the cleaning of molding and cleaning
dusts.  The process wastewater from these units is  pumped  to  a
collection  sump  and then to a lagoon.  No dust scrubber process
wastewater is recycled externally.

This plant also has a sand washing system  to  reclaim  sand  for
reuse.   The  process wastewater from this operation also is sent
to the lagoons.  The lagoons are arranged to give maximum use  of
the land area.  The inlet to the first lagoon  is arranged so that
the  heavy solids can be removed readily.  The lagoon overflow is
discharged to a receiving stream.

Plant 57775, Figure V-13, has a process wastewater  from  a  dust
scrubber.   The  process  wastewater  flows to a drag tank, where
solids separation occurs, and sludge is removed.  At the time  of
the  plant  visit  in   1974,  88  percent  of  the dust  collection
process wastewater was  recycled.   Since  that  time,  the  dust
collection  process wastewater has been combined with the melting
furnace scrubber process wastewater recirculation system, and 100
percent recycle of all process wastewater has  been achieved.   At
the  time  of  sampling,  a  raw  wastewater   sample could not be
                               149

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obtained;  therefore,  only  effluent  analytical  data  are   presented
for this plant  in  Table  V-22.

Plant  54219, Figure V-13,  has  a  scrubber  which cleans molding  and
cleaning   dusts.   The process  wastewaters from the  scrubber  drain
to a drag  tank, where a  flocculant  is   added,   and  solids  are
removed.   Ninety-eight  percent of   the  process  wastewater is
recycled to  the   collector,   while  the   overflow  goes  to  the
sanitary sewer.

Plant  55217,   Figure V-15,   has   a   wet  dust  collector  system.
Scrubber process wastewater flows to  a large   lagoon.    From  the
lagoon,  process   wastewater   is recirculated  back  to the dust
collection scrubbers.  This recirculation system is common  with
the  melting  furnace scrubber recirculation system.  There  is no
discharge  from  this common system.    All   process   wastewater   is
recirculated.

Plant  67100, Figure  V-15, has four scrubbers  to clean dusts from
sand mixing, mold  shakeout, and  shot  blast cleaning  operations.
They are mechanical-centrifugal  type  collectors.  After  settling,
a  portion of  the   wastewater  is  recycled  back to  the dust
collector, while the  remainder is   discharged  to   the   municipal
sanitary treatment plant.

Plant  56771,   Figure V-17, produces  dusts from  the molding  area,
core room  shakeout and cleaning  areas.  These  dusts are  cleaned
by  means  of a scrubber.  The process wastewater is settled in a
drag tank, where chemical  additions aid settling.   A  portion  of
the  process  wastewater is recycled,  while the  remaining  process
wastewater flow was discharged to a POTW  prior   to  1974.    Since
then the discharge has been eliminated.

Plant  15520, Figure V-18,  is a large  foundry with a complex  water
balance.   Dust  collection  scrubber  process   wastewaters, slag
quench process wastewaters, and  sand  washing process  wastewaters
are  settled  and  recycled  with make-up from noncontact  cooling
water.   As water balance upsets  occur, overflow   is  periodically
discharged to a POTW.

Plant  20009, Figure  V-19,  has four wet dust collectors  which  are
operated with an overflow  to a   POTW.   A  sand  reclaim   process
washes  the  sand  for  sand   recovery.    The  waste products  are
settled in a series of four lagoons.   Settled   sludge   from   the
ponds  is removed to  landfill.   Forty percent of the lagoon water
is discharged by overflow  to a POTW   ,  and  60  percent   of   the
process wastewater flow is recycled.
                               150

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Plant  07929,  Figure  V-20,  has  operated  nine dust collection
scrubbers at 100 percent  recycle  of  process  wastewater' since
1973.    These   nine   scrubbers  remove  airborne  particulates
generated in  the  casting  shakeout  area,  core  room  mullers,
pouring casting cooling lines, sand handling and transfer system,
and  the molding floor and molding line areas.  Western bentonite
clay is used in the foundry sand.   A  two  compartment  settling
concrete   tank   was  installed  in  1973.   Only  one  settling
compartment  is  used  at  a, time,  and,   as   necessary,   the
compartments  are  switched  to  allow  for  sludge removal.  The
solids are landfilled on  company  property.   An  inertial  grit
separator  was  installed  in 1978.  Prior to the installation of
the  grit  separator,   the   scrubbers   would   become   fouled
approximately  once-per month.  The fouling was believed by plant
personnel to be caused by bentonite clay.  The  cleaning  of  all
the  scrubbers  required  a  maintenance  effort of three men for
three 8-hour shifts.   At the;time of the installation of the grit
separator, a maintenance program employing a 1,000 psi  pump  and
hand held cleaning wand was initiated to clean the scrubbers on a
routine  basis.   All  scrubber cleaning is performed one weekend
per month by one maintenance man and a helper.

Plant 51115, Figure V-21,  has  two  interconnected  100  percent
recycle  process  wastewater  systems.   The treatment system was
originally installed in 1959.  Prior to 1976, process  wastewater
was  discharged to a navigable water.  In 1976 this discharge was
eliminated, when 100 percent recycle of  the  process  wastewater
was  achieved.   Three  scrubbers which clean dusts from the core
room and shakeout area are in operation at this foundry.  Process
wastewaters from the sand washer and the dust scrubbers  flow  by
gravity to a collection tank.  Water in the collection tank flows
via  gravity  to  the  grit  building  where  alum,  polymer, and
flocculant aids are added.  Solids are removed in  a  drag  tank.
Wastewater from the drag tank flows to a settling basin, where it
is  pumped  as  needed  to  the  dust collectors and sand washing
equipment.   Problems  were  encountered  with  the  100  percent
recycle   system  immediately  after  closing  the  loop.   These
problems were: 1) the determination  of  the  correct  amount  of
polymer  addition  required for optimum settling took a number of
weeks; 2) during this transition period plugging of the scrubbers
occurred; and 3) a larger than normal amount of solids  collected
in  the  settling  basin.   However,  after the correct amount of
polymer addition was determined and the proper water balance  was
achieved throughout the system, these problems were eliminated.
                               151

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Plant  50315,  Figure  V-22,  generates  process  wastewater from
scrubbers which clean dusts from sand  molding  operations.   The
process  wastewater drains to a lagoon for settling.  One hundred
percent of this process wastewater has been recycled back to  the
dust collection scrubbers since 1974.

Plant  59212,  Figure V-23, generates dust collector, slag quench
and  melting  scrubber  process  wastewaters,  which   are   then
collected in a drag tank.  Chemical additions to aid settling are
made, and the water is recirculated.

Solids are removed by the drag conveyor, and overflow wastewaters
drain  to  a  second settling tank.  Two settling ponds have been
added since 1974.  Treated wastewaters are discharged to a POTW.

Plant 53642, Figure V-24, has a scrubber system for the  cleaning
of  dusts  collected in the molding, core room, pouring, cooling,
and cleaning areas.  The process wastewater flows  to  a  primary
settl-ing  tank  and  then  is pumped to a cyclone separator.  The
cyclone underflow  flows  to  a  classifier  for  dewatering  and
removal of solids, with the settled wastewaters being returned to
the  primary tank.  The upflow from the cyclones goes to a second
tank for recycle, with a blowdown  (10 percent)  to  a  thickener.
Alum  and polymer are added at the thickener.  The underflow goes
to a vacuum filter.  The filter cake goes to a landfill, and  the
filtrate is returned to the thickener.  The thickener overflow is
available for reuse or discharge to the river.

Plant   06956,  Figure  V-25,  generates  wastewaters  from  dust
collection,  melting  furnace  scrubber,   and   slag   quenching
operations.   These  wastewaters are combined for treatment.  The
wastewaters are first treated in a clarifier with  polymer  added
to  enhance  solids  removal  and  lime added for pH control.  The
clarifier effluent flows to a lagoon from which a portion of  the
treated  wastewaters  are recycled to the processes listed above.
The lagoon not only provides system  holding  capacity  but  also
provides  additional solids removal capability.  Clarifier sludge
is transported to a landfill disposal site.  The overall  recycle
rate  of this combined system is 95%; the remainder is discharged
to a receiving stream.

Table  V-22  summarizes  the  raw  waste  and  treated   effluent
concentrations  and  waste  loads  observed  during  the sampling
programs.
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Melting Furnace Scrubber Process

An estimated 118.7  billion  liters  (31.4  billion  gallons)  of
process  wastewater  are  generated  each year in melting furnace
scrubber operations.  This represents 30  percent  of  the  total
process  wastewater  flow  at  plants  within the ferrous casting
subcategory.  Approximately 79 percent of this" flow is  recycled,
while  19.6  percent  is  discharged to navigable waters, and 1.0
percent is discharged to POTWs.  An  estimated  41.8  percent  of
this  flow  is  recycled  at 100 percent.  Plant survey responses
indicated a range of applied  flow  rates  from  620  1/kkg  (149
gal/ton) to 39,780 1/kkg (9,555 gal/ton).

A  general  process  and  water  flow diagram of a representative
ferrous foundry melting furnace scrubber operation  is  presented
in Figure II1-7.

The  major  pollutant  load  is  due  to  the  amount,  type  and
cleanliness of scrap and metal used in the furnace charge and the
various by-products associated with the melting process.

A review  of  the  82  plants  responses  with  furnace  scrubber
operations  indicates  that  the process wastewaters are not only
generated  in  a  similar  manner,  but  also  are   treated   in
essentially   the   same  manner.   Refer  to  Table  III--11-  for
descriptions of the treatment systems  used  by  plants  in  this
subcategory  segment.   Recycle  rates  may  vary  from  0 to 100
percent,  and  recycle  systems  employ   both   "internal"   and
"external" treatment systems.

Of the 82 plant responses indicating the use of a melting furnace
scrubber  system, 42 plants have 100 percent recycle systems.  Of
these 42 plants,  20  have  "internal"  recycle  systems  and  22
provide  external treatment for the recycled process wastewaters.
Another 40 plants employ recycle systems with recycle rates  less
than  100  percent.   Of these 40 plants, 4 plants have untreated
discharges  to  POTWs,  13  plants  discharge   treated   process
wastewaters  to  a  POTW,  19  plants  discharge  treated process
wastewaters to a receiving  stream,  and  four  plants  discharge
untreated  process  wastewaters to a receiving stream.  The above
mentioned untreated discharges  are  typically  internal  recycle
system blowdowns.
The
are:
various  treatment  technologies indicated in the plant data
a.   Internal Recycle:  These systems provide solids removal  via
     some  type  of settling operaton.  In some instances various
                               153

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     chemicals are added to provide pH
     solids removal.
adjustment  and  enhanced
b.   External  Recycle,  Settling  With   or   Without    Chemical
     Addition:    These  systems  use  lagoons,  settling  tanks,
     dragout chambers, or clarifiers to accomplish      solids
     removal.  Various chemicals are added for the purposes of pH
     adjustment and enhanced solids removal.
Note that both the  internal and external
essentially the same treatment process.
  treatment  systems  use
Plant  06956,  Figure  V-25,  generates  wastewaters from melting
furnace scrubber, slag quenching, and dust collection operations.
These wastewaters are combined for  treatment.   The  wastewaters
are first treated in a clarifier with polymer addition to enhance
solids  removal  and lime addition for pH control.  The clarifier
effluent flows to a lagoon from which a portion  of  the  treated
wastewaters  are  recycled  to  the  processes listed above.  The
lagoon  not  only  provides  system  holding  capacity  but  also
provides  additional solids removal capability.  Clarifier sludge
is transported to a landfill disposal site.   A  portion  of  the
wastewater  flow is discharged from the lagoon.  The recycle rate
of the combined treatment system is 95 percent.

Plant 52491, Figure V-26, has a Venturi scrubber for  control  of
cupola  emissions.   The  process  wastewater  is  collected in a
settling tank where caustic is added.  The overflow  is  recycled
to  the Venturi scrubber.  This flow is adjusted to give a slight
surplus of return water in the settling tank.   This  surplus  is
discharged  to the city sewer.  The settling tank is dumped daily
to a dewater box.  After additional settling in the dewater  box,
the  water  is  returned  to the settling tank and the solids are
landfilled.

Plant 57775, Figure V-13, produces  process  wastewaters  from  a
melting  furnace scrubber system which are treated in a drag tank
by addition of caustic and polymer.  Solids  are  landfilled  and
the  process wastewater is recycled.  At the time of the sampling
in 1973, some overflow from the drag tank drained to the sanitary
sewer.  However, since collection of plant  data  in  1973,  this
plant has closed the loop on the melting furnace scrubber system,
i.e., no process wastewater is now discharged.

Plant  53219, Figure V-14, has a Venturi scrubber and a separator
on the cupola.  The separator has a conical bottom that  collects
heavy  solids.   Caustic  is  added  to the separator via a pump.
Water is pumped  from  the  separator  to  the  process,  and  an
overflow  from  the  separator  discharges to the sanitary sewer.
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The separator is drained, at the end of  the  cupola  run,
dewatering tank, and the solids are sent to a landfill.
to
Plant  56789,  Figure  V-27,  operates a cupola Venturi scrubber.
The scrubber process wastewater drains to a classifier tank where
caustic and polyelectrolytes are added.  The underflow goes to  a
drag  tank  where  solids are settled and removed.  The drag tank
overflow is recycled to the classifier and the excess is  drained
to  a transfer tank.  Wastewater in the overflow transfer tank is
pumped to a storage tank.  Caustic is added at the overflow  tank
for  corrosion  control.  All process wastewater from the melting
furnace scrubber has been recycled since 1974.

Plant 58589 Figure V-28, has a melting furnace  scrubber  process
wastewater  which is collected in a separator, and then pumped to
a large sump.  After settling overnight, the contents of the sump
are siphoned to a second sump.  Water from this  second  sump  is
recycled to the quench chamber scrubber the next day.  This plant
recycles  all of its melting ;furnace process wastewaters.  Solids
are removed from the Jirst sump on a bi-monthly basis.
Plant 56123,  Figure  V-29,  collects  melting  furnace  scrubber
process  wastewaters  in  a  drag tank where caustic is added and
heavy solids are removed.  The overflow from this tank goes to  a
filtrate  tank  where  a  portion  of  the  process wastewater is
recycled  to  the  furnace  scrubber.   A  sidestream  from  this
filtrate  tank  passes  through  cyclone  classifiers and then to
pressure sand filters.  From the sand filters the treated process
wastewater returns to the filtrate tank.  The filter backwash  is
blown down to a surge tank and then to a floe tank where chemical
additions are made.  The floe tank overflows to a clarifier. L The
clarifier  underflow is delivered to a landfill, and the overflow
is discharged to municipal sanitary sewers.

Plant 55217, Figure V-l5, generates process wastewaters from  the
melting  furnace  scrubber  on a triplex cupola arrangement.  The
process wastewaters are collected in a slurry tank.   Caustic  is
added,  and  the  wastewater  is pumped to a large lagoon that is
shared with another plant.  Since 1974,  all  process  wastewater
from the melting furnace scrubber has been recycled.

Plant 50315, Figure V-22, and Plant 55217 share settling lagoons.
The  process  wastewater from the melting furnace scrubbers flows
to the lagoon and is recycled  from  the  lagoon  to  the  cupola
emission  system.   Since  1974,  all process wastewater from the
melting furnace scrubber has been recycled.

Plant 54321, Figure  V-30,  generates  melting  furnace  scrubber
process wastewaters and slag quench process wastewaters which are
                               155.

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drained to a drag tank.  A classifier removes solids continuously
from   a  sidestream,  while  the  settled  material   is  removed
continuously by the drag conveyor.  Hydrated  lime  is  added  to
control corrosion.  Pumps recycle water from the drag  tank to the
quencher  and Venturi scrubber on the melting furnace.  Since the
collection of plant data in 1974, this plant has closed the  'loop
on  the  recycle  of  process wastewater from the melting furnace
scrubber.  There is no process  wastewater  discharge  from  this
system.

Plant  56771,  Figure  V-17,  has a system similar to plant 54321
with the addition of an aftercooler and a cooling  tower.   These
two units reduce stack temperature and carryover.  And like plant
59321,  this  plant has closed the loop on the recycle of process
wastewater from the melting furnace scrubber.

Plant 52881, Figure V-31, has a system that is a duplicate of the
treatment system used at Plant 54321.  As at  Plant  54321,  this
plant has closed the loop on the furnace scrubber recycle system.

Plant  59212,  Figure  V-23,  generates  melting furnace scrubber
process wastewaters, together with dust scrubber and slag  quench
process   wastewaters   which  are  collected  in  a  drag  tank.
Chemicals are added to the drag tank to  aid  settling.   Process
wastewater  from  the  drag  tank  is  recirculated  to  the mist
eliminator.  Process  wastewater  from  the  mist  eliminator  is
pumped   through   two   cyclones,  with  the  clarified  process
wastewater going to the furnace scrubber  and  returning  through
the  mist  eliminator  to the cyclones.  The cyclone underflow is
drained to the drag tank.  Solids are removed in the drag tank by
a drag conveyor.  Overflow from the drag tank drains to a  second
settling  tank.  Process wastewater from the second settling tank
discharges to a POTW.

Plant 00001, Figure V-32,  operates  a  cupola  furnace  with  an
emission  control  system  similar  to  plant 07170.  The settled
particulates are discharged to a  landfill  daily.   Settling  is
aided  by  a  cyclone  and a classifier in the system, as well as
chemicals that are  added  during  operation.   The  particulates
settle  to  the  bottom  of  the  cyclone due to inertial action.
These are piped  to  the  classifier,  where  further  settlement
collects  them  at  the  bottom of the cone.  After the cupola is
shut  down,  this  sludge  is  dumped  to  a  tote  bucket.   The
recirculating  pumps  are operated for a short period to cool the
system and to move  any  particulates  in  the  system  into  the
classifier.    After  settling  overnight,  the  classifier  cone
sediment is  again  dumped  to  the  tote  bucket.   This  system
operates  with  the  recycle of all process wastewater.  However,
due to the nature  of  this  system's  operations,  discrete  raw
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wastewater and treated effluent quality and load values could not
be determined.                ._,„       „,„_.

Plant 00002, Figure V-33, is similar to Plant 00001 with an added
feature  of  energy  recuperation  before the Venturi scrubber to
reclaim heat from the furnace exhaust gas stream.   The  Venturi,
separate  the  equipment,  hydraulic  cyclone  and classifier are
similar to Plant  00001.   The  methods  of  operation  are  also
similar.    Again,  this  system  recycles  all  of  its  process
wastewater. . As with plant OOOOT,  discrete  raw  wastewater  and
treated effluent quality and load values could not be determined.

Plant  15520, • Figure  V-18,  has a separate treatment system for
melting furnace  scrubber  process  wastewaters.   The  treatment
system  consists  of chemical'additions, clarification and vacuum
filtering  of  the  settled  material.   Clarifler  overflow   is
recycled  to  a  balance  tank  and  then  to the melting furnace
scrubber.  Noncontact cooling water is  used  as  makeup  to  the
melting furnace scrubber recirculating system.

Plant  07170,  Figure  V  34,  is a small gray iron foundry which
operates a melting furnace scrubber system.  The melting  furnace
operates  approximately  two  hours per day during which time all
system process wastewaters are recycled.  Caustic and polymer are^
added  to  the  process  wastewater  system   following   furnace
operation,  and  the  process  wastewater  is  allowed  to settle
overnight.  Prior to operation of the furnace the following  day,
the- settled  solids  are  drained  from  the system to a company
landfill.  All  process  wastewaters  are  recirculated  in  this
system.  As with plant 00001, discrete raw wastewater and treated
effluent quality and load values could not be determined.

Table   V-23  summarizes  the  raw  waste  and  treated  effluent
concentrations and  waste  loads  observed  during  the  sampling
programs.
Slag Quench Process

An  estimated  43.2  billion  liters   (11.4  billion  gallons) of
process wastewater are generated  each  year  by  slag  quenching
operations.   This  represents  10.8 percent of the total process
wastewater flow at plants within the ferrous casting subcategory.
Approximately 43 percent of this flow  is recycled,  53.4  percent
is  discharged to navigable waters, and 3.7 percent is discharged
to POTWs.  An estimated 11 percent of  this process wastewater  is
recycled  at  100  percent.   Plant  survey responses indicated a
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range of applied flow rates varying from  10.0  1/kkg  (2.4 gal/ton)
to 23,860 1/kkg (5,731 gal/ton).

Figure III-7 presents a general process and water flow diagram of
a representative ferrous foundry slag quenching operation.

In this operation, the slag removed during the melting  operation
is  quenched  in  order  to cool and thus solidify the slag.  The
quenched slag is subsequently removed for disposal   or  reuse  in
other  applications.   The  pollutants in this process wastewater
result from the slag quenching operation.

A review of the responses of the 63 plants  with  slag  quenching
operations  indicates  that  the process wastewaters are not only
generated in a similar manner but also are generally treated in a
similar manner.  Refer to Table II1-12 for  descriptions  of  the
treatment  systems  used  in  this  process.   Degrees of process
wastewater treatment  vary  from  no  treatment  at  all  to  the
recycling  of TOO percent of all process wastewaters.  The oldest
process wastewater treatment component was installed in 1948.

Of the  62  ferrous  foundries  with  slag  quenching  operations
indicated  in  the  plant  data,  16  plants recycle all of their
process wastewater, while 7  foundries  discharge  all  of  their
process  wastewaters  untreated to a POTW, and 4 plants discharge
all of their process wastewaters untreated to receiving  streams.
Eleven  plants  treat  and  then  discharge  all of  their process
wastewaters to POTWs, and 24 foundries treat and  then  discharge
all  of  their process wastewaters to receiving streams.  Twenty-
three plants have recycle systems with recycle  rates  less  than
100  percent;  14  of  these 23 facilities discharge a portion of
their wastewater flow to a  receiving  stream,  and  9  of  these
plants discharge a portion of their wastewater flow  to a POTW.

Settling with or without chemical addition is the basic treatment
system  indicated  in  the  plant  data.  Settling tanks, dragout
tanks, or clarifiers were  used  as  the  main  means  of  solids
removal.    Various  chemicals  (polymer, lime, caustic, etc.) are
added to the process wastewaters to aid in solids removal.

Plant 51026, Figure V-35, generates slag  quench,  mold  cooling,
casting   quench,   dust  collecting,  and  sand  washing  process
wastewaters which are drained to a series of lagoons,  and  after
84  hours  detention time are discharged to the river.  The first
lagoon in the series is  periodically  dredged  with  the  sludge
trucked  to  a nearby landfill.  During this clean-out operation,
the flow is diverted to a duplicate lagoon.
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Plant  54321,  Figure  V-30,  generates   slag   quench   process
wastewaters  and  melting  furnace  scrubber  process wastewaters
which, in turn,  drain  to  a  drag  tank.   A  sidestream  to  a
classifier removes solids continuously, as well as the continuous
removal  of settled material by the drag conveyor.  Hydrated lime
is added to control corrosion.  Pumps recycle all of the  process
wastewater from the drag tank to the quencher and Venturi.  There
are  insufficient data from this plant visit to characterize slag
quenching wastewater quality.

Plant 56771, Figure V-17, has a slag quenching system similar  to
the system atPlant 54321.   All process wastewater is recycled.

Plant 52881, Figure V-31, has a system that is a duplicate of the
system  at Plant 54321.  This system also recirculates all of its
process wastewater.

Plant 59212, Figure V-23, generates slag quench, dust  collector,
and  melting  furnace  scrubber  process  wastewaters  which  are
collected in a drag tank.  Chemical additions to aid settling are
made, and the water  is  recirculated  to  the  mist  eliminator.
Drainage  from the mist eliminator is pumped through two cyclones
with the clarified water  going  to  the  Venturi  and  returning
through  the  mist  eliminator  to  the  cyclones.   The  cyclone
underflow is drained to the drag tank.  Solids are removed by the
drag conveyor, and overflow water drains  to  a  second  settling
tank.   Treated  wastewaters  are discharged to a POTW.  There is
insufficient data from this  plant  visit  to  characterize  slag
quenching wastewater quality.

Plant  15520,  Figure  V-18,  generates  slag  quench water, dust
collection scrubber water,  and sand washing  process  wastewaters
which  are  settled  and  recycled  with  makeup  from noncontact
cooling water.  The wastewater discharge is directed to a POTW.

Plant 06956, Figure  V-24,   generates  process  wastewaters  from
melting  furnace  scrubber,  slag  quenching, and dust collection
operations.  These wastewaters are then combined  for  treatment.
The  process  wastewaters  are  first treated in a clarifier with
polymer added to enhance solids removal and  lime  added  for  pH
control.   The clarifier effluent flows to a lagoon, from which a
portion of the treated wastewaters are recycled to the  processes
listed  above.   The  lagoon  not  only  provides  system holding
capacity, but also provides additional solids removal capability.
Clarifier sludge is transported to a landfill disposal  site.   A
portion  of  the  wastewater  flow is discharged from the lagoon.
The recycle rate of the combined treatment system is 95 percent.
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Plant 55217, Figure V-15, applies water to the slag discharge  of
a cupola.  These wastewaters convey the solidified slag to a slag
quench  pit,  where  a  conveyor mechanism removes the slag.  The
slag  is  transported  to  a  disposal  site.    Slag   quenching
wastewaters  are  recycled, at a rate of 95%, from the pit to the
process.  The discharge from this quenching process is  delivered
to  a large lagoon which is shared with Plant 56123.  Since 1974,
all process wastewater has been recycled.   Plant  56123,  Figure
V-29,  operates  a slag quenching system similar to the system at
Plant 55217.  However, the  slag  quench  pit  discharges  to  an
additional  basin,  the  separation sump.  From this sump, 95% of
the flow is recycled to the slag quenching operation,  while  the
remainder  is  discharged  to a POTW.  There is insufficient data
from this plant visit to characterize slag  quenching  wastewater
quality.

Table   V-24  summarizes  the  raw  waste  and  treated  effluent
concentrations and  waste  loads  observed  during  the  sampling
programs.
Casting Quench and Mold Cooling Process

An  estimated  18.4  billion  liters  (4.87  billion  gallons) of
process wastewater are generated each year by casting quench  and
mold  cooling  operations.   This  represents  4.6 percent of the
total process  wastewater  flow  at  plants  within  the  ferrous
casting  subcategory.   Approximately  79 percent of this flow is
recycled, 12.3 percent is discharged to navigable waters, and 8.5
percent is discharged to POTWs.  An estimated 46 percent  of  the
total  process  wastewater  flow  is  completely recycled.  Plant
survey responses indicated a range of applied flow rates  varying
from 17 1/kkg (4 gal/ton) to 39,280 1/kkg (9,434 gal/ton).

Figure III-7 presents a general process and water flow diagram of
a  representative ferrous foundry mold cooling and casting quench
operation.

In this process, process wastewaters are generated as a result of
operations requiring quenching and contact cooling  waters.   The
various  types  of cooling and quenching operations are listed on
the summary Table 111-13.  The mold  cooling  operations  require
contact  cooling  waters (those mold cooling operations indicated
as using noncontact cooling  waters  were  not  included  on  the
summary  tables).   Quenching  of the castings takes place either
subsequent to casting or to a heat treatment operation  following
the  casting  operation.   The major impact on the waste loads is
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the suspended  solids,  which  consist  primarily  of  scale-like
material from the surface of the castings.

A  review  of the 48 plant responses with casting.quench and mold
cooling  operations  indicates   that,   although   the   process
wastewaters  are  similar in origin, several approaches are taken
for process wastewater treatment.   Refer  to  Table  111-13  for
descriptions   of   the   treatment   systems  employed  in  this
subcategory segment.  The degree of recycle varies from 0 to  TOO
percent.  The oldest treatment system dates from  1964.  Of the 48
foundries   with  casting  quench  and  mold  cooling  operations
indicated in  their  data,  11  plants  employ  complete  recycle
systems,   while   10  plants  discharge  all  of  their  process
wastewaters to POTWs untreated, and 8 plants discharge all of the
process wastewaters to a receiving stream without treatment.  Ten
plants provide  treatment  prior  to  discharging  all  of  their
process  wastewaters  to  receiving streams, and  9 plants provide
treatment for all of process wastewaters prior to discharge to  a
POTW.   Fourteen  foundries  employ  recycle systems with recycle
rates  less  then  100  percent,  with  10  of  these  operations
discharging  a portion of their process wastewater flow to a POTW
and  4  operations  discharging  a  portion  of   their   process
wastewater flow to receiving streams.

The  treatment  technologies  noted  in  the  plant  data  are as
follows:

a.   Settlings Solids removal is provided.  In some cases recycle
     follows.

b.   Cooling Tower and Settling:  The cooling tower  is  used  to
     provide a means of reducing the heat load on the system.  In
     some  cases  settling  is  incorporated  to  provide  solids
     removal as necessary.  The  cooling  tower   system  is  used
     generally on the higher recycle rate operations.

Plant 51026, Figure V-35, generates casting quench, mold cooling,
slag  quench, dust collecting, and sand washing wastewaters which
are drained to a series of lagoons, and after 84  hours  detention
time are discharged to the river.  The first lagoon in the series
is  periodically  dredged,  and the sludge is trucked to a nearby
landfill.  During this clean-out operation, the flow is  diverted
to a duplicate lagobn.

Plant  15654,  Figure V-36, employs a heat treated casting quench
operation  involving  the  complete  recycle   of   all   process
wastewaters.   The  treatment system utilizes a settling channel,
from which solids are removed infrequently, and a  cooling  tower
to provide for quench water cooling.
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Table   V-25  summarizes   the   raw  waste   and   treated   effluent
concentrations and  waste   loads  observed  during   the   sampling
program.
Sand Washing Process

An  estimated   9.89  billion   liters   (2.61  billion  gallons) of
process wastewater  are  generated  each  year  by  sand  washing
operations.   This  represents 2.5  percent of the total process
wastewater at plants  within   the  ferrous  casting  subcategory.
Approximately   65  percent  of this flow is recycled, while 25.3
percent is discharged to navigable  waters  and  9.4  percent  is
discharged  to  POTWs.   Though  two  plants have been identified
which completely recycle their process wastewaters.  One of these
plants, which lies outside of  the statistical  survey  framework,
was  sampled  during  the  original foundry industry study.  This
plant recirculates (at 100 percent) 171.8  million  liters  (45.4
million  gallons)  of  process wastewater per year in a combined
sand washing and dust collection system.  Seventy-two percent  of
the  process  wastewater  comes  from the sand washing operation.
Plant survey responses indicated an applied flow  rate  range  of
826 1/kkg (198  gal/ton) to 12,840 1/kkg (3,085 gal/ton).

A general process and water flow diagram of a representative sand
washing and reclamation system is presented in Figure II1-7.

In this operation, wastewaters are generated as a result of using
water  to  wash  the  used  casting sand.  The waters are used to
remove impurities, primarily "spent" binders and sand,  from  the
casting  sand  prior  to its reuse in the molding processes.  The
sand and binders become "spent" as a result of the  heat  present
in the casting process.  The major pollutant waste load is due to
the  various materials (primarily metals and binders) washed from
the sand.

It should be noted that various pieces  of  settling  and  solids
removal equipment are used in  the sand washing process to collect
and  dewater  the  sand  prior  to  its  drying  and reuse.  This
equipment is considered to be  part of the sand washing  operation
rather  than  a  part of the process wastewater treatment system.
As such, process wastewater treatment equipment is applied to the
discharges from the various pieces of sand washing equipment.

A review of the responses from 10 plants with  sand  washing  and
reclaiming  operations indicates that the process wastewaters are
not only generated in the same basic manner, but also are treated
in essentially  similar  systems.    Refer  to  Table  111-14  for
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descriptions  of  the  treatment  systems  used  in this process.
These systems vary from TOO  percent  discharge  to  100  percent
recycle  systems.   The  oldest  treatment  technology in use was
installed in 1950.

Of the 10 foundries with sand washing operations indicated "in the
plant  data,  1  plant  (01381)  recycles  all  of  its   process
wastewater,  while 4 plants treat and then discharge all of their
process wastewaters  to  receiving  streams.   Five  plants  have
recycle  rates less than 100 percent, with 4 plants discharging a
portion of their, wastewater flow to POTWs and 1 plant discharging
a portion of its process wastewater flow to a  receiving  stream.
As noted above, one of the previously sampled plants recycles all
of its process wastewaters.

Settling  is the basic treatment technology observed in all plant
responses.  Settling tanks, clarifiers, etc. are used in order to
provide solids removal.  Four of the plants incorporate a polymer
feed in order to enhance solids removal capabilities.

Plant 51473, Figure V-37, has a sand washing process.   The,  sand
from  shakeout  is  conveyed  to  a screen.  A magnetic separator
removes  all  metallicparticles  from  the  sand.   The  screen
oversize  (3/8  in.)  goes  to a mixer vessel where city water is
added.  This is thoroughly agitated and then pumped to  a  slurry
tank.   The  slurry tank meters the mix to a dewater table, where
the solids are screw conveyed to a rotary dryer.   The  underflow
from  the  dewater  table  is  pumped  to  a  settling tank.  The
settling tank is cleaned out on a weekly schedule, and the solids
are removed to landfill.  The treated effluent is discharged to a
receiving stream.

Plant 51115, Figure V-21,  generates  dust  collection  and  sand
washing wastewaters which are collected, treated with flocculants
and sent to a drag tank.  The sludge from this settling operation
goes  to  a landfill; the overflow water is drained to a settling
pond for additional settling.  Overflow from the  settling  basin
goes  to  a pump wet well.  This is pumped to a tank, where it is
pumped (as needed) to the dust collectors and  the  sand  washing
equipment.  This is a complete recycle system.

Plant   15520,   Figure  V-18,  generates  sand  washing  process
wastewaters, dust collection scrubber  process  wastewaters,  and
slag  quench  process wastewaters which are settled and recycled*
Makeup water is  from  noncontact  cooling  water.   Overflow  is
discharged to a POTW.

Plant  20009,  Figure  V-19, operates a sand reclamation process.
The sand washing process wastewater is settled  in  a  series  of
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four  lagoons.   Sixty  percent  of  the  process  wastewater  is
recycled, while 40 percent is discharged by overflow to a POTW.

Plant 51026, Figure V-35, generates sand washing,  mold  cooling,
casting quench, slag quench, and dust collecting scrubber process
wastewaters  which  are drained to a series of lagoons, and after
84 hours detention time are discharged to the river.   The  first
lagoon  in  the  series  is  periodically dredged with the sludge
being trucked  to  a  nearby  landfill.   During  this  clean-out
operation, the flow is diverted to a duplicate lagoon.

Plant  59101,  Figure  V-12, has a sand washing system to reclaim
sand for reuse.  The process wastewater from this operation flows
to lagoons.  The lagoons are arranged to give maximum use of  the
land area.  The inlet to the first lagoon is arranged so that the
heavy  solids  can  be  removed  readily.  The lagoon overflow is
discharged to a nearby creek.

Table  V-26  summarizes  the  raw  waste  and  treated   effluent
concentrations  and  waste  loads  observed  during  the sampling
program.

Lead Casting Operations

An estimated  86.3  million  liters  (22.8  million  gallons)  of
process  wastewater  are generated in the casting of lead.  Three
processes have been identified as using or having  the  potential
to use water in the casting of lead.
Continuous Strip Casting Process

An  estimated  8.58  million  liters
process wastewater result each year
casting  of  lead.   This  represents
process  wastewater  flow  at  plants
subcategory.  Plant survey responses
flow rates from 96 1/kkg (23 gal/ton)
with  one complete recycle operation
operation.  All wastewater effluents
discharged to POTWs.
 (2.27  million  gallons) of
from  the  continuous  strip
  9.8  percent  of the total
   in   the   lead   casting
indicated a range of applied
 to 207 1/kkg (49.7 gal/ton)
and one 85.5 percent recycle
in this process segment  are
Water  is  applied,  as a cooling medium, to the molds and to the
product itself.   These  waters  thus  become  contaminated  with
pollutants,  primarily the toxic metals, which are characteristic
of this subcategory and process segment.
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Refer to Table II1-16 for summaries of the  treatment  approaches
used in this process segment. Plant 10145, Figure V-38, employs a
neutralization tank, lagoon and filter to treat wastewaters prior
to discharge to a POTW.  The continuous strip casting wastewaters
are  combined  with  other  process wastewaters for treatment and
discharge.                 _                 -.--'.-•
Table V-27 summarizes the waste  concentration
observed in the sampling program.
and  waste  loads
Melting Furnace Scrubber Process

An  estimated  77.7  million  liters  (20.5  million  gallons) of
process wastewater result each year  from  lead  casting  melting
furnace  scrubber  operations.   This represents 90% of the total
process  wastewater  flow  at  plants   in   the   lead   casting
subcategory.  Plant survey respinses, summarized on Table 111-16,
indicated a range of applied flow rates from 25 1/kkg {6 gal/ton)
to 13,344 1/kkg (3,200 gal/ton).

Wastewaters  are  geherated in the process segment as "a result of
cleaning the gaseous and particulate emissions from  the  melting
furnace.   The  process  wastewaters  from these scrubbers may be
recirculated either within  the  scrubber  equipment  package  or
discharged to an external treatment system and then recycled.  Of
the  five  plants  in  the industry, four operate at 100% recycle
within the scrubber equipment package, while the remaining  plant
operates  with  a  99% recycle and a 1% blowdown to a POTW.  This
last   plant   recycles   its   process   wastewaters   following
sedimentation in a central treatment lagoon.


Grid Casting Process

As   incomplete   casting  data  were  provided  by  the  Battery
Manufacturing Industry, the Agency does not have specific process
wastewater   flow   information   for   this   process   segment.
Wastewaters  are  generated  in  this  segment  by  air pollution
control devices which are used to scrub.the  fumes  generated  in
the  pouring  and  casting  of  lead  into  battery grids.  After
evaluating the data and information  provided  by  air  pollution
control  equipment  vendors  and  the  industry,  the  Agency has
concluded that the grid casting and lead melting furnace scrubber
process segments are similar with respect to  the  generation  of
process wastewaters and wastewater characteristics.
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Magnesium Foundries

An  estimated  4.37  million  liters   (1.15  million  gallons) of
process wastewater are generated each  year  in  the  casting  of
magnesium.   Two  manufacturing processes have been identified as
using water in the magnesium casting subcategory.


Grinding Scrubber Process

An estimated  1.89  million  liters  (0.50  million  gallons)  of
process  wastewater  result  each  year from scrubbers collecting
dusts from the grinding of magnesium castings.   This  represents
43.3  percent  of  the total process wastewater flow at plants in
the  magnesium  casting  subcategory.   Plant  survey   responses
indicated  an  applied  flow  rate of  6,660 1/kkg (1,600 gal/ton)
with one 100  percent  recycle  operation  and  one  100  percent
discharge operation.

Figure II1-8 presents a general process and water flow diagram of
a representative magnesium foundry grinding scrubber operation.

Scrubbers  are  provided  on  grinding systems in order to remove
particulate magnesium generated  as  a  result  of  the  grinding
operation.   The  scrubbing process not only serves to remove the
particulate  magnesium  as  an  airborne  contaminant,  but  also
reduces the fire hazards which can result from an accumulation of
fine magnesium particles.

Of  the two foundries with grinding scrubber systems indicated in
the plant data,  one plant recycles all of its process  wastewater
and  one plant .discharges all of its process wastewater untreated
to  a  receiving  stream.   The  recycle  operation  employs   an
"internal"  scrubber  equipment  package  to  treat  the  process
wastewater.   Refer  to  Table  111-17  for  descriptions  of  the
treatment  approaches  used  in  the  magnesium  foundry grinding
scrubber systems.

Plant 08146, Figure V-39, employs a dust collector scrubber and a
magnesium grinding scrubber.  The process wastewaters from  these
scrubbers are discharged untreated to a receiving stream.

Table   V-28  summarizes  the  raw  waste  and  treated  effluent
concentrations and waste loads observed in the sampling program.
                              166

-------
Dust Collection Scrubber Process

An estimated 49962  liters  (0.65  million  gallons)  of  process
wastewater are generated each year in dust collection operations.
This represents 56.7% of the total process wastewater flow in the
magnesium  casting  subcategory.   One dust collection system was
indicated in the  plant  survey  data.   This  operation  had  an
applied  flow rate of 92 1/kkg  (22 gal/ton).  Refer to Table III-
18 for a summary of the DCP survey data from this plant.

Figure III-8 presents a general process and water flow diagram of
a representative magnesium foundry dust collection operation.

As described in the previous dust collection  system  discussion,
this  system is used to remove  airborne particulates generated as
a result of sand handling, mold making, and shakeout  operations.
The  major  pollutant  load  results  from  the  various  process
chemicals and binders withinthe casting sand.

The one foundry indicated in the plant data as utilizing  a , dust
collector   system  discharges  all  of  its  process  wastewater
untreated to a receiving stream.

Plant 08146, Figure V-39, uses  scrubbers to clean  sand  handling
dusts  and dusts arising from the grinding of magnesium castings.
The process wastewater flow is  discharged untreated.

This plant was visited during the sampling program, and  the  raw
waste  and  treated  effluent concentrations waste  loads observed
during this visit are summarized  in Table V-29.

Zinc Foundries

An estimated  9.48  billion  liters   (2.50  billion  gallons)  of
process  wastewater  are  generated   each  year  by  the  casting of
zinc.  Ninety-two and a half percent  of  this  flow  is  recycle,
while  1.9  percent  is  discharged   to  navigable waters and 5.5
percent  is discharged to POTWs.  Two  manufacturing processes have
been identified which use water in the zinc casting subcategory.

Die Casting and Casting Quench  Process

An estimated  548 million  liters (145  million  gallons) of  process
wastewater  are  generated  each  year  in die  casting and casting
quench operations.  This  represents   5.8  percent   of   the   total
process  wastewater  flow   at   plants within   the  zinc  casting
subcategory.  Of this process1  wastewater  flow  23.8  percent   is
recirculated,  while   30.2  percent   is  discharged to navigable
waters,  and 46.0 percent  is discharged  to  POTWs. An estimated  16
                               167

-------
 percent of the process wastewater is recirculated at 100 percent.
 Plant survey responses indicated that applied flow  rates  ranged
 from  20  1/kkg  to  8,960  1/kkg  (4.8  to  2,152 gal/ton) while
 effluent discharge flow rates ranged from 0 and 8,960 1/kkg to (0
 to 2,152 gal/ton.)

 General process and water flow diagrams of a  representative  die
 casting and casting quench operation are presented in Figure III-
 9.    The  process wastewater considered in this operation is that
 which is discharged from the casting quench tanks.

 Raw waste loads will vary depending  upon  the  duration  of  the
 quenching  cycle,   the degree of quenching recycle,  the nature of
 the quenching solutions used,  the nature (hardness,   corrosivity,
 etc.)  of the raw makeup water and the contamination  of the quench
 wastewater with wastes from other sources (example:  hydraulic oil
 leaks  from  the  die  casting  machines).    However,  all process
 wastewaters sampled  contained  zinc.    Test  data  from  casting
 quench   operations   indicated   the   expected  higher   metal
 concentrations from the  more  corrosive  streams  and  also  the
 expected results of contamination from other sources.

 A   review of the plant data within this subcategory  segment indi-
 cates  that die casting and casting quench process  wastewaters are
 handled in a variety of ways ,  although they are generated in the
 same   manner.    These  treatment  schemes  range  from  untreated
 discharges  to  discharges  to  publicly  owned treatment  works
 (POTWs),  and contractor  hauling  to   complete  recycle   systems.
 Refer   to  Table 111-19 for descriptions of  the treatment systems
 used  in this subcategory  segment.   Generally,  all plants  use some
 form of settling,  even if  this is only accomplished  in  the quench
 tank  itself.   However,  the quantity   of  castings  quenched,   the
 waste   flow  through  the  quench tank,  and  the size  of  the quench
 tank are factors which may necessitate the  need for   a   separate
 settling  stage.    One plant   employing emulsion   breaking,  pH
 adjustment,   flocculation   with   a  variety   of  chemicals    and
 clarification   installed   the   treatment equipment in  1956,  while
 two other  emulsion  breaking  systems were installed   in   1973   and
 1974.

Of the  20  zinc  foundries with  casting  quench  operations  indicated
 in the  plant data,  4  of these plants  indicated  that  they  employed
systems   involving   the  complete   (100  percent) recycle  of  their
casting  quench process wastewaters.  Four other  plants   utilized
systems  with  varying  rates  of  recycle less  than 100  percent.
Three of these systems had untreated discharges  to  POTWs,  while
the  other  plant  provided  more  extensive   treatment including
emulsion  breaking,   chemical  precipitation,   and  clarification
prior   to discharge  to a receiving stream.  Five of the 20 plants
                              168

-------
discharged, all of their casting quench wastewaters  untreated  to
publicly   owned   treatment   works  (POTWs),  and  five  plants
discharged treated wastewaters to a POTW.  Two plants  discharged
all   of  their  wastewaters  to  a  receiving•- stream  following
treatment.  The wastes of one plant were removed  by  a  contract
hauler.       ;  •             ;

Of  the 10 plants using some type of process wastewater treatment
system, the various technologies used are as follows:

     Settling and skimming: Removal of primary solids  and  tramp
     oils  is  achieved  through  settling and skimming.  In some
     instances recycle follows.

     Emulsion  breaking:   Using  alum   and  sulfuric  acid,   the
     emulsified  oils are broken out of  the emulsion and are then
     removed as a scum.
a.
b.
c.
     pH  adjustment,  flocculation  and   clarification:    Lime,
     polymer,  alum and other chemicals are used to adjust pH and
     promote floe formation after which the floe   is  allowed  to
     settle  in  the  clarifier.   This  step  provides for heavy
     metals removal, some oil removal, and   enhanced      solids
     removal compared to settling tanks.

Plant 18139, Figure V-3, has a number of die casting machines and
associated  quench  tanks which are emptied on a scheduled basis.
The-schedule results in the emptying of  one.  1135.5  "liter •• 1300
gallon)  quench  tank  each operational day.  Each quench tank is
emptied about once a month.  The quench tank discharge mixes with
melting furnace  scrubber  process  wastewater,  aluminum  casting
quench  tank flows, and other non-foundry flows prior to settling
and skimming.  The treated process :wastewaters are discharged  to
a   POTW.  The zinc quench process wastewater makes up 0.2 percent
of  the total flow.

Plant  04622,  Figure  V-40,  generates   casting   quench  process
wastewater  which   is  hauled   away  on   a   contract  basis  by  a
reprocessor.  The oil and grease and phenol  concentrations  in  the
process wastewater  of this plant are substantially higher than  in
the wastewaters  of  the other  two plants  sampled.   The   analytical
information for  this plant  is of  interest,  in  that  it  shows  the
results  of extensive,  contamination  with    non-quench    wastes
 (casting machine hydraulic  fluids  in particular).

Table   V-30   summarizes  the  raw   waste  and  treated  effluent
concentrations  waste  loads  for  those plants  visited.
                               169

-------
 Melting Furnace Scrubber Process

 An estimated  8.93  billion  liters  (2.36  billion  gallons)   of
 process  wastewater  are  generated  each year by melting furnace
 scrubber operations.   This represents 94  percent  of  the  total
 process  wastewater  flow  at  plants  within  the  zinc  casting
 subcategory.   Approximately ninety-seven percent of this  process
 wastewater   is  recirculated,  while 3.0 percent is discharged to
 POTWs,  and  0.2 percent is discharged  to  navigable  waters.    An
 estimated  63.2 percent of the process wastewater is recirculated
 at complete recycle operations.   Plant survey responses indicated
 a  low applied  flow rate of 22,770 1/kkg  (5,468  gal/ton)   and  a
 high  applied   flow  rate  of  102,840  1/kkg  (24,700  gal/ton).
 Recycle  rates  within  the  manufacturers'   scrubber   equipment
 packages ranged between 85 percent and TOO percent.

 A   general   process  and  water   flow diagram of a representative
 melting furnace scrubber operation is presented in Figure  III-9.

 The major effluent load is due to the amount  and the  cleanliness
 of the scrap  used in the furnace charge.   The cleanliness of  the
 scrap influences the  furnace  emissions.   Generally,  zinc  melting
 furnaces which  melt  high  quality  scrap  do  not  require  air
 pollution control  devices.  However,  when dirty,   oily  scrap   is
 used,   furnace  emissions  are  often  controlled  by  the use of
 scrubbers.   The process wastewater from these  scrubbers  may   be
 either   recirculated  within the  scrubber equipment package (which
 includes a  settling chamber)  or  may flow to an external  treatment
 system  and  then recycle back  to  the scrubber.

 Plant 18139, Figure V-3,  has  melting  furnace  scrubber systems  for
 both its  aluminum  and zinc  furnaces.    The  quench  tank  process
 wastewater   mixes    with   melting   furnace   scrubber  process
 wastewater, aluminum  casting  quench tank flows,   and  other  non-
 foundry   flows   prior   to   settling  and skimming.    The  treated
 process wastewaters are   discharged  to   a  POTW.    The  scrubber
 process  wastewater   comprises   27  percent of  the  total  treatment
 flow.

 Table  V-31  summarizes   the   raw   waste and   treated   effluent
 concentrations   and  waste  loads   observed   during   the sampling
program.  Table  111-20 describes the  treatment  approach  used   for
 the zinc melting furnace scrubber system.
                              170

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                                    TABLE V-1-.
          ANNUAL  PRODUCTION OF  PLANTS WHICH  GENERATE  PROCESS WASTEWATERS
                     (THOUSAND  TONS OF METAL POURED PER YEAR)
Subcategory

Aluminum
Copper
Ferrous
Lead
Magnesium
Zinc
Produc tion
 of Direct
Dischargers

  477.2
  39.6
  32,166.0
  0
  0.5
  84.8
 Production
  of POTW
Dischargers

  388.0
  20.0
  10,119.1
  45.7
  0
  447.9
 Production
  of Zero
Dischargers

  48.3
  33.7
  16,705.0
  32.4
  0.07
  209.1
 Total

913.5
93.3
58,990.1
78.1
0.6
741.8
Totals
  32,768.1
  11,020.7
  17,028.6
60,817.4
                                            171

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                TABLE V-2

METALS CASTING INDUSTRY DISCHARGE SUMMARY
 DIRECT DISCHARGERS - BY PROCESS SEGMENT

Subeategory
AluainuB








Aluainua Total
Copper



Copper Total
Ferrous (Ductile Iron)







Ferrous (Ductile Iron)
Ferrous (Cray Iron)








Process
Casting Quench

Die Casting

Die Lube
Investment Casting

Melting Furnace
Scrubber


Mold Cooling and
Casting Quench
Dust Collection


Mold Cooling and
Casting Quench

Melting Furnace
Scrubber

Slag Quench


Dust Collection
Total
Mold Cooling and
Casting Quench

Melting Furnace
Scrubber


Slag Quench



Emp.
Group
<50
50-249
50-249
£250
£250
<50
50-249
50-249
£250


<50
50-249
<50
50-249

50-249
£250

50-249
£250

50-249
£250

£250

50-249
£250

<50
50-249
£250

50-249
£250

Applied
Flow _.
(gal/yr x 10 )
236.0
2.638.4
2,874.4
269,654.4
295,258.1
564, 912. S
559.7
835.2
2,675.9
3,511.1
9,773.9
321,474.5
331,248.4
903,106.1
46.4
19,881.7
19,928.1
229.7
6,108.9
6,338.6
26,266.7
30,596.1
1,374,676.5
1,405,272.6
153,343.7
7,331,992.8
7,485,336.5
129,801.1
3,639,539.5
3,769,340.6
5,094,230.8
17,754,180.5
31,378.2
92,033.5
123,411.7
221,523.5
298,949.2
7,122,440.1
7,642,912.8
299,508.7
3,710,316.3
4,009,825.0
Discharge
Flow ,
(gal/yr x 10~J)
236.0
2.638.4
2,874.4
189,084.6
60,429.4
249,514.0
559.7
835.2
2,675.9
3,511.1
5,053.6
128,589.8
133,643.4
390,102.6
46.4
19,881.7
19,928.1
229.7
6,108.9
6,338.6
26,266.7
11,014.6
295,949.5
306,964.1
69,086.6
3,759,902.8
3,828,989.4
26,313.6
3,600,587.2
3,626,900.8
2,478,142.2
10,240,996.5
31,378.2
92,033.5
123,411.7
2,215.2
70,202.9
2,251,091.2
2,323,509.3
299,508.7
2,093,597.6
2,393,10671
Recycle
Flow ,
(gal/yr x 10 )
0.0
0.0
bTo
80,569.8
234,828.7
315,398.5
0.0
0.0
0.0
0^0
4,720.3
192,884.7
197,605.0
513,003.5
QA
• U
0.0
0.0
0.0
0.0
oTo
0.0
19,581.5
1,078,727.0
1,098,308.5
84,257.1
3,572,090.0
3,656,347.1
103,487.5
38,952.3
142,439.8
2,616,088.6
7,513,184.0
0.0
0.0
070
219,308.3
228,746.3
4,871,348.9
5,319,403.5
0.0
1,616,718.7
1,616,718.7
               172

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TABLE V-2
METALS CASTING INDUSTRY. DISCHARGE SUMMARY
DIRECT DISCHARGERS - BY PROCESS SEGMENT
PAGE 2
Subcategory
Ferrous (Gray Iron)


Ferrous (Gray Iron) Total
Ferrous (Malleable Iron)


Ferrous (Malleable Iron)
Ferrous (Steel)


Ferrous (Steel,) Total
Ferrous Total
Magnesium

Magnesium Total
Zinc


Process
Sand Washing
Dust Collection


Slag Quench
Dust Collection

Total ;
Mold Cooling and
Casting Quench
Sand Washing
Dust Collection


Grinding Scrubbers
Dust Collection

Die Casting and
Casting Quench

Melting Furnace
Scrubber
Emp.
Group
>250
<50
50-249
>250


50-249
^250
50-249
^250


50-249
^250
>250
50-249
>250


<50
<50

50-249
>250 .'

50-249 "
Applied
Flow -
(sal/yr x 10 )
1,792,610.1
148,623.0
1,137,140.6
19,689,252.7
20,975,016.3
34,543,775.9
1,393.0
70,454.0
71,847.0
59,150.3
454,162.1
513,312.4
585,159.4
3,931.5
164,003.0
167,934.5
76,929.8
51,055.2
153,606.3
204,661.5
449,525.8
53,332,641.6
390.1
654.2
1,044.3
51,024.9
2,100.3
53,125.2
297,520.4
\
Discharge
Flow ,
(gal/yr x 10 )
583,592.4
1,486.2
76,158.3
8,429,461.0
8,507,105.5
13,930,725.2
1,393.0
70,454.0
71,847.0
13,563.1
15,295.1
28,858.2
100,705.2
3,931.5
164,003.0
167,934.5
76,929.8
51,055.2
29,254.9
80,310.1
325,174.4
24,597,601.3
.390.1
654.2
1,044.3 .
41,571.2
2,100.3
43,671.5
5,057.8
Recycle
Flow ,
(Kal/yr x 10 J)
1,209,017.7
147,136.8
1,060,982.3
11,259,791.7
12,467,910.8
20,613,050.7
0.0
0.0
0.0
45,587.2
438,867.0
484,454.2
484,454.2
0.0
0.0
0.0
0.0
0.0
124.351-.4 .
124,351.4
124,351.4
28,735,040.3
0.0
0.0
0.0
9,453.7
0.0
9,453.7
292,462.6
           Zinc Total


 DIRECT DISCHARGERS TOTALS
   350,645.6


54,613,704.3
    48,729.3


25,063,744.2
   301,916.3


29,549,960.1
                                                            •173

-------
                     2   S
                     _   _  o
--J   O   4) *~f
                             174

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                TABLE V-4

METALS CASTING INDUSTRY DISCHARGE SUMMARY
  POTW DISCHARGERS  - BY PROCESS SEGMENT
Sgbcateg<
Aluminum




Copper
Ferrous


Ferrous





irv Process
Gas ting Quench
Die Casting
Die Lube
Investment Casting
Aluminum Total
Mold Cooling and
Casting Quench
Copper Total
(Ductile Iron) Mold Cooling and
Casting Quench
Slag Quench
Dust Collection ,
Ferrous (Ductile Iron) Total
(Gray Iron) Mold Cooling and
Casting Quench
Mel ting Furnace , .
Scrubber
Slag Quench
Sand Washing
Dust Collection
Ferrous (Gray Iron) Total
Emp.
Group
<50
50-249
XZ50
50-249
50-249
^250
<50

<50
50-249
50-249
50r249
>250
<50
50-249
XJ50

50-249
>250
<50
50-249
>250
50-249
i250
>250
<50
50-249
>250

Applied Discharge
Flow , Flow -
(aal/yr x 10 ) (fal/yr x 10 )
10,250.7
4,711.5
246.0
15,208.8
100,580.8
534.1
738.9
1,273.0
8,463.4
125,525.4
5,776.7
456,511,4
462,288.1
25,692.6
61,674.3
1,695,732.0
1,757,406.3
41,639.7
160,063.8
33,881.5
235,585.0
2,018,683.9
7,086.8
34,651.6
41,738.4
23,490.0
895,661.1
1,917,544.2
2,836,695.3
22,661.8
482,504.4
505,166.2
249,464.8
133,138.3
282,053.6
2,434,515.5
2,849,707.4
6,482,772.1
10,250.7
1,109.9
246.0
11,606.6
40,554.0
534.1
738.9
1,273.0
8,463.4 .
61,897.0
5,776.7
2,282.6
8,059.3
22,095.6
13,335.6
10,174.4
23,510.0
4,164.0
9,830.9
2,066.8
16,061.7
61,667.3
7,086.8
6,930.3
14,017.1
11,745.0
7,559.3
285,623.1
304,927.4
11,016.7
365,984.3
377,001.0
47,398.3
9,093.5
166,466.9
179,511.6
355,072.0
1,098,415.8
Recycle
Flow ,
(aal/yr x 10 J)
0.0
3,601.6
0.0
3,601.6
60,026.8
0.0
0.0 •
0.0
0.0
63,628.4
0.0
454,228.8
454,228.8
3,597.0
48,338.7
1,685,557.6
1,733,896.3
37,475.7
150,232.9
31,814.7
219,523.3
1,957,016.6
0.0
27,721.3
27,721.3
11,745.0
888,101.8
1,631,921.1
2,531,767.9
11,645.1
116,520.1
128,165.2
202,066.5
124,044.8
115,586.7
2,255,003.9
2,494,635.4
5,384,356.3
                   175

-------
TABLE V-4
METALS CASTING INDUSTRY DISCHARGE SUMMARY
KJTW DISCHARGERS - BY PROCESS  SEGMENT
PACE 2

Subcatogory
Ferrous (Malleable Iron)




Ferrous (H«lle«ble Iron)
Ferroui (Steel)





Ferroui (Steel) Total
Ferroui Total
Laid


Lead Total
Zinc






Zinc Total
fOTW DISCHARGERS TOTALS

Process
Melting Furnace
Scrubber
Slag Quench
Dust Collection


Total
Mold Cooling and
Casting Quench

Sand Washing
Dust Collection




Continuous
Strip Casting
Melting Furnace
Scrubber

Die Casting and
Casting Quench



Melting Furnace
Scrubber




Emp.
Group
>250
50-249
50-249
£250


50-249
>250

i250
50-249
£250



£250
£250



<50
50-249
£250

50-249
£250



Applied
Flow
(gal/yr x 10 )
295,944.4
39,726.3
58,813.2
99,701.9
158,515.1
494,185.8
433,092.2
451,656.6
884,748.8
451,805.3
172,950.1
269,136.5
442,086.6
1,778,640.7
10,774,282.5
2,353.0
123.7

2,476.7

7,858.3
60,754.1
14.8
68,627.2
504,588.0
67,365.8
571,953.8
640,581.0
12,005,153.7
Discharge
Flow
(gal/yr x 10 )
887.8
20,368.4
58,535.6
997.0
59,532.6
80,788.8
1,297.2
378,051.1
379,348.3
198,794.3
8,647.5
196,429.2
205,076.7
783,219.3
2,024,091.2
2,032.8
12.4

2,045.2

5,884.3
60,754.1
14.8
66,653.2
64,705.4
6,736.6
71,442.0
138,095.2
2,234,987.9
Recycle
Flow ,
(gal/yr x 10 )
295,056.6
19,357.9
277.6
98,704.9
98,982.5
413,397.0
431,795.0
73,605.5
505,400.5
253,011.0
164,302.6
72,707.3
237,009.9
995,421.4
8,750,191.3
320.2
111.3

431.5

1,974.0
0.0
0.0
1,974.0
439,882.6
60,629.2
500,511.8
502,485.8
9,770,965.8
                                                         176

-------
                       en   CO
                      • es   er»
                       en   —*
O

O
                       r^   o   -H
                            o   r^
                    o

                    o
                               177

-------
                                               TABLE  V-6

                                METALS  CASTING  INDUSTRY DISCHARGE SUMMARY
                                  ZERO DISCHARGERS - BY PROCESS  SEGMENT
Subeategorv
Aluainua

Aluainua Total
Copper

Copper Total
Farrou* (Ductile Iron)



Ferrous (Ductile Iron)
Ferrous (Gray Iron)



Process
Casting Quench
Die Lube

Dust Collection
Mold Cooling and
Casting Quench

Mold Cooling and
Casting Quench
Melting Furnace
Scrubber
Slag Quench
Duse Collection
Total
Mold Cooling and
Casting Quench
Melting Furnace
Scrubber
Slag Quench
Sand Washing
Dust Collection
Emp.
Group
<50
>250

<50
50-249
^250

50-249
50-249
>250
>;250
<50
50-249
>250

50-249
>250
<50
50-249
>250
50-249
>250
XZ50
<50
50-249
>250
Applied
Flow
(gal/yr x 10 )
9,544.6
2,030.1
11,574.7
164,073.9
44,555.9
208,629.8
1,205,663.7
1,414,293.5
14,288.6
68,090.4
53,363.2
121,453.6
42,065.7
61,926.6
317,013.9
264,322.2
643,262.7
821,070.6 !
14,288.6
34,651.6 '
48,940.2
190,733.9
3,382,002.4
9,169,190.9
12,741,927.2
1,088,264.4
14,859.9 .
1,103,123.9
41,478.9
49,681.0
5,344,388.0
15,261,120.7 ,
20,655,189.7
Discharge
Flow
(gal/yr x 10~J)
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
bTo
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
Recycle
Flow ,
(gal/yr x 10 )
9,544.6
2,030.1
11,574.7
164,073.9
44,555.9
208,629.8
1,205,663.7
1,414,293.5
14,288.6
68,090.4
53,363.2
121,453.6
42,065.7
61,926.6
317,013.9
264,322.2
643,262.7
821,070.6
14,288.6
34,651.6
48r940.2
190,733.9
3,382,002.4
9,169,190.9
12,741,927.2
1,088,264.0
14,859.9
1,103,123.9
41,478.9
49,681.0
5,344,388.0
15,261,120.7
20,655,189.7
Ferrous (Gray Iron) Total
                                                         34,590,659.9
                                                                                     0.0
                                                                                               34,590,659.9
                                              178

-------
TABLE V-6
METALS CASTING INDUSTRY DISCHARGE SUMMARY
ZERO DISCHARGERS - BY PROCESS SEGMENT
PAGE 2
Subcategory
Ferrous (Malleable Iron)

.

Ferrous (Malleable Iron)
Ferrous (Steel)

Ferrous (Steel) Total
Ferrous Total
Lead

Lead Total
Magnesium ^
Magnesium Total
Zinc

Process
Mold Cooling and
Casting Quench
Melting Furnace
Scrubber
Slag Quench .
Dust Collection
Total
Mold Cooling and
Casting Quench
Dust Collection


Continuous Strip
Casting
Melting Furance
Scrubber

Grinding Scrubbers

Die Casting and
Casting Quench
Melting Furnace
Emp.
Group
>250
50-249
^250
50-249
>250
50-249
>250

<50
50-249
>250
50-249
>250


>250
>250

<50

<50
^250
50-249
Applied
Flow . -
(gal/yr x 10 )
14,032.8
184,552.2
48,195.0
232,747.2
66,736.6
48,195.0
114,931.6
266,578.8
2,113,268.2
2,379,847.0
2,741,558.6
18,614.0
506,171.1
1,616,996.7
2,141,781.8
47,081.1
999^925.2
1,047,006.3
3,228,671.8
41,342,077.2
361.4
20,401.6
20,763.0
110.5
110.5
13,451.3
9j544.4
22,995.7
1,490,107;0
Discharge
Flow ,
(gal/yr x 10 V
0.0
0.0
0.0
O
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
oTo
0.0
0.0
0.0
; o.o
0.0
"o.o
0.0
0.0
0.0
0.0
0.0
Recycle
Flow ,
(Kal/yr x 10 )
14,032.8
184,552.2
.48_,195.0
232,747.2
66,736.6
48,195.0
114,931.6
266,578.8
2jll3,268.2
2,379,847.0
2,741,558.6
18,614.0
506,171.1
Jj616,996.7
2,141,781.8
47,081.1
999,925.2
1,047,006.3
3,228,671.8
41,342,077.2
361.4
20,401.6
20,763.0
110.5
110.5
13,451.3
9,544.4
22,995.7
1,490,107.0
                                    Scrubber
           Zinc  Total
                                                                     1,513,102.7
                                                                                                0.0
                                                                                                           1,513,102.7
 ZERO DISCHARGER TOTALS
                                                                    44,301,921.6
                                                                                                0.0
                                                                                                         44,301,921.6
                                                            179

-------

n
 "o
                     o
                     o
                    o
                    o
              s
              to
              o
    CD
    O
CM   VO
O*   r-
          o
          o
                                        o
                                        o

  I
                 1
                                          180

-------
                                         TABLE V-8

                             ACTIVE WET FOUNDRY OPERATIONS
                                  DISCHARGE MODE PROFILE
(1)
Aluminum Casting
Copper and Copper
Alloy Casting
Ferrous Casting
Lead Casting
Magnesium Casting
Zinc Casting
TOTAL
Direct
Discharge
28
29
212
0
6
12
287
Discharge
to POTWs
45
21
196
5
0
60
327
Zero
Discharge
33
28
275
5 :
1
9
351
Total
106
78
683
10
7
81
965
(1)
   Statistically based projections.
                                          181

-------
                                    TABLE V-9

                             LIST OF TOXIC  POLLUTANTS
Number

001
002
003
004
005
006
007
008
009
010
Oil
012
013
014
015
016
017
018
019
020
021
022
023
024
025
026
027
028
029
030
031
032
033
034
035
036
037
038
039
040
Type of
Compound

Base/Neutral
Volatile
Volatile
Volatile
Base/Neutral
Volatile
Volatile
Base/Neutral
Base/Neutral
Volatile
Volatile
Base/Neutral
Volatile
Volatile
Volatile
Volatile
Volatile
Base/Neutral
Volatile
Base/Neutral
Acid
Acid
Volatile
Acid
Base/Neutral
Base/Neutral
Base/Neutral
Base/Neutral
Volatile
Volatile
Acid
Volatile
Volatile
Acid
Base/Neutral
Base/Neutral
Base/Nuetral
Volatile
Base/Neutral
Base/Neutral
Parameter

Acenaphthene
Acrolein
Acrylonitrile
Benzene
Benzidine
Carbon tetrachloride
Chlorobenzene
1,2,4-trichlorobenzene
Hexachlorobenzene
1,2-dichloroethane
1,1,1-trichloroethane
Hexachloroethane
1,1-dichloroethane
1,1,2-trichloroethane
1,1,2,2 -tetrachloroethane
Chloroethane
bis(chloromethy1)ether
bis(2-chloroethy1)ether
2-chloroethyl vinyl ether
2-chloronaphthalene
2,4,6-trichlorophenol
Parachlorometacresol
Chloroform
2-chlorophenol
1,2-dichlorobenzene
1,3-dichlorobenzene
1,4-dichlorobenzene
3,3"-dichlorobenzidine
1,1-dichloroethylene
1,2-trans-dichloroethylene
2,4-dichlorophenol
1,2-dichloropropane
1,3-dichloropropylene
2,4-dimethylphenol
2,4-dinitrotoluene
2,6-dinitrotoluene
1,2-diphenylhydrazine
Ethylbenzene
Fluoranthene
4-chlorophenyl phenyl ether
                                            182

-------
TABLE V-9
LIST OF TOXIC POLLUTANTS
PAGE 2

Number
041
042
043
044
045
046
047
048
049
050
051
052
053
054
055
056
057
058
059
060
061
062
063
064
065
066
067
068
069
070
071
072
073
074
075
076
077
078
079
080
Type of
Compound
Base/Neutral
Base/Neutral
Base/Neutral
Volatile
Volatile
Volatile
Volatile
Volatile
Volatile
Volatile
Volatile
Base/Neutral
Base/Neutral
Base/Neutral
Base/Neutral
Base/Neutral
Acid
Acid
Acid
Acid
. Base/Neutral
Base/Neutral
Base/Neutral
Acid
Acid
Base/Neutral
Base/Neutral
Base/Neutral
Base/Neutral
Base /Neutral
. .. Base/Neutral
Base/Neutral
Base/Neutral
Base/Neutral
Base/Neutral
Base/Neutral
Base/Neutral
Base/Neutral
Base/Neutral
,.;... Base/Neutral
                                                       Parameter

                                                       4-bromophenyl phenyl ether
                                                       bis (2-chloroisopropyl)ether
                                                       bis (2-chloroethoxy)methane
                                                       Methylene chloride
                                                       Methyl chloride
                                                       Methyl bromide
                                                       Bromoform
                                                       Dichlorobromomethane
                                                       Trichlorofluoromethane
                                                       Dichlorodifluoromethane
                                                       Chlorodibromomethane
                                                       Hexachlorobutadiene
                                                       Hexachlorocyclopentadiene
                                                       Isophorone
                                                       Naphthalene
                                                       Nitrobenzene
                                                       2-nitrophenol
                                                       4-nitrophenol
                                                       234-dinitrophenol
                                                       4,6-dinitro-o-cresol
                                                       N-nitrosodimethylamine
                                                       N-nitrosodiphenylamine
                                                       N-nitrosodi-n-propylamine
                                                       Pentachlorophenol
                                                       Phenol
                                                       bis (2-ethylhexyl)phthalate
                                                       Butyl benzyl phthalate
                                                       Di-n-butyl phthalate
                                                       Di-n-octyl phthalate
                                                       Diethyl phthalate
                                                       Dimethyl phthalate
                                                       Benzo(a)anthracene
                                                       Benzo(a)pyrene
                                                       3,4-benzofluoranthene
                                                       Benzo(k)fluoranthene
                                                       Chrysene
                                                       Ac enaph thy1ene
                                                       Anthracene
                                                       Benzo(ghi)perylene•
                                                       Fluorene
                                          183

-------
TABLE V-9
LIST OF TOXIC POLLUTANTS
PAGE 3

Number
081
082
083
084
085
086
087
088
089
090
091
092
093
094
095
096
097
098
099
100
101
102
103
104
105
106
107
108
109
110
111
112
113
114
115
116
117
118
119
120
121
Type of
Compound
Base/Neutral
Base/Neutral
Base/Neutral
Base/Neutral
Volatile
Volatile
Volatile
Volatile
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Pesticide
Inorganic
Inorganic
Inorganic
Inorganic
Inorganic
Inorganic
Inorganic
Inorganic
                                                       Parameter

                                                       Phenanthrene
                                                       Dibenzo(a,h)anthracene
                                                       Indeno(1,2,3,cd)pyrene
                                                       Pyrene
                                                       Tetrachloroethylene
                                                       Toluene
                                                       Trichloroethylene
                                                       Vinyl chloride
                                                       Aldrin
                                                       Dieldrin
                                                       Chlordane
                                                       4,4'-DDT
                                                       4,4'-DDE
                                                       4,4'-ODD
                                                       a-endosulfan-Alpha
                                                       b-endosulfan-Beta
                                                       Endosulfan sulfate
                                                       Endrin
                                                       Endrin aldehyde
                                                       Heptachlor
                                                       Heptachlor expoxide
                                                       a-BHC-Alpha
                                                       b-BHC-Beta
                                                       r-BHC-Gamma
                                                       g-BHC-Delta
                                                       PCB-1242
                                                       PCB-1254
                                                       PCB-1221
                                                       PCB-1232
                                                       PCB-1248
                                                       PCB-1260
                                                       PCB-1016
                                                       Toxaphene
                                                       Antimony
                                                       Arsenic
                                                       Asbestos
                                                       Beryllium
                                                       Cadmium
                                                       Chromium
                                                       Copper
                                                       Cyanide
                                          184

-------
TABLE V-9
LIST OF TOXIC POLLUTANTS
PAGE 4
Number

122
123
124
125
126
127
128
129

130
Type of
Compound

Inorganic
Inorganic ;
Inorganic
Inorganic
Inorganic
Inorganic
Inorganic
Base/Neutral

Volatile
 Parameter
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
•2,3,7,8, -tetrachloro-
dibenzo-p-dioxin (TCDD)
Xylene
                                         185

-------
                   TABLE  V-10




  CONVENTIONAL AND NONCONVENTIONAL POLLUTANTS
Acidity, free




Acidity, total




Alkalinity (Methyl Orange)




Alkalinity (Phenolphthalein)




Aluminum




Ammonia-N




Calcium




Carbon, Organic




Chloride




Cyanate




Fluoride




Hardness




Iron




Magnesium




Manganese
Nitrogen




Phenolic Compounds




Potassium




Silica, Soluble




Sodium




Sulfate




Sulfide




Temperature




Thiocyanate




Tin




Oil and Grease




Solids, Dissolved




Solids, Suspended




Solids, Volatile




pH
                       186

-------
                                     TABLE  V-11    •   •••-.;.      ;

                PLANT ASSESSMENT  OF  THE  KNOWN OR BELIEVED  PRESENCE
              OF TOXIC POLLUTANTS IN FOUNDRY RAW PROCESS WASTEWATERS
                          SUBCATEGORY:  Aluminum Casting

                                   All Processes
 Pollutant

 012  - Hexachloroethane
 020  - 2-chloronaphthalene
 031  - 2,4-dichlorophenol
 065  - Phenol
 101  - Heptachlor  epoxide
 105  - g-BHC-Delta
 110  - PCB-1248
 117  - Beryllium
 118  - Cadmium
 119  — Chromium
 120  - Copper
 122  - Lead
 124  - Nickel
 128  - Zinc
 Known
 to  be
 Present
   4
   5
   3
   3
   2
 Believed
 to  be
 Present


    1
    1
 -;'"- 1


    1
    1


    1
 ,   1
 .   2
.   1
                   SUBCATEGORY:  Copper & Copper Alloy Casting

                                  All Processes
Pollutant

114 - Antimony
119 - Chromium
120 - Copper
122 - Lead
124 - Nickel
Known
to be
Present
   2
   2
Believed
to be
Present

   1
   1
   2
   2
   1
                               137

-------
TABLE V-ll
PLANT ASSESSMENT OF THE KNOWN OR BELIEVED PRESENCE
OF TOXIC POLLUTANTS IN FOUNDRY RAW PROCESS WA^TEWATERS
PAGE 2	;	-	•

                          SUBCATEGORY:  Ferrous Casting

                            PROCESS!  Dust Collection
Pollutant

004 - Benzene
007 - Chlorobenzene
008 - 1.,2,4-trichlorobenzene
009 - Hexachlorobenzene
021 - 2,4,6-trichlorophenol
024 - 2-chlorophenol
025 - 1,2-dichlorobenzene
026 - 1,3-dichlorobenzene
027 - 1,4-dichlorobenzene
031 - 2,4-dichlorophenol
034 - 2,4-dimethyl phenol
035 - 2,4-dinitrotoluene
036 - 2,6-dinitrotoluene
038 - Ethylbenzene
052 - Hexachlorobutadiene
055 - Naphthalene
064 - Pentachlorophenol
065 - Phenol
086 - Toluene
114 - Antimony
118 - Cadmium
119 - Chromium
120 - Copper
121 - Cyanide
122 - Lead
124 - Nickel
125 - Selenium
126 - Silver
127 - Thallium
128 - Zinc
Known
to be
Present
   30

   1
   2
   11
   12

   10
   9

   2
   1
   10
Believed
to be
Present

   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   1
   15
   2
   1
                                 18C

-------
TABLE V-ll
PLANT ASSESSMENT OF THE KNOWN OR BELIEVED PRESENCE
OF TOXIC POLLUTANTS IN FOUNDRY RAW PROCESS WASTEWATERS
PAGE 3

SUBCATEGORY: Ferrous
Casting
PROCESS: Melting Furnace Scrubber


Pollutant
065 - Phenol
105 - g-BHC-Delta
114 - Antimony
115 - Arsenic
118 - Cadmium
119 - Chromium
120 - Copper
121 - Cyanide
122 - Lead
123 - Mercury
124,- Nickel
125 - Selenium
126 - Silver
127 - Thallium
128 - Zinc
Known
to be
Present
2
-•--. i
2
2
4-
9
9
2
10
	 3
10
4
4
1
14
Believed
to be
Present
2



3
5
7
2
3^

4




                          SUBCATEGORY:  Ferrous Casting

                             PROCESS: Slag Quenching
Pollutant
114
118
119
120
122
123
124
125
126
127
128
Antimony
Cadmium
Chromium
Copper
Lead
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
Known
to be
Present
1
4
6
6
6
2
4
1
3
1
7
Believed
to be
Present


1
1







                                139

-------
TABLE V-ll
PLANT ASSESSMENT OF THE KNOWN OR BELIEVED PRESENCE
OF TOXIC POLLUTANTS IN FOUNDRY RAW PROCESS WASTEWATERS
PAGE 4                            	'	
                          SUBCATEGORY:  Ferrous Casting

                              PROCESS:   Sand Washing
Pollutant

065 - Phenol
122 - Lead
124 - Nickel
128 - Zinc
Known
to be
Present

   1
   1
   1
   1
Believed
to be
Present
                            SUBCATEGORY:   Lead Casting

                                  All Processes
Pollutant

010 - 1,2-dichloroethane
Oil - 1,1,1-trichloroethane
044 - Methylene Chloride
050 - Dichlordifluoromethane
055 - Naphthalene
086 - Toluene
106 - PCB-1242
107 - PCB-1254
111 - PCB-1260
114 - Antimony
115 - Arsenic
118 — Cadmium
119 - Chromium
120 - Copper
122 - Lead
123 - Mercury
124 - Nickel
125 - Selenium
126 - Silver
128 - Zinc
130 - Xylene
Known
to be
Present
    38
    30
    24
    15
    14
    65

    20
    6
    6
    21
Believed
to be
Present

   1
   5

   4
   6
   1
   1
   1
   1
   8
   7
   2
   2
   32
   9
   6
   8

   5
   7
   3
                                 190

-------
TABLE V-ll
PLANT ASSESSMENT OF THE KNOWN OR BELIEVED PRESENCE
OF TOXIC POLLUTANTS IN FOUNDRY RAW PROCESS WASTEWATERS
PAGE 5
                         SUBCATEGORY:  Magnesium Casting

                                  All Processes
Pollutant

117 - Beryllium
120 - Copper
124 - Nickel
128 - Zinc
Believed
to be
Present
Known
to be
Present

   1
   1
   1
   1
                            SUBCATEGORY:   Zinc  Casting

                                  All Processes
Pollutant

055 - Naphthalene
065 - Phenol
073 - Benzo(a)pyrene
114 - Antimony
115 - Arsenic
117 - Beryllium
118 - Cadmium
120 - Copper
121 - Cyanide
124 - Nickel
128 - Zinc
Known
to be
Present


1
3
1

3
1
1
1
9
Believed
to be
Present
1
1



1
1

1

1
                                191

-------
                                    TABLE V-12

                        TOXIC POLLUTANTS CONSIDERED TO BE
                      PRESENT IN FOUNDRY PROCESS WASTEWATERS
SUBCATEGORY:  Aluminum Casting
ALL PROCESSES

004 - Benzene
006 - Carbon tetrachloride
044 - Methylene chloride
061 - N-nitrosodimethylamine
062 - N-nitrosodiphenylamine
063 - N-nitrosodi-n-propylamine
065 - Phenol
086 - Toluene
124 - Nickel
125 - Selenium
128 - Zinc

SUBCATEGORY:  Ferrous Casting
PROCESS:  Dust Collection

003 - Acrylonitrile
004 - Benzene
055 - Naphthalene
061 — N-nitrosodimethylamine
062 - N-nitrosodiphenylamine
063 — N-nitrosodi-n-propylamine
065 - Phenol
086 - Toluene
119 - Chromium
120 - Copper
121 - Cyanide
122 - Lead
124 - Nickel
125 - Selenium
128 - Zinc
SUBCATEGORY:  Copper Casting
ALL PROCESSES

114 - Antimony
117 - Beryllium
119 r Chromium
120 - Copper
122 - Lead
124 - Nickel
128 - Zinc
SUBCATEGORY:  Ferrous Casting
PROCESS:  Melting Furnace Scrubber

004 - Benzene
055 - Naphthalene
061 T N-nitrosodimethylamine
062 - N-nitrosodiphenylamine
063 f N-nitrosodi-n-propylamine
065 - Phenol
086 - Toluene
118 - Cadmium
119 - Chromium
120 - Copper
122 - Lead
124 - Nickel
125 - Selenium
128 - Zinc
                                       192

-------
TABLE V-12
TOXIC POLLUTANTS CONSIDERED TO BE
PRESENT IN FOUNDRY PROCESS WASTEWATERS
PAGE 2                             '
SUBCATEGORY:  Ferrous Casting
PROCESS:  Slag Quenching

055 - Naphthalene
061 - N-nitrosodimethylamine
062 - N-nitrosodiphenylamirie
063 - N-nitrpsodi-n-propylamine
065 - Phenol
086 - Toluene
118 - Cadmium
119 - Chromium
120 - Copper
122 - Lead
124 - Nickel
125 - Selenium
128 - Zinc
SUBCATEGORY:  Ferrous Casting
PROCESS:  Sand Washing

003 - Acrylpnitrile
004 - Benzene
055 - Naphthalene
061 - N-nitrosodimethylamine
062 - N-nitrospdiphenylamine
063 - N-nitrosodi-n-propylamine
065 - Phenol
086 - Toluene
119 - Chromium
120 - Copper
121 - Cyanide
122 - Lead
124 - Nickel
125 - Selenium
128 - Zinc
SUBCATEGORY:  Lead Casting
ALL PROCESSES

Oil -  1,1,1-trichloroethane
023 -  Chloroform
044 -  Methylene chloride
055 -  Naphthalene
065 -  Phenol
078 -  Anthracene
081 -  Phenanthrene
084 -  Pyrene
114 -  Antimony
115 -  Arsenic
118 -  Cadmium
119 -  Chromium
120 -  Copper
122 -  Lead
123 -  Mercury
124 -  Nickel
126 -  Silver
128 -  Zinc
SUBCATEGORY:  Magnesium Casting
ALL PROCESSES

065 - Phenol
                                        193

-------
TABLE V-12
TOXIC POLLUTANTS CONSIDERED TO BE
PRESENT IN FOUNDRY PROCESS WASTEWATERS
PAGE 3
SUBCATEGORY:  Zinc Casting
ALL PROCESSES

004 - Benzene
006 - Carbon tetrachloride
044 -'Methylene chloride
061 - N-nitrosodimethylamine
062 - N-nitrosodiphenylamine
063 - N-nitrosodi-n-propylamine
065 - Phenol
086 - Toluene
124 - Nickel
128 - Zinc
                        194

-------
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                                          195

-------
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-------
                                   -TABLE V-15

                        ;  ; CHARACTERISTICS OF ALUMINUM
                      INVESTMENT CASTING PROCESS WASTEWATERS
Raw Wastewater

Plant:
Production (kkg/day):
Flow (1/kkg):
Sample Points:
Pollutants

085 Tetrachloroethylene
087 Trichloroetfaylene
120 Copper
128 Zinc

    Oil and Grease
    TSS
    pH (Units)

Treated Effluent

Plant:
Flow (1/kkg):
Sample Points:
C&TT:
 mg/1
0.105
0.067
0.48
0.53

27
951
            4704
        4.54 (5 TPD)
       20296 (4867 GPT)
           B+D+E
    kg/kkg
(lbs/1000 Ibs)

      0.00213
      0.00136
      0.0097
      0.0107

      0.54
      19.29
         6.6-8.6
      J       4704
        20296 (4867 GET)
      (B+D+E)/(B+D+E+F))H
          FLP,TP,FFOG
Pollutants

085 Tetrachloroethylene
087 Trichloroethylene
120 Copper
128 Zinc

    Oil and Grease
    TSS
    pH (Units)
 mg/1
0.098
0.074
0.06
0.10

11
81
    kg/kkg
(lbs/1000 Ibs)

      0.00199
      0.0015
      0.00123
      0.00203

      0.22
      1.65
         6.6-9.8
Note:  For  definitions  of  C&TT  codes  refer  to Table  111-21.
                                       197

-------
                                                   TABLE  V-16
                                          CHARACTERISTICS OF ALUMINUM
                                  MELTING FURNACE SCRUBBER PROCESS WASTEWATERS
Rav Hasteuater

Planes
Production (kkg/day):
Flov U/kkg):
Staple Points:
Pollutants

021  2,4,6-erichlorophenol
039  Fluoranthene
073  Bcnzo(a)pyrene
128  Zinc

     Asoonia (N)
     Phenols (4AAP)
     Sulfide

     Oil and Creese
     TSS
     pH (Units)
    17089
 207.9 (229 TPD)
 11854 (2842 GPT)
       E
SI/I

0.139
0.012
TO
0.26

0.10
0.841
1.40

13
48
                kg/kkg
            (lba/1000 Iba)

               0.00165
               0.000146
               0.000
               0.00313

               0.00119
               0.00996
               0.0166
               0.154
               0.569
                                     18139
                                 42.4 (46.7 TPD)
                                  4116 (987 GPT)
                                       C
mg/1

0.014
0.010
0.036
18.54

0.30
0.032
0.33
                                                                                                     Average
kg/kkg
(lbs/1000 Iba)
0.000056
0.000041
0.000148
0.0542
0.00124
0.000132
0.00137
0.0110
0.0384
kg/kkg
(lbs/1000 Ibs)
0.000853
0.000094
0.000075
0.0287
0.00122
0.00505
0.0180
0.0825
0.304
      7.3-7.4
                                      8.1-8.2
Treated Effluent

Plane:
Flov (1/kkg):
Sample Points:
C&TT:
Pollutants
         17089
    4143 (994 GPT)
     ((E/(0+E+A))G
OS,FLA,FLP,CL,T,FDSP,CY,RTP-65

                kg/kkg
            (lba/1000 Ibo)
                                       18139
                                   4116 (987 GPT)
                                  (C/(B+C+D+E+H))G
                                       OS, SB
                                                                                  kg/kkg
                                                                              (lbs/1000 Ibs)
021  2,4,6-erichlorophenol       0.051
039  Fluoranthene                0.009
073  Benzo(a)pyrene              0.0
128  Zinc                        0.05

     Armenia (N)                 0.1
     Phenols (4AAP)              0.151
     Sulfide                     0.5
     Oil and Grease              2
     TSS                         9
     pH (Units)
               0.000211
               0.000037
               0.000
               0.000227

               0.000415
               0.000626
               0.00217

               0.0081
               0.0378
                                0.006
                                0.017
                                ND
                                13.24

                                0.30
                                0.005
                                0.40

                                3
                                7
                0.000025
                0.000072
                0.000
                0.0387

                0.00136
                0.000020
                0.00165

                0.012
                0.0291
    7.0-8.0
                                                                      7.1-8.4
HO:  Hoe Detected

Koto:  For definitions of CSTT codes, refer to Table 111-21.
                                                   198

-------
                                                       TABLE V-17
                                               CHARAClERISTICS OF ALUMINUM
                                           CASTING QUENCH PROCESS tfASTEWATERS
Raw Wastewater

Plant:
Production (kkg/day):
Flow (1/kkg):
Sample Points:
Pollutants

021  2,4,6-trichlprophenol
031  2,4-dichlorophenol
039  Fluoranthene

067  Butyl benzyl phthalate
084  Pyrene
085  Tetrachloroethylene

120  Copper
128  Zinc
130  Xylene

     Sulfide
     Oil and Grease
     TSS
     pH (Units)

Treated Effluent

Plant:
Flow (1/kkg):
Sample Points:
C&TT:
 Pollutants

 021   2,4,6-trichlorophenol
 031   2,4-dichlorophenol
 039   Fluoranthene

 067   Butyl  benzyl phthalate
 084   Pyrene
 085   Tetrachloroethylene

 120   Copper
 128   Zinc
 130   Xylene

      Sulfide
      Oil and Grease
      TSS
      pH (Units)
10308
25.3 (27.9 TPD) .
116 (27.9 GPT)
C
kg/kkg
ag/1 (lbs/1000 Ibs).
0.325 0.000035
ND 0.000
0.011 0.000001
0.043 0.000005
0.011 0.000001
0.107 0.000012
0.08 0.000008
9.85 0.00106
ND 0.000
40.0 0.0043
150 0.0162
63 ' 0.0067
8.6
10308
116 (27.9 GPT)
(C/(B+C+D+E))I
NA,NC,GF,EB,FLA,
FLC,FLP,SB,SS
kg/kkg
mg/1 (Ibs/lOOO Ibs)
ND 0.000
0.00 0.000
ND 0.000
ND 0.000
ND 0.000
0.064 0.000007
o.bz : 0.000002
1.01 0.000109
ND 0.000
7.8 0.00084
8 0.00085
5 0.00059
17089
234.3 (258 TPD)
5069 (1216 GPT)
C
kg/kkg
jng/1 (lbs/1000 Ibs)
0.702 0.0036
0.073 0.000371
0.003 0.000017
ND 0.000
0.010 0.000052
0.007 0.0034
0.07 ' 0.00036
0.84 0.0043
ND 0.000
0.40 0.0019
505 2.56
111 0.56
7.2-7.7
17089
1769 (424 GPT)
(D/(D+E+A))G
OS,FLA,FLP,CL,
-T,FDSP,CY,RTP-65
kg/kkg
njt/1 (lbs/1000 Ibs).
0.285 0.000503
0.017 0.000031
0.002 0.000004
0.00 0.000
0.003 0.000005
0.069 0.000121
0.01 0.000034
0.63 0.0032
ND 0.000
0.5 0.0023
12 0.058
8 0.041
18139
'. 1.9 (2.1 TPD)
600 (144 GPT)
E
kg/kkg
mg/1 (lbs/1000 Ibs)
0.203 0.00012
ND 0.000
0.226 0.00013
0.053 0.0030
0.279 0.000159
0.135 0.000077
0.26 0.00015
0.31 0.000174
0.022 0.000012 .
1.05 0.00060
163 0.093
990 0.56
5.4-6.1
18139
600 (144 GPT)
(E/(B+C+D+E+H))G
OS, SB
kg/kkg
ma/1 , (lbs/1000 Ibs)
0.091 0.000052
0.00 0.00
0.395 0.000226
0.032 0.000018
0.328 0.000187
0.169 0.000097
0.30 0.000174
0.22 0.000124
ND 0.000
1.26 0.00072
181 0.103
749 0.428
Average
kg/kkg
(lbs/1000 Ibs)
0.00125
0.000124
0.0000493
0.0010
0.0000071
0.00116
0.000173
0.00553
0.000004
0.00227
0.890
0.376





7.9-9.1
                          7.0-8.0
                                                    5.4-8.4
 ND:  Not Detected

 Note:  For definitions of CSTT codes, refer to Table.111-21.
                                                         199

-------
                                                    TABLE V-18
                                            CHARACTERISTICS OF ALUMINUM
                                          DIE CASTING PROCESS WASTEWATERS
  Rav Waatevater

  Plane:
  Production (kkg/d«y):
  Fiov U/kkg):
  Staple Points:
  Pollutants

  001  Acenaphthene
  021  2,4,6-trichlorophenol
  022  Parachlorometacreaol

  023  Chloroform
  039  Fluoranthene
  063  N-nitrosodi-n-propylaraine

  065  Phenol
  067  Butyl benzyl phthalate
  072  Benzo(a)anthracene

  076  Chrysene
  084  Pyrene
  OSS  Tetrachloroethylene

  122  Lead
  128  Zinc
  130  Xylene

       Phenols (4AAP)
      Oil and Grease
      TSS
      pH (Units)

 Treated Effluent

 Plant:
 Flow  (1/kkg):
 Staple Points:
 CSTT:
 Pollutants

 001  Acenaphthene
 021  2,4,6-trichlorophenol
 022  Parachlotometacresol

 023  Chloroform
 039  Fluoranthene
 063  H-nitrosodi-n-propylamine

 065  Phenol
 067  Butyl benzyl phthalate
 072  Benzo(a)anthracene

 076  Chryaene
 084  Pyrene
 085  Tetrachloroethylene

 122  Lead
 128  Zinc
 130  Xylene

      Phenols (4AAP}
      Oil and Grease
      TSS
      pH (Units)
17089
234.3 (258 TPD)
5074 (1217 GPT)
C
kg/kfcg
mg/1 (lba/1000 Iba)
ND 0.000
0.702 0.00356
0.032 0.000161
0.275 0.0014
0.003 0.000017
ND 0.000
1.673 0.0085
ND 0.000
6.2* 0.032
6.2* 0.032
0.010 0.000052
0.007 0.000034
0.05 0.0013
0.84 0.0043
ND 0.000
3.26 0.0165
505 2.56
111 0.56
7.2-7.7
17089
1768 (424 GPT)
(D/(D+E+A))G
OS,FLA,FLP,CL,T, -
FDSP,CY,RTP-65
kg/kkg
ng/1 (lbs/1000 Ibs)
0.00 0.000
0.285 0.000503
ND 0.000
0.419 0.000741
0.002 0.000004
ND 0.000
0.053 0.000093
0.00 0.000
* #
t #
0.003 0.000005
0.069 0.000121
0.05 0.000089
0.64 0.0011
ND 0.000
0.689 0.0012
12 0.0204
8 0.0143
7.0-8.0
12040
46.1 (50.8 TPD)
5556 (1333 GPT)
B
kg/kkg
mg/1 (lbs/1000 Ibs)
0.204 0.0011
ND 0.000
0.108 0.000599
0.018 0.00010
0.437 0.0024
0.05 0.000275
0.026 0.000143
0.685 0.0038
ND 0.000
0.806 0.00447
0.082 0.00046
0.082 0.00046
0.25 0.0014
3.67 0.0204
0.045 0.00025
0.087 0.00048
708 3.93
536 2.98
7.1-7.2
12040
5556 (1333)
(B/D)E
EB,FLP,GF,NC,SB,
VF,HA,FLA,SS
kg/kkg
mg/1 (lbB/1000 Iba)
# #
# #
0.061 0.00034
t f
t *
ND 0.000
t t
0.017 0.000098
# #
0.258 0.00143
# #
0.032 .0.000178
0.103 0.00057
4.29 0.0238
0.0158 0.000088
0.064 0.000357
3.57 0.0198
2.4 0.0135
7.1-9.1
   Average
    kg/kkg
(lbs/1000 Ibs)
   0.00055
   0.00178
   0.00038

   0.00075
   0.00121
   0.00014

   0.0043
   0.0019
   0.016

   0.0182
   0.000256
   0.000247

   0.00135
   0.0124
   0.000125

   0.00849
   3.245
   2.05
HD:  Hot Detected
i s  Calculation could not be completed.
* :  Could not be separated.

Mote:  For definitions of C&TT codes, refer to Table 111-21.

                                                      200

-------
                                    TABLE  V-19

                           CHARACTERISTICS OF ALUMINUM
                          DIE  LUBE  PROCESS WASTEWATERS
Raw Wastewaters

Plant:
Production (kkg/day):
Flow (1/kkg):
Sample Points:
Pollutants

005  Benzidine
006  Carbon  tetrachloride
007  Chlorobenzene

010  1,2-dichlor'oethane
Oil  1,1,1-trichloroethane
013  1,1-dichloroethane

021  2,4,6-trichlorophenol
023  Chloroform
039  Fluoranthene

044  Methylene  chloride
055  Naphthalene
058  4-nitrophenol

064  Pentachlorophenol
065  Phenol
066  bis(2-ethylhexyl)phthalate

067  Butyl benzyl  phthalate
072  Benzo(a)anthracene
077  Acenaphthylene

078  Anthracene
080  Fluorene
081  Phenanthrene :

084   Pyrene
 085   Tetrachlorethylene
 087   Trichloroethylene

 091   Chlordane
 120  Copper
 122  Lead

 128  Zinc                .
 130  Xylene              ,  ,

      Ammonia (N)
      Phenols (4AAP)
      Sulfide

      Oil  and Grease
      TSS
      pH (Units)
          20147
     156.2 (172 TPD)
     153.5 (36.8 GPT)
           C+G
                                                mg/1
1.385 ,
0.305
0.295

O.:160
17.466
0.053

0.225
0.527
2.915

3.085
1.439
0.082

1.020  ,
21.863
382.335

0.029
11.295
0.82  ..,-

0.66*
3.664
0.66*

0.346
0.132
0.281

0.068
0.65
2.55  ;

2.15
33.119

22.95
 81.02
 1..6

 21193
 2092
    kg/kkg
(lbs/1000 Ibs)

    0.000213
    0.000047
    0.000045

    0.000024
    0.268
    0.0000081

    0.000035
    0.0081
    0.000447

    0.000474
    0.000221
    0.000013

    0.000157
    0.00336
    0.0587

    0.0000045
    0.00173
    0.000126,....

 '.   0.000098
    0.000562
    0.000098

    0.000053
    0.000020
    0.000043

    0.000010
    0.000099
    0.000391

    0.000330
    0.00508

    0.0035
     0.0124 -
     0.000239

     3.25
     0.32
              6.9-7.7.
                                         201

-------
  TABLE V-19
  CHARACTERISTICS OF ALUMINUM
  DIE LUBE PROCESS WASTEWATERS
  PAGE 2
  Treated Effluent

  Plant:
  Flow (1/kkg):
  Sample  Points:
  C&TT:
 Pollutants

 005  Benzidine
 006  Carbon tetrachloride
 007  Chlorobenzene

 010  1,2-dichloroethane
 Oil  1,1,1-trichloroethane
 013  1,1-dichloroethane

 021  2,4,6-trichlorophenol
 023  Chloroform
 039  Fluoranthene

 044  Methylene chloride
 055  Naphthalene
 058  4-nitrophenol

 064  Pentachlorophenol
 065  Phenol
 066  Bis(2-ethylhexyl)phthalate

 067  Butyl benzyl phthalate
 072  Benzo(a)anthracene
 077  Acenaphthylene

 078  Anthracene
 080  Fluorene
 081  Phenanthrene

 084  Pyrene
 085  Tetrachloroethylene
 087  Trichloroethylene

 091  Chlordane
 120  Copper
 122  Lead

 128  Zinc
 130  Xylene

      Ammonia (N)
      Phenols (4AAP)
      Sulfide

      Oil and Grease
      TSS
      pH (Units)
             20147
           0 (0 GPT)
               E
        CY,FFOG,RTP-100
   mg/1
 ND
 0.605
 1.00

 ND
 1.262
 ND

 1.877
 0.286
 ND

 2.204
 0.090
 ND

 ND
 40.75
 404.12

 ND
 ND
 ND

 ND
 5.70
 ND

 0.18
 0.965
 0.125

 0.037
 0.61
 2.95

 2.14
 36.271

 16.8
82.29
0.2

26809
3078
    kg/kkg
(lbs/1000 Ibs)
                                                           6.7-7.1
ND:  Not Detected
* :  Could not be separated.
- :  Zero discharge, therefore, no effluent loads.

Note:  For definitions of C&TT codes, refer to Table 111-21.

                                        202

-------
                                   TABLE V-20

                            CHARACTERISTICS OF COPPER
                       DUST COLLECTION PROCESS WASTEWATERS
Raw Wastewater

Plant:
Sand Handled (kkg/day):
Flow (1/kkg):
Sample Point:
Pollutants

067  Butyl benzyl phthalate
074  3,4-faenzofluoranthene
075  Benzo(k)fluoranthene

084  Pyrene
120  Copper
122  Lead

124  Nickel               ;
128  Zinc

     Manganese
     Phenols  (4AAP)
     Oil and  Grease

     TSS
     pH (Units)

Treated Effluent

Plant:
Flow (1/kkg):
Sample  Points:
C&TT:
 Pollutants

 067  Butyl benzyl phthalate
 074  3,4-benzo fluoranthene
 075  Benzo(k)fluoranthene

 084  Pyrene
 120  Copper
 122  Lead

 124  Nickel
 128  Zinc

      Manganese
      Phenols (4AAP)
      Oil and Grease

      TSS
      pH (Units)
mg/1

0.191
0.010*
0:010*

0.022
107.27
26.97

0.76
129.62

0.93  "
2.093
11.6

613
 0.005
 ND
 ND

 0.016
 0.16
• 0.08

 0.01
 0.43

 0.03
 0.018
 0.58

 2.0
              9094
         386.8 (426 TPD)
          549 (132 GPT)
               D+E
    kg/kkg
(lbs/1000 Ibs)

    0.00105
    0.000006
    0.000006

    0.000012
    0.0589
    0.0148

    0.00415
    0.0712

    0.000509
    0.00115
    0.00603

    0.00337
           7.0-7.3
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            0(0  GPT)
         ((D+E)/(B+E))c
           IR,SL,RTP-100
                                                                   kg/kkg
                                                               (lbs/1000 Ibs)
           7.0-8.3
 -:  Zero discharge, therefore, no effluent loads.
 *:  Could not be separated

 Note:  For definitions of C&TT codes, refer to Table 111-21.

                                     - 203

-------
                                    TABLE V-21

                             CHARACTERISTICS OF COPPER
                MOLD COOLING AND CASTING QUENCH PROCESS WASTEWATERS
 Raw Wastewater

 Plant:
 Production (kkg/day):
 Flow (1/kkg):
 Sample  Points:
 Pollutants

 120   Copper
 128   Zinc

      Oil and  Grease
      TSS
      pH (Units)

 Treated Effluent
         6809
    648.3 (714  TPD)
    757  (181.5  GPT)
           C

                kg/kkg
mg/1        (lbs/1000 Ibs)

0.36           0.000273
2.10           0.00159

45             0.0338
56             0.0424
       8.2-8.4
                           4736
                       102 (112 TPD)
                            (1)
                             D
                    mg/1

                    1.1
                    3.5
                    16
    kg/kkg
(lbs/1000 Ibs!
                                        8.1
     (1)
Plant:
Flow  (1/kkg):
Sample Points:
C&TT:
Pollutants

120  Copper
128  Zinc

     Oil and Grease
     TSS
     pH (Units)
         6809
    757 (181.5 GPT)
       (C/DXE)
     CT,RTP-(Unk)
mg/1
    kg/kkg
(lbs/1000 Ibs)
0.109
1.405
5.6
13.1
0.000165
0.00213
0.00845
0.0199
                            NA
       7.6-8.4
(1)  Flow data were not available.
MA:  Not Applicable

Note:  For definitions of C&TT codes, refer to Table 111-21.
                                            204

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-------
Raw Wastewaters
                                                   TABLE V-25

                                    CHARACTERISTICS OF  FERROUS MOLD COOLING
                                     AND CASTING QUENCH PROCESS WASTEWATERS
Plant:
Production  (kkg/day)
Flow (1/kkg):
Sample Points:
      15654
  196.1 (216 TPD)
  21700 (5200 GPT)
        C
                               51026
                           408.6 (450 TPD)
                            977 (235 GPT)
                                 3+6
Pollutants

Iron
Oil and Grease
TSS
pH (Units)
            kg/kkg
        (lbs/1000 Ibs)
NA         NA
  9.0      0.188
147        3.191
    8.5-8.7
                                      kg/kkg
                          mg/1    (lbs/1000 Ibs)

                            7.8      0.00774
                           22.4      0.022
                          170        0.1687
                              7.2-11.1
                                                                                             Average
                                      kg/kkg
                                  (lbs/1000 Ibs)

                                       0.00774
                                       0.105
                                       1.680
Treated Effluent
Plant:
Flow (1/kkg):
Sample Points:
C&TT:
Pollutants

Iron
Oil and Grease
TSS
pH (Units)
     15654
   0 (0 GPT)
       E
  CT,SB,RTP-100
mg/1
    kg/kkg
(lbs/1000 Ibs)
NA
  9.0
216
    8.5-8.6
      51026
        NA
        NA
        SL

            kg/kkg ,
mg/1    (lbs/1000 Ibs)

NA         NA
NA         NA
NA         NA
HA         NA
Note: For definitions, of C&TT codes refer to Table 111-21.

-:   Zero discharge; therefore, no effluent loads.
NA:  Not available .             -..            :'"-"'"-.
                                                 221

-------
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-------
                                TABLE V-27

                         CHARACTERISTICS OF LEAD
               CONTINUOUS STRIP CASTING PROCESS  WASTEWATERS
Raw Wastewater

Plant:
Flow (1/kkg):
Sample Point:

Pollutants

120 Copper
122 Lead
128 Zinc

    Oil and Grease
    TSS
    pH (units)
 mg/1

 0.046
 0.848
 0.014

<5
 5
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(lbs/1000 Ibs)

   0.000001
   0.000021
   0.0000004
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   0.000126
                7.7
Note:  A representative discrete continuous strip casting
       treated effluent sample could not be obtained.
                                      224

-------
                                    TABLE  V-28

                           CHARACTERISTICS OF MAGNESIUM
                      GRINDING SCRUBBER PROCESS WASTEWATERS
Raw Wastewater

Plant:
Production (kkg/day):
Flow (1/kkg):
Sample Points:
Pollutants

128  Zinc
     Manganese
     Oil and Grease

     TSS
     pH (Units)

Treated Effluent

Plant:
Flow:
Sample Points:
C&TT:
Pollutants

128  Zinc
     Manganese
     Oil and Grease

     TSS
     pH (Units)
mg/1

 1.19
 0.29
 4.0

 37.0
mg/1
                08146
          0.726 (0.80 TPD)
           6737 (1616 GPT)
                  B
           9.4-10.0
               08146
               None,
          NO TREATMENT
    kg/kkg
(lbs/1000 Ibs)

    0.00802
    0.00196
    0.030

    0.251
    kg/kkg
(lbs/1000 Ibs)
                                         225

-------
                                    TABLE V-29

                           CHARACTERISTICS OF MAGNESIUM
                       DUST  COLLECTION PROCESS WASTEWATERS
Raw Wastewater

Plant:
Sand Handled  (kkg/day):
Flow (1/kkg):
Sample Points:
Pollutants

128  Zinc
     Phenols (4AAP)
     Sulfide

     Oil and Grease
     TSS
     pH (Units)

Treated Effluent

Plant:
Flow:
Sample Points:
C&TT:
Pollutants

128  Zinc
     Phenols (4AAP)
     Sulfide

     Oil and Grease
     TSS
     pH (Units)
mg/1
0.36
1.141
12.6

11.0
26.0
mg/1
              08146
         90.8 (100 TPD)
          90 (21.6 GPT)
                C
           7.4-7.8
             08146
                                                 None
         NO TREATMENT
     kg/kkg
 (lbs/1000 Ibs)

     0.000033
     0.000103
     0.00113

     0.000992
     0.00232
    kg/kkg
(lbs/1000 Ibs)
                                        226

-------
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-------
                                     TABLE V-31

                              CHARACTERISTICS OF ZINC
                              MELTING FURNACE  SCRUBBER
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 Raw Wastewater

 Plant:
 Production (kkg/day):
 Flow (1/kkg):
 Sample Points:
 Pollutants

 021   2,4,6-trichlorophenol
 022   Parachlorometacresol
 031   2,4-dichlorophenol

 034   2,4-dimethylphenol
 055   Naphthalene
 065   Phenol

 067   Butyl benzyl phthalate
 128   Zinc

      Phenols  (4AAP)
      Oil and  Grease
      TSS
      pH (Units)

 Treated Effluent

 Plant:
 Flow  (1/kkg):
 Sample Points:
 C&TT:

 Pollutants

 021   2,4,6-trichlorophenol
 022  Parachlorometacresol
 031  2,4-dichlorophenol

034  2,4-dimethylphenol
055  Naphthalene
065  Phenol

067  Butyl benzyl phthalate
128  Zinc

     Phenols
     Oil and Grease
     TSS
     pH (Units)
     18139
59.7 (65.7 TPD)
 2925 (701 GPT)
        B
                                               mg/1
                                               1.374
                                               0.081
                                               1.268

                                               4.342
                                               1.623
                                               15.697

                                               0.080
                                               18.54

                                               90.744
                                               760
                                               429
                                                         4.6-4.7
               kg/kkg
           (lbs/1000 Ibs)

                 0.00402
                 0.000273
                 0.00376

                 1.269
                 0.00474
                 0.0459

                 0.000234
                 0.0542

                 0.265
                 2.221
                 1.254
                                                         18139
                                                     2925  (701 GPT)
                                                    (B/(B+C+D+E+H))G
                                                        OS, SB
                                                                  kg/kkg
                                              mg/1            (lbs/1000 Ibs)
                                              0.617
                                              ND
                                              0.220

                                              0.096
                                              0.049
                                              1.65

                                              0.049
                                              13.24

                                              14.194
                                              845
                                              325
                0.00180
                0.000
                0.000643

                0.000281
                0.000144
                0.00484

                0.000144
                0.0387

                0.0415
                2.470
                0.949
                                                        4.6-8.2
Note: For definitions of C&TT codes refer to Table 111-21.

ND: Not Detected
                                         223

-------
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                           SECTION VI
                     SELECTION OF POLLUTANTS
Section  V  presented  the pollutants to be examined for possible
regulation  along  with  data  from  plant  sampling  visits  and
chemical analyses.

This  section  discusses those pollutants which were not found in
the raw process wastewaters or were detected at such small levels
that their  presence  could  not  be  quantified.   Additionally,
pollutants  known  to  be  present in raw process wastewaters are
discussed.  Toxic pollutants known to be present are discussed in
numerical order, followed by nonconventional pollutants and  then
conventional pollutant parameters, each in alphabetical order.
                •	•' *"'n •• • •	r1' •• '' • !!•	   j L "   H" j_ .HI	   i,  , ,  ,   L    ...•".

Finally,  the pollutant parameters selected for consideration for
specific regulation for the discharge alternatives  discussed  in
Sections  IX  through XIII of this document, and those eliminated
from further consideration in  each  subcategory  are  discussed.
The rationale for those selections is also presented.

POLLUTANTS NOT DETECTED IN RAW PROCESS WASTEWATERS

Table  VI-1 lists the 21 pollutants that were not detected in any
raw  process  wastewater  samples  in   this   category.    These
pollutants  have  been  eliminated from further consideration for
regulation*       ~           ;                -=

POLLUTANTS DETECTED IN
RAW PROCESS WASTEWATERS BELOW QUANTIFIABLE LIMITS

Table VI-2 lists the 14 pollutants that were found  in raw process
wastewaters  at  npnquantifiable  levels  in  all   raw   process
wastewaters  samples analyzed in this category,  These pollutants
have  also  been  eliminated  from  further   consideration   for
regulation.

POLLUTANTS PRESENT IN RAW PROCESS WASTEWATERS

Table  VI-3 lists those pollutants present  in quantifiable in raw
process wastewaters.  A pollutant is considered to  be present  if
any  of   the  following  three  conditions  are satisfied: 1) the
average raw wastewater  concentration  of   a  pollutant  for  all
plants  sampled  within the subcategory is  0.010 mg/1 or greater,
2) the pollutant  is  identified as "known to be  present"  in  the
plant  DCP  response,  or 3) examination of the metal molding and
                               287

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casting manufacturing processes  indicates  that  a  pollutant   is
associated  with  a  specific  manufacturing  process  due to the
nature of the manufacturing  process,  raw  materials  used,  air
pollution   control   devices,   or   other   production  related
parameters.

Ninty-two toxic pollutants were  found in quantifiable amounts   in
wastewaters  of  the  metal  molding and casting category.  These
pollutants are listed in Table VI-3  and  are  discussed  briefly
below.   These discussions: provide details regarding the process
origin of the pollutant;  discuss  whether  the  pollutant  is  a
naturally   occurring  • element,   processed  metal,  or  process
chemical; describe the general physical properties and  the  form
of each pollutant; describe the  toxic effects of the pollutant  in
humans  and  other  animals;  and  discuss  the  behavior of each
pollutant in POTWs at the concentrations that might  be  expected
from  industrial  dischargers.   The  literature  relied upon for
these discussions is listed in Section XV.  Particular  attention
has  been  given  to  documents  generated by the EPA Criteria and
Standards Division, and the Monitoring and Data Support Division.
                                           i
Acenaphthene(1).   Acenaphthene  (1,2-dihydroacenaphthylene,    or
1,8-ethylene-naphthalene)  is  a polynuclear aromatic hydrocarbon
(PAH) with molecular weight of 154 and a formula of C12Hj0.   The
structure is:

Acenaphthene  occurs in coal tar produced during high temperature
coking of coal.  It has been  detected  in  cigarette  smoke  and
gasoline exhaust condensates.

The   pure   compound  is  a  white  crystalline  solid  at  room
temperature, with a melting range of 95 to 97°C  (203  to  207°F)
and  a  boiling,  range of 278 to 280°C (532 to 536°F).  Its vapor
pressure  at  room   temperature   is   less   than   0.02 mm Hg.
Acenaphthene  is  slightly  soluble in water (100 mg/1), but even
more soluble in organic solvents such as  ethanol,  toluene,  and
chloroform.    Acenaphthene  can be oxidized by oxygen or ozone  in
the presence of certain catalysts.  It is stable under laboratory
conditions.

Acenaphthene is used as a dye intermediate, in the manufacture  of
some plastics, and as an insecticide and fungicide.

So little research has been performed on  acenaphthene  that  its
mammalian  and  human  health effects are virtually unknown.  The
water quality criterion of 0.02 mg/1 is  recommended  to  prevent
the  adverse effects on humans due to the organoleptic properties
of acenaphthene in water.  Limited  acute  ;and  chronic  toxicity
                              288

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data  for freshwater aquatic life show that adverse effects occur
at higher concentrations than Jthose cited for human health risks.

No detailed study of acenaphthene behavior in POTWs is available.
However, it has  been  demonstrated  that  none  of  the  organic
priority  pollutants  studied  so  far  can  be  broken  down  by
biological  treatment  processes  as  readily  as  fatty   acids,
carbohydrates, or proteins.  Many of the priority pollutants have
been  investigated,  at  least  in  laboratory  scale studies, at
concentrations higher than those expected to be contained by most
municipal wastewaters.  General observations  relating  molecular
structure  to  ease of degradation have been developed for all of
the organic priority pollutants.

The conclusion reached by study  of  the  limited  data  is  that
biological   treatment  produces  little  or  no  degradation  of
acenaphthene.  No evidence is available to draw conclusions about
its possible toxic or inhibitory effect on POTW operations.

Its water solubility would  allow  acenaphthene  present  in  the
influent   to. pass  through  a  POTW  into  the  effluent.   The
hydrocarbon character of  this  compound  makes  it  sufficiently
hydrophobic  that  adsorption onto suspended solids and retention
in the sludge may also be a  significant  route  for  removal  of
acenaphthene from the POTW.

Acenaphthene has been demonstrated to affect the growth of plants
through  improper  nuclear  division  and  polypoidal  chromosome
number.  However, it is not expected  that  land  application  of
sewage  sludge containing acenaphthene, at the low concentrations
which are to be expected in a POTW sludge, would  result  in  any
adverse effects on animals ingesting plants grown in such soil.

Benzene  (4).   Benzene  (C6H«)  is  a  clear,  colorless, liquid
obtained mainly from petroleum feedstocks  by  several  different
processes.   Some  is recovered from light oil obtained from coal
carbonization gases.  It boils at 80°C and has a  vapor  pressure
of  100  mm Hg at 26°C.  It is slightly soluble in water (1.8 g/1
at 25°C) and it dissolves in hydrocarbon solvents.   Annual  U.S.
production is three to four million tons.

Most  of  the  benzene  used  in  the  U.S.  goes  into  chemical
manufacture.  About half of that  is  converted  to  ethylbenzene
which   is  used  to  make styrene.  Some benzene is used in motor
fuels.

Benzene  is  harmful  to  human  health  according  to   numerous
published  studies.   Most  studies  relate  effects  of  inhaled
benzene vapors.  These effects include  nausea,  loss  of  muscle
                              289

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 coordination,   and  excitement,   followed by depression and coma.
 Death  is  usually the result  of  respiratory  or   cardiac  failure.
 Two  specific   blood  disorders  are related to benzene exposure.
 One  of   these,   acute   myelogenous   leukemia,    represents   a
 carcinogenic   effect  of   benzene.    However, most  human exposure
 data is based  on exposure in occupational settings,   and  benzene
 carcinogenesis is not considered to  be  firmly established.

 Oral   administration  of   benzene to laboratory animals produced
 leukopenia, a  reduction in the  number of  leukocytes  in  the blood.
 Subcutaneous injection of  benzene-oil   solutions   has  produced
 suggestive,     but    not   conclusive,    evidence    of   benzene
 carcinogenesis.

 Benzene demonstrated teratogenic effects  in   laboratory  animals,
 and mutagenic  effects in  humans  and  other animals.

 For  maximum   protection   of human   health   from  the   potential
 carcinogenic effects of exposure to  benzene,  through ingestion of
 water  and contaminated   aquatic organisms,  the ambient   water
 concentration   is  zero.   Concentrations of  benzene estimated to
 result in additional lifetime cancer risk  at   levels   of   10~7,
 10-«,  and  10~s   are 0.00015 mg/1,  0.0015  mg/1, and 0.015  mg/1,
 respectively.    If  contaminated aquatic organisms alone   are
 consumed,   excluding  the   consumption of   water,   the   water
 concentration  should be less than 0.478 mg/1  to keep the lifetime
 cancer risk below 10~s.   Available data show  that adverse effects
 on aquatic life occur at  concentrations higher  than   those   cited
 for human risks.

 Some studies have been reported  regarding the behavior  of benzene
 in  POTWs.   Biochemical   oxidation   of   benzene  under  laboratory
 conditions, at concentrations of 3 to 10  mg/1,  produced  24,  27,
 24,  and  29  percent degradation   in  5,   10,   15,  and 20  days,
 respectively, using  unacclimated seed cultures   in   fresh water.
 Degradation  of   58,   67,  76, and 80 percent was produced in the
 same time periods using acclimated seed cultures.  Other studies
 produced  similar results.   Based   on   these  data and general
 conclusions   relating    molecular    structure    to   biochemical
 oxidation, it  is  expected  that biological  treatment  in  POTWs will
 remove  benzene   readily   from the water.  Other  reports indicate
 that most of the  benzene   entering   a POTW   is   removed to  the
 sludge,   and that influent concentrations  of  1  g/1 inhibit sludge
 digestion.  An EPA study  of  the  fate  of   priority  pollutants  in
 POTWs  reveals removal efficiencies  of 70  to 98 percent  for  three
 POTWs where influent  benzene  levels  were  5 x  10~3 to  143  x  10~3
mg/1.      Four   other   POTW   samples    had    influent   benzene
 concentrations of  1  or 2   x   10~3  mg/1,   and   removals   appeared
 indeterminate   because  of  the  limits   of  quantification  for
                               290

-------
analyses.  There is no  information  about  possible  effects  of
benzene  on  crops  grown in soils amended with sludge containing
benzene.

Benzidine (5).  Benzidine (NHZ(C6H4)2NH2)  is  a  grayish-yellow,
white  or  reddish-gray  crystalline  powder.   It melts at 127°C
{260°F), and boils at 400°C (752<>F).  This chemical is soluble in
hot water, alcohol, and  ether,  but  only  slightly  soluble  in
water.   It  is  derived  by:  (a) reducing nitrobenzene with zinc
dust in an alkaline solution followed by  distillation;  (b)  the
electrolysis  of  nitrobenzene, followed by distillation; or, (c)
the nitration of diphenyl followed by reduction  of  the  product
with   zinc   dust  in  an  alkaline  solution,  with  subsequent
distillation.  It is used  in  the  synthesis  of  a  variety  of
organic   chemicals,   such    as   stiffening  agents  in  rubber
compounding.

Available data  indicate  that  benzidine  is  acutely  toxic  to
freshwater aquatic life at concentrations as low as 2.50 mg/1 and
would  occur  at lower concentrations among species that are more
sensitive than those tested.   However,  no  data  are  available
concerning  the  chronic  toxicity  to  sensitive  freshwater and
saltwater aquatic life.

For the maximum protection of  human  health  from  the  potential
carcinogenic  effects  due  to exposure to benzidine, through the
ingestion  of  contaminated  water   and   contaminated   aquatic
organisms,  the  ambient  water  concentration  should  be  zero.
Concentrations  of  this  pollutant  estimated   to   result   in
additional lifetime cancer risk at risk levels of  TO-5, 10-«, and
TO-*  are  0.0000012  mg/1, 0.00000012 mg/1, and 0.000000012 mg/1
respectively.

With respect to treatment in POTWs, laboratory studies have shown
that  benzidine  is  amenable  to   treatment   via   biochemical
oxidation.    The   expected   30-day  average  treated  effluent
concentration is 0.025 mg/1.

Carbon  tetrachloride   (6).   Carbon  tetrachloride   (CC14),  also
called    tetrachloromethane,   is  a  colorless  liquid  produced
primarily by the  chlorination of  hydrocarbons   -  particularly
methane.   Carbon  tetrachloride  boils  at  77°C  and has a vapor
pressure  Of  90 mm Hg at 20°C.  It is slightly  soluble   in  water
(0.8  mg/1   at  25°C)  and  soluble  in  many  organic  solvents.
Approximately one-third of a million tons  is produced annually in
the U.S.

Carbon  tetrachloride,  which was displaced  by perchloroethylene as
a  dry cleaning agent in the  1930's, is  used  principally   as  an
                               2-91.

-------
 intermediate   for   production   of    chlorofluoromethanes   for
 refrigerants,  aerosols,  and blowing agents.   It  is also used as a
 grain fumigant.

 Carbon tetrachloride  produces   a  variety   of toxic  effects  in
 humans.    Ingestion of  relatively  large quantities - greater than
 five grams - has  frequently proven fatal.   Symptoms  are  burning
 sensation   in   the mouth,   esophagus,   and  stomach,  followed by
 abdominal  pains,  nausea,  diarrhea, dizziness, abnormal  pulse,  and
 coma.   When death does  not  occur immediately,  liver  and   kidney
 damage  are usually found.   Symptoms  of chronic  poisoning  are not
 as well  defined.   General fatigue,  headache,  and  anxiety  have
 been   observed,   accompanied   by digestive tract  and   kidney
 discomfort or  pain.

 Data  concerning   teratogenicity  and  mutagenicity   of   carbon
 tetrachloride   are scarce   and inconclusive.   However,   carbon
 tetrachloride   has been  demonstrated   to   be   carcinogenic   in
 laboratory animals.   The  liver  was the  target organ.

 For   the  maximum protection   of  human health from the potential
 carcinogenic effects  of exposure to carbon  tetrachloride,  through
 ingestion   of  water  and   contaminated aquatic   organisms,   the
 ambient  water concentration   is  zero.  Concentrations of  carbon
 tetrachloride  estimated to  result  in  additional  lifetime   cancer
 risk  at  risk levels of 10~7,  10~«, and 10~5 are 0.000026  mg/1,
 0.00026  mg/1,  and 0.0026 mg/1,  respectively.

 Data on  the  behavior  of carbon  tetrachloride  in   POTWs are  not
 available.   Many of  the   organic priority pollutants have been
 investigated,  at least  in    laboratory   scale    studies,    at
 concentrations  higher  than  those   expected to be  found  in most
 municipal  wastewaters.  General  observations have  been   developed
 relating  molecular   structure   to ease  of degradation  for all  of
 the  organic  priority pollutants.   The conclusion reached by  study
 of the limited data   is  that   biological  treatment  produces  a
 moderate  degree  of removal of  carbon tetrachloride  in  POTWs.   No
 information  was found  regarding   the  possible  interference   of
 carbon   tetrachloride  with  treatment   processes.   Based on  the
 water solubility  of carbon  tetrachloride, and the  vapor  pressure
 of   this   compound,   it  is  expected that some of  the  undegraded
 carbon tetrachloride will pass  through  to the POTW  effluent,   and
 some will  be volatilized in aerobic processes.


 Chlorobenzene   (7).     Chlorobenzene    (C6H5C1),   also   called
monochlorobenzene  is a clear, colorless, liquid  manufactured   by
 the  liquid  phase  chlorination  of benzene over a catalyst.   It
boils at 132°C (270°F) and has a vapor pressure of  12.5 mm Hg   at
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25°C.   It  is  almost  insoluble in water (0.5 g/1 at 30°C), but
dissolves in hydrocarbon solvents.   IkS.  annual  production  is
near 150,000 tons.

Principal  uses  of  chlorobenzene  are  as  a  solvent and as an
intermediate for dyes and pesticides.  Formerly it was used as an
intermediate for DDT production, but elimination of production of
that compound reduced annual  U.S.  production  requirements  for
chlorobenzene by half.

Data  on  the  threat  tohuman health posed by chlorobenzene are
limited in number.  Laboratory animals administered  large  doses
of  chlorobenzene  subcutaneously,  died  as  a result of central
nervous system depression.  At slightly lower dose rates, animals
died of liver or kidney damage.  Metabolic disturbances  occurred
also.    At   even   lower  dose  rates  of  orally  administered
chlorobenzene, similar effects were observed,  but  some  animals
survived  longer than at higher dose rates.  No studies have been
reported regarding evaluation of the teratogenic,  mutagenic,  or
carcinogenic potential of chlorobenzene.

For  the  prevention  of  adverse effects due to the organoleptic
properties of chlorobenzene in water, the  recommended  criterion
is 0.020 mg/1.

Limited data are available on which to base conclusions about the
behavior  of  chlorobenzene  in POTWs.  Laboratory studies of the
biochemical oxidation of chlorobenzene have been carried  out  at
concentrations greater than those expected to normally be present
in  POTW  influents.  Results showed the extent of degradation to
be 25, 28, and 44 percent after 5, 10, and 20 days, respectively.
In another, similar  study  using  a  phenol-adapted  culture,  4
percent  degradation  was  observed after 3 hours with a solution
containing 80 mg/1.  On the basis of these  results  and  general
conclusions  about  the  relationship  of  molecular structure to
biochemical oxidation, it is concluded that chlorobenzene will be
removed to a moderate degree by biological treatment in POTWs.  A
substantial percentage of the chlorobenzene remains intact and is
expected to volatilize from the POTW in aeration processes.   The
estimated  half-life  of  chlorobenzene  in water, based on water
solubility, vapor pressure and molecular weight, is 5.8 hours.

1,2,4-trichlorobenzene  (8).    1,2,4-trichlorobenzene    (C6H3C13,
1,2,4-TCB)  is  a  liquid  at   room temperature, solidifying to a
crystalline solid at  17°C (3°F) and boiling at 214°C (417°F).  It
is produced by  liquid  phase   chlorination , of  benzene  in  the
presence  of  a catalyst.   Its  vapor pressure is 4 mm Hg at  25°C.
1,2,4-TCB is  insoluble in water and soluble in organic  solvents.
Annual U.S. production is in ,the  range of  15,000 tons.   1,2,4-TCB
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is  used   in  limited quantities as a solvent and as a dye carrier
in the textile  industry.   It  is also  used  as  a  heat  transfer
medium   and  as  a  transformer  fluid.   The  compound  can  be
selectively   chlorinated   to   1,2,4,5-tetrachlorobenzene   using
iodine plus antimony trichloride  as catalysts.

No   reports  were  available  regarding  the  toxic  effects  of
1,2,4-TCB  on  humans.  Limited data, from studies  of  effects  in
laboratory animals fed  1,2,4-TCB, indicate depression of activity
at  low doses and predeath extension convulsions at lethal doses.
Metabolic  disturbances  and  liver changes  were  also  observed.
Studies  for  the purpose  of determining teratogenic or mutagenic
properties of 1,2,4-TCB have not  been conducted.  No studies have
been made  of  carcinogenic  behavior  of  1,2,4-TCB  administered
orally.

For  the   prevention  of   adverse effects due to the organoleptic
properties of 1,2,4-trichlorobenzene in water, the water  quality
criterion  is  0.013 mg/1.

Data  on   the   behavior  of 1,2,4-TCB in POTWs are not available.
However, this compound  has  been  investigated  in  a  laboratory
scale  study  of  biochemical  oxidation at concentrations higher
than  those  expected   to  be   contained   by   most   municipal
wastewaters.    Degradations  of   0,  87,  and  100  percent  were
observed after  5, 10, and  20  days,  respectively.   Using  this
observation and general observations relating molecular structure
to   ease   of  degradation  for  all  of  the  organic  priority
pollutants/ the conclusion was reached that biological  treatment
produces a high degree  of removal in POTWs.

1,2-dichloroethane  (10).   1,2-dichloroethane  (C1CH2CH2C1) is a
colorless, oily liquid with a chloroform-like odor  and  a  sweet
taste.   Stable in  the  presence  of water, alkalies, acids, or
actively   reacting  chemicals,  it  is  resistant  to  oxidation.
Miscible   with  most common solvents, it is only slightly soluble
in water.  It boils at  83.5°C (182°F), flashes at 21°C (70°F) and
has a vapor pressure of 100 mm Hg at 29.4°C-   This  chemical  is
derived  by  the  action  of chlorine on ethylene with subsequent
distillation, with ethylene dibromide as a catalyst.  It is  used
as  a  solvent  for oils, resins,   gums, and other products and for
metal degreasing.

Available  data  indicate that acute toxicity to freshwater aquatic
life occurs at  118 mg/1, and that chronic toxicity  occurs  at  a
concentration   of 29 mg/1.  Available data for saltwater fish and
invertebrate species indicate that acute toxicity occurs  at  113
mg/1.
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For  the  maximum  protection  of human health from the potential
carcinogenic  effects  due  toi exposure  to  1,2-dichloroethane,
through  the  ingestion  of  contaminated  water and contaminated
aquatic organisms, the  ambient  water  concentration  should  be
zero.   Concentrations  of  this pollutant estimated to result in
additional lifetime cancer risk at risk levels of J0-s> TO «, and
lO-^  are  0.0094  mg/1,  0.00094   mg/1,   and   0.000094   mg/1
respectively.

With respect to treatment in POTWs, laboratory studies have shown
that  V,2-dichloroethane is only moderately amenable to treatment
via biochemical oxidation.  This is corroborated by the  Physical
property  data  presented  above.   It  should  be noted that the
optimum estimated 30-day average treated  effluent  concentration.
of  0.10  mg/1  is greater than  the level at which this pollutant
was found in any  foundry process wastewater.

l,l,l-trichloroethane(n).   1,1,1-trichloroethane is^one  of  the
t££—possible"	trichloroethanes.     It    is   manufactured   by
hydrochlorinating vinyl chloride to 1  1-dichloroethane, ^ich^is
then  chlorinated  to  the desired  product.  1,1,1-trichlproethane
is a liquid  at room  temperature  with  a  vapor pressure of 96 mm Hg
at 20°C and  a boiling  point  of 74oc.   Its formula is CCljCHa-  Jt
is slightly  soluble  in water (0.48 g/1)  and is  very  soluble  in
organic   solvents.   U.S.    annual production  is  greater   than
one-third of a million tons.

1,1,1-trichloroethane   is  used  as   an  industrial  solvent  and
degreasing  agent.

Most  human toxicity   data  for 1,1 ', 1-trichloroethane  relates to
inhalation   and   dermal  exposure  routes.    Limited^   data   are
available     for     determining      toxicity      of     ^"^ted
1  1  1-trichloroethane, and those data are all   for   the  compound
itself,   not.  for  solutions  in  water.    No  data are available
regarding its  toxicity to fish and aquatic  organisms.    For  the
protection   of    human  health   from  the  toxic   properties of
 1  l,1-trichloroethane, ingested  through the consumption of   water
and  fish,   the   ambient   water   criterion  is   15.7   mg/1.    The
 criterion is based on bioassay for possible carcinogenicity.

No detailed study of 1,1,1-trichloroethane behavior in  POTWs  is
 available.    However,   it  has been  demonstrated that none of the
 organic priority pollutants  of this  type can  be  broken  down  by
 biological    treatment  processes  as  readily   as  fatty  acids,
 carbohydrates,  or proteins.

 Biochemical oxidation of many of  the organic  priority  pollutants
 has  been  investigated,  at least in laboratory scale studies,  at
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 concentrations  higher  than  commonly  expected   in   municipal
 wastewater.  General observations relating molecular structure to
 ease  of  degradation  have  been  developed  for  all  of  these
 pollutants.  The conclusion reached by study of the limited  data
 is  that  biological  treatment  produces  a  moderate  degree of
 degradation of 1,1,1-trichloroethane.  No evidence  is  available
 for  drawing  conclusions  about its possible toxic or inhibitory
 effect on POTW operations.  However, for degradation to occur,  a
 fairly constant input of the compound would be necessary.

 Its  water  solubility would allow 1,1,1-trichloroethane, present
 in the influent and not biodegradable,  to  pass  through  a  POTW
 into the effluent.   One factor which has received some attention,
 but  no  detailed  study,   is  the  volatilization  of  the lower
 molecular weight organics from POTWs.   If  1,1,1-trichloroethane
 is  not biodegraded,  it will volatilize  during aeration processes
 in the POTW.

 1,1-dichloroethane(13).      l,1-dichloroethane,     also    called
 ethylidene  dichloride  and  ethylidene   chloride,  is  a colorless
 liquid manufactured by  reacting  hydrogen  chloride   with  vinyl
 chloride  in  1,1-dichloroethane  solution  in   the presence of  a
 catalyst.     However,    it   is    reportedly   not   manufactured
 commercially  in the  U.S.   1,1-dichloroethane boils  at  57°C  and
 has  a  vapor pressure   of   182 mm Hg   at   20°C.    It is  slightly
 soluble  in  water   (5.5  g/1 at  20°C) and  very soluble in organic
 solvents.                                                    v

 1,1-dichloroethane  is used as an extractant  for   heat-sensitive
 substances and as a solvent  for  rubber and silicone grease.

 1,1-dichloroethane    is     less    toxic    than    its    isomer
 (1,2-dichloroethane), but  its  use   as  an  anesthetic  has  been
 discontinued  because  of  marked  excitation  of   the  heart.  It
 causes  central nervous system depression  in  humans.    There  are
 insufficient   data   to   derive    water  quality  criteria  for
 1,1-dichloroethane.
                                           l
 Data on  the behavior  of   1,1-dichloroethane  in  POTWs   are  not
 available.   Many  of  the  organic priority pollutants have been
 investigated,  at  least   in   laboratory   scale   studies,   at
 concentrations higher than those expected  to be contained  by most
municipal wastewaters.  General  observations have been developed,
relating  molecular  structure to ease of  degradation,  for all of
the organic priority pollutants.  The conclusion reached by  study
of the limited data is that biological treatment produces only  a
moderate removal of 1,1-dichloroethane in  POTWs by degradation.
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The  high  vapor  pressure  of  1,1-dichloroethane is expected to
result in volatilization of some of  the  compound  from  aerobic
processes  in POTWs.  Its water solubility will result in some of
the 1,1-dichloroethane which  enters  the  POTW  leaving  in  the
effluent from the POTW.

1.1.2-trichloroethane(14).   1,1,2-trichloroethane  is one of the
two possible trichloroethanes  and  is  sometimes  called  ethane
trichloride  or  vinyl  trichloride.  It is used as a solvent for
fats,  oils,  waxes,  and   resins,   in   the   manufacture   of
1,1-dichloroethylene,   and   as   an   intermediate  in  organic
synthesis.

1,1,2-trichloroethane  is  a  clear,  colorless  liquid  at  room
temperature  with   a  vapor pressure of 16.7 mm Hg at 20°C, and a
boiling point of 113°C.   It  is  insoluble  in  water  and  very
soluble in organic  solvents.  The formula is CKC1ZCEZC1.

Human  toxicity data for  1,1,2-trichloroethane does not appear in
the literature.  The  compound  does  produce  liver  and  kidney
damage    in    laboratory    animals    after     intraperitoneal
administration.   No  literature  data  were   found   concerning
teratogenicity    or   mutagenicity   of   l,1,2-trichloroethane.
However, mice treated with  1,1,2-trichloroethane showed increased
incidence of hepatocellular carcinoma.  Although bioconcentration
factors are not available for  1,1,2-trichloroethane  in  fish  and
other  freshwater aquatic organisms,  it is concluded on the basis
of octanol-water  partition  coefficients  that  bioconcentration
does  occur.

For   the  maximum   protection   of human health from  the potential
carcinogenic  effects  of  exposure   to   1,1,2-trichloroethane,
through   ingestion   of  water  and contaminated aquatic organisms,
the  ambient water concentration is  zero.  Concentrations of   this
compound  estimated to result  in additional lifetime cancer risks
at  risk  levels  of 10~7,  10-«,  and  10~s are 0.000027  mg/1,  0.00027
mg/1,  and 0.0027 mg/1, respectively.

No  detailed study of 1,1,2-trichloroethane behavior  in  POTWs  is
available.  However,  it  is  reported that  small amounts  are formed
by  chlorination processes,  and that this  compound  persists in the
environment   (greater   than two years) and  it  is  not biologically
degraded.   This information is not  completely  consistent with the
conclusions   based   on  laboratory   scale biochemical  oxidation
studies   and  relating  molecular structure to ease  of degradation.
That study  concluded that  biological  treatment   in  POTWs  will
produce  moderate  removal  of 1,1,2-trichloroethane.
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 The  lack  of  water  solubility  and  the  relatively high vapor
 pressure may lead to removal  of  this  compound  from  POTWs  by
 volatilization.

 1,1,2,2-tetrachloroethane     (15).      1,1,2,2-tetrachloroethane
 (CHC12CHC12)  is  a  heavy,  colorless,   mobile,   nonflammable,
 corrosive, toxic liquid.  While it has a chloroform-like odor, it
 is  more  toxic  than  chloroform.   It  is soluble in alcohol or
 ether,  but insoluble in water.   It has no flash point,  boils  at
 146.5°C  (296°F)  and  has a vapor pressure of 5 mm Hg at 20.7°C.
 It results from the interaction of acetylene and  chlorine,   with
 subsequent  distillation.    This  chemical  is  used  in  organic
 synthesis, as a solvent, and for metal cleaning and degreasing.

 Available freshwater data  indicate that acute toxicity occurs  at
 concentrations  of 9.32 rng/1,  and that chronic toxicity occurs at
 4.000   mg/1.    Available  saltwater   data  indicate  that   acute
 toxicity occurs at 9.020 mg/1.

 For the  maximum  protection   of human health from the potential
 carcinogenic  effects   due   to  exposure   to   1,1,2,2-tetra-
 chloroethane,  through contaminated water and contaminated aquatic
 organisms,   the  ambient  water   concentration  should  be  zero.
 Concentrations  of  this  pollutant   estimated   to   result   in
 additional lifetime cancer risk  at risk levels of 10-s,  10-*,  and
 10-7 are 0.0017 mg/1,  0.00017 mg/1,  and 0.000017 mg/1

 With respect  to treatment  in POTWs,  laboratory studies  have  shown
 that  1,1,2,2-tetrachloroethane   is  not amenable to treatment  via
 biochemical  oxidation.   As this  pollutant  is insoluble  in  water,
 any  removal  of  this  pollutant which  would  occur in a  POTW,  would
 be  related to  physical  treatment processes.

 Bis(2-chloroethvl)    ether  (18).     Bis(2-chloroethyl)     ether
 (C1CH2CH2OCH2CH2CL)   is  a  colorless,  stable, non-corrosive liquid
 with an  odor similar  to  that of  ethylene dichloride.    Its   boils
 at  178.5°C   (353°F),  flashes   at   55°C   (131°F) and has a  vapor
 pressure of  1 mm  Hg at 23.5°C.   It is  miscible with most  organic
 solvents,    immiscible   with    the  paraffin  hydrocarbons,   and
 insoluble with water.  It  is used as a  solvent for  oils,  waxes,
 and  resins,  as  a wetting  and penetrating  compound, as a solvent
 in the production of  lubricating oils,  and  in  the  synthesis  of
 various organics.

 The  available  data  for   this  pollutant   indicate  that   acute
 toxicity to freshwater aquatic life occurs  at  concentrations  as
 low   as  238  mg/1.   No   data  are  available  concerning  this
pollutant's chronic toxicity to freshwater  aquatic life and  acute
and chronic toxicity to saltwater aquatic life.
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For the maximum protection of human  health  from  the  potential
carcinogenic  effects  of  exposure  to  this  pollutant, through
ingestion  of  contaminated  water  and  aquatic  organisms,  the
ambient  water  concentration  should be zero.  Concentrations of
this pollutant estimated to result in additional lifetime  cancer
risks  at  risk  levels  of 10-*, 10-«, and 10-* are 0.0003 mg/1,
0.00003 mg/1, '0.000003 mg/1 respectively.

With respect to treatment in POTWs, laboratory studies have shown
that bis(2-chloroethyl) ether is not amenable  to  treatment•. via
biochemical  oxidation.  As this pollutant is insoluble  in water,
any removal of this pollutant, which would occur in a POTW,, would
be related to physical treatment processes.

2.4.6-trichlorophenol  (21).   2,4,6-trichlorophenol  (Cl3C6H2OH,
abbreviated  heTe"~to"  2,4,6 TCP) is a  colorless crystalline solid
at room temperature.   It  is prepared by the   direct  chlorination
of  phenol.   2,4,6-TCP   melts   at  68°C   (154°F) and is ,slightly
soluble in water  (0.8  gm/1  at  25°C).    This  phenol   doe* not
produce  a   color  with   4-aminoantipyrene, therefore it does not,
contribute to the  non-conventional  pollutant  parameter   Total
Phenols."  No data were  found on production volumes.

2  4 6-TCP   is  used  as   a   fungicide,  bactericide,  glue and wood
preservative, and  for  antimildew treatment.   It  is  also  used for
the     manufacture      of      2,3,4,6,-tetrachlorophenol    and
pentachlorophenol.

No data were found  on   human   toxicity  effects   of^  2,4,6-TCP.
Reports    of  studies  with  laboratory  animals   indicate  that
 2  4  6-TCP  produced convulsions  when  injected  interpentoneally.
Body   temperature  was elevated also.   The compound also produced
 inhibition of ATP production in isolated rat  liver   mitochondria,
 increased   mutation rates in one strain of bacteria,  and produced
 a  genetic  change in rats.   No   studies  on  teratogenicity  were
 found.

 For   the  maximum  protection  of  human health from the potential
 carcinogenic  effects   of  exposure   to   2,4,6-trichlorophenol,
 through  ingestion  of  water and contaminated aquatic organisms^
 the ambient water concentration should be  zero.    The  estimated
 levels  which  would result in increased lifetime cancer risks of
 ID-*  10-6,  and 10-s are 1.18 x 10-s mg/1, 1.18 x 10~* mg/1,  and
 1  18   x   10~3   mg/1,  respectively.   If  contaminated  aquatic
 organisms alone are consumed, excluding the consumption of water,
 the water concentration should be less than 3.6 x  10-*  mg/1  to
 keep  the  increased  lifetime cancer risk below 10-s.  Available
 data  show that adverse effects  in aquatic species  can  occur  at
 9.7 x 10~4 mg/1.
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 Although   no   data were  found  regarding  the behavior  of  2,4,6-TCP
 in POTWs,  studies of  the biochemical  oxidation   of  the   compound
 ftave  been made  on  a  laboratory  scale at concentrations  higher
 than  those    normally    expected   in    municipal    wastewaters.
 Biochemical  oxidation   of   2,4,6-TCP at  100   mg/1  produced  23
 percent  degradation  using  a phenol-adapted   acclimated   seed
 culture.   Based on these results,  biological treatment  in  a POTW
 is expected to produce a moderate degree of degradation.  Another
 study indicates that  2,4,6-TCP  may  be produced  in   POTWs   by
 chlorination of phenol during  normal  chlorination treatment.

 Parachlorometacresol  (22)_.    Parachlorometacresol  (C1C,H«OH)  is
 thought to  be  4-chloro-3-methylphenol   (4-chlorometacresol,   or
 2-chloro-5-  hydroxytoluene, but is also  used by some authorities
 to  refer  to  6-chloro-3-methylphenol   (6-chlorometacresol,    or
 4-chloro-3-hydroxytoluene),  depending on whether the chlorine  is
 considered to be para to the methyl or to the hydroxy group.    It
 is  assumed  for  the  purposes of this document that the subject
 compound  is  2-chloro-5-hydroxytoluene.    This  compound  is   a
 colorless  crystalline  solid melting at 66-68°C (151-154op)    it
 is slightly soluble in water (3.8 gm/1)  and  soluble  in  organic
 solvents.    This  phenol   reacts with 4-aminoantipyrene to give a
 colored  product and therefore contributes to the non-conventional
 pollutant parameter designated "Total  Phenols."  No information on
 manufacturing  methods  or  volumes produced was found.

 Parachlorometacresol  (abbreviated here as PCMC)  is marketed  as  a
 microbicide,   and  was  proposed as an antiseptic  and disinfectant,
 TnvS   an  5??ty Year!  a?°'   Ifc  is used in  Slues,  gums,   paints
 inks,  textiles,   and   leather   goods.   PCMC was  found  in raw
 wastewaters from  the  die  casting  quench   operation  from  one
 subcategory of  foundry operations.

 Although  no  human toxicity  data  are  available  for  PCMC,  studies
 on laboratory animals  have demonstrated   that this  compound  is
 toxic  when administered  subcutaneously and  intravenously.   Death
 was proceeded by severe muscle  tremors.   At  high dosages,  kidney
 damage  occurred.   On the   other hand,  an  unspecified  isomer of
 chlorocresol, presumed to be  PCMC, is  used at a  concentration  of
 0.15  percent   to  preserve   mucous  heparin,  a  natural  product
 administrated intravenously as  an anticoagulant.   The  report does
 not indicate the total amount of  PCMC typically received    No
 information  was  found   regarding  possible teratogenicity,  or
 carcinogenicity of PCMC.                                ^il-y'

 Two  reports  indicate  that  PCMC   undergoes    degradation   in
 biochemical  oxidation  treatments  carried  out  at concentrations
 higher than are expected  to be  encountered   in   POTW  influents
One  study  showed  59  percent  degradation  in  3.5 hours, when  a
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phenol-adapted acclimated seed culture was used with  a  solution
of  60 mg/1 PCMC.  The other study showed 100 percent degradation
of a 20 mg/1  solution  of  PCMC  in  two  weeks  in- an.  aerobic
activated  sludge  test  system.  No degradation of PCMC occurred
under anaerobic conditions.  From a review of limited data, it is
expected that PCMC will be biochemically  oxidized  to  a  lesser-
extent .than domestic sewage by biological treatment in POTWs.

Chloroform(23).   Chloroform  is  a colorless liquid manufactured
commercially "by chlorination  of  methane.   Careful  control  of
conditions  maximizes  chloroform  production, but other^products
must be separated.  Chloroform boils at 61°C .<142.oF)  and  has  a
vapor  pressure  of 200 mm Hg at 25<>C.  It is slightly soluble in
water  (8.22 g/1 at 20°C) and readily soluble in organic solvents.

Chloroform  is used as a solvent and to manufacture  refrigerants,
Pharmaceuticals, plastics, and anesthetics.  It is seldom used as
an anesthetic.

Toxic  effects  of  chloroform  on humans  include central nervous
system depression, gastrointestinal irritation, liver and  kidney
damage   and   possible    cardiac   sensitization  to  adrenalin
Carcinogenicity  has  been   demonstrated    for   chloroform   on
laboratory animals.

For   the   maximum  protection   of human health; from  the potential
carcinogenic  effects  of exposure  to chloroform, through  ingestion
of water and  contaminated"aquatic organisms,   the  ambient   water
concentration is  zero.  Concentrations of  chloroform estimated  to
result in  additional  lifetime  cancer  risks at  the  levels  of  lO^,
 10-«   and  10-5 were  0.000021 mg/1,  0.00021  mg/1, and 0.0021  mg/1,
respectively.     If   contaminated  aquatic  organisms  alone  are
consumed,   excluding   the   consumption  of  water,    the   water
concentration should  be   less  than  0.157  mg/rto.keep  the
 increased  lifetime cancer  risk below  10-*.   Available  data  show
 that   adverse effects   on  aquatic  life occur  at  concentrations
 higher than those cited for human health  risks.

 No data are available regarding the behavior of  chloroform  in  a
 POTW    However,   the  biochemical  oxidation of  this compound was
 studied in one laboratory scale study  at  concentrations  higher
 than   those   expected   to   be  contained  by  most  municipal
 wastewaters.    After  5,   10,   and  20  days  no  degradation _of
 chloroform   was<   observed.   The  conclusion  reached  is_ that-
 biological treatment produces little or no removal by degradation
 of chloroform in POTWs.  An EPA study of  the  fate  of  priority
 pollutants  in  POTWs  reveals  removal  efficiencies  of 0 to^SO
 percent for influent concentrations ranging from 5 to 46  x  10
 mg/1 at seven POTWs.
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 The  high  vapor  pressure of chloroform is expected to result in
 volatilization of the compound from aerobic  treatment  steps  in
 POTWs.   Remaining chloroform is expected to pass through into the
 POTW effluent.

 2-chlorophenol  (24).   2-chlorophenol  (C1C6H4OH),  also  called
 ortho-chlorophenol,  is a colorless liquid  at  room  temperature,
 manufactured   by  direct  chlorination  of  phenol  followed  by
 distillation to separate it from  the  other  principal  product,
 4-chlorophenol.   2-chlorophenol  solidifies below 7°C (45°F) and
 boils at 176°C (349°F).   It is soluble in  water  (28.5  gm/1  at
 20°C)  and  soluble   in   several types of organic solvents.   This
 phenol  gives a strong color with 4-aminoantipyrene and  therefore
 contributes  to  the  non-conventional pollutant parameter "Total
 Phenols."    Production   statistics   could   not    be    found.
 2-chlorophenol   is    used   almost  exclusively  as  a  chemical
 intermediate  in  the production   of   pesticides   and   dyes.
 Production of some phenolic resins uses 2-chlorophenol.

 Very few   data  are  available  concerning  the toxic effects of
 2-chlorophenol  on  humans.    The  compound  is  more  toxic   to
 laboratory   mammals  when   administered    orally,    than   when
 administered subcutaneously or  intravenously.    This  effect  is
 attributed  to the fact  that the compound is almost completely in
 the  un-ionized state at  the low pH of  the stomach,  and hence,   is
 more readily  absorbed   into  the  body.    Initial   symptoms are
 restlessness,   increased  respiration   rate,   followed  by   motor
 weakness   and  convulsions  induced by-noise or touch,  and  coma.
 Following  lethal doses,  kidney,  liver,  and  intestinal damage were
 observed.    No  studies   were   found  which   addressed    the
 teratogenicity or  mutagenicity  of   2-chlorophenol.   Studies of
 2-chlorophenol  as  a  promoter  of  carcinogenic  activity  of   other
 carcinogens  were conducted by dermal application.   Results do not
 bear   a   determinable    relationship   to   results   of    oral
 administration  studies.

 For  controlling undesirable  taste  and   odor  quality   of  ambient
 water  due   to  the   organoleptic  properties of 2-chlorophenol  in
 water, the estimated level  is 1  x   10~4   mg/1.    Data  show   that
 adverse  effects   on  aquatic life occur  at concentrations higher
 than  that  cited for  organoleptic effects.

 Data  on   the  behavior  of   2-chlorophenol   in  POTWs  are    not
 available.   However,   laboratory  scale  studies have been conducted
 at  concentrations   higher  than   those  expected  to  be found  in
municipal  wastewaters.   At   1  mg/1   of    2-chlorophenol,    an
 acclimated    culture   produced    100   percent   degradation   by
biochemical oxidation  after 15 days.  Another   study   showed   45,
 70,  and 79 percent  degradation by biochemical  oxidation after  5,
                               302

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10, and 20 days, respectively.   The conclusion,  reached  by  the
study  of  thes4  limited  data, and general observations, on all
organic priority pollutants relating molecular structure to  ease
of  biochemical oxidation, is that 2-chlorophenol is removed to a
high degree or  completely  by  biological  treatment  in^ POTWs.
Undegraded  2-chlorophenol is expected to pass through POTWs into
the   effluent   because   of   the   water   solubility.    Some
2-chloropheno~l  is  also expected to.be generated by chlorination
treatments of POTW effluents containing phenol.
T .2-trans-dichlQr0ethvlene(30) .        1 , 2
( trans- 1,2-DCE) — is  a  clear,  colorless liquid with the formula
CHC1CHC1   Trans- Tf2-DCE  is  produced  in  a  mixture  with  the
cis-isomer  by  chiorination- of  acetylene.   The cisTisomer has
distinctly  different  physical  properties.   Industrially,  the
mixture   is used rather than the separate isomers.  Trans-1 ,2-DCE
has a boiling point of 48°C, and a vapor pressure of 324 mm Hg  at
25°C.

The principal use" of  1 ,2-dich'loroethylene  (mixed  isomers)   is   to
produce   vinyl  chloride.    It   is   used  as   a  lead scavenger  in
gasoline, as* a  general solvent,  and  for the synthesis of  various
other    organic chemicals.   When   it  is  used  as  a solvent,
trans- 1 ,2-DCE can enter wastewater streams.

For the  maximum protection  of  human   health   from  the   potential
effecte   of    exposure   to  1 , 2-trans-dichloroethylene,   through
 ingest ion  of   water   and  contaminated   aquatic  organisms,   the
 ambient   water  concentration   is   zero.   Concentrations   of
 T?2-l?ans-d?chloroethylene   estimated  to  result  in   ad ditional
 lifetime cancer  risk at risk levels of  10-' f 10-',  and 1 0 -are
 33   x   ID-*  mg/1,   3.3   10-s   mg/1,  and  3.3   x    10 *    mg/1,
 respectively.     If   contaminated   aquatic  organisms,  alone  are
 consumed excluding   the   consumption   of   water,    the   water
 coSratf on  should be less than  0.018  mg/1  to  keep the lifetime.
 cancer  risk  below .10-«.   Limited  acute and chronic toxicity data
 for  freshwater  aquatic life show that adverse  effects  occur  at
 concentrations  higher than  those cited for human health risks.

 The  behavior   of  trans-1 , 2-DCE  in  POTWs has not ^been studied
 However, its high vapor pressure is expected  to  result -in  the
 release  of  a  significant  percentage  of  this compound to the
 atmosphere in any treatment involving aeration.    Degradation  o£
 ?he  dichloroethylenes  in  air  is  reported  to  occur,  with a
 half-life of 8 weeks.

 Biochemical oxidation of many of the organic priority  pollutants
  has   been   investigated   in   laboratory   scale    studies  at
  concentrations  higher  than  would  normally  be   expected   in
                               303

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 municipal  wastewater.   General  observations  relating molecular
 structure to ease of degradation have been developed  for  all  of
 these  pollutants.   The  conclusion  reached by the  study of the
 limited data, is that biochemical oxidation produces  little or no
 degradation  of  1,2-trans-dichloroethylene.    No   evidence   is
 available  for  drawing  conclusions  about the possible toxic or
 inhibitory  effects   of   1,2-trans-dichloroethylene   on   POTW
 operations.   It  is  expected  that its low molecular weight and
 degree of water solubility will result in  trans-1,2-DCE  passing
 through  a  POTW  to  the  effluent,  if  it  is  not degraded or
 volatilized.   Very little trans-1,2-DCE is expected to  be  found
 in sludge from POTWs.

 2,4-dichlorophenol  (31 ).    2,4-dichlorophenol  (C12C6H3OH)   is a
 colorless,  crystalline  solid  manufactured  by  chlorination  of
 phenol  dissolved  in liquid sulfur dioxide or by chlorination of
 molten  phenol   (a  lower   yield   method).     2,4-dichlorophenol
 (2,4-DCP)   melts at 45°C  (113°F) and has a vapor pressure of less
 than 1  mm Hg  at 25°C (vapor pressure equals 1  mm  Hg  at  53°C).
 2,4-DCP  is  slightly  soluble  in   water  (4.6  g/1  at 20°C)  and
 soluble in  many organic  solvents.    2,4-DCP  reacts   to  give  a
 strong  color  development   with 4-aminoantipyrene,  and therefore
 contributes to  the non-conventional  pollutant  designated  "Total
 Phenols." Annual U.S.  production of  2,4-DCP is about  25,000  tons.

 The  principal   use   of  2,4-DCP is  for  the manufacture of  the
 herbicide   2,4-dichloro-phenoxyacetic   acid   (2,4-D)   and   other
 pesticides.

 Few data exist  concerning the  toxic  effects  of 2,4-DCP on humans.
 Symptoms  exhibited   by  laboratory  animals   injected with  fatal
 doses of 2,4-DCP included loss  of muscle  tone,  followed by rapid,
 then slow breathing.   In vitro  experiments revealed inhibition of
 oxidative  phosphorylation   (a   primary   metabolic  function)  by
 2,4-DCP  in rat  liver mitochondria and rat brain homogenates.  No
 studies were found which addressed   the   teratogenicity,  or  the
 mutagenicity  in  mammals,  of   2,4-DCP.   The   only   studies  of
 carcinogenic properties of 2,4-DCP used dermal application, which
 has  no established relationship  to oral administration  results.
For the prevention of adverse effects  due  to  the
properties  of  2,4-dichlorophenol  in  water,  the
0.0005 mg/1.
organoleptic
criterion is
Data on the behavior  of  2,4-dichlorophenol  in  POTWs  are  not
available.  However, laboratory scale studies have been conducted
at  concentrations  higher  than  those  expected  to be found in
municipal   wastewaters.     Biochemical    oxidation    produced
degradation  of  70,72,  and  72  percent -after 5,10 and 20 days,
                              304

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respectively,  in  one  study.   In  another  study,   using   an
acclimated  phenol-adapted  culture,  30  percent degradation was
measured after 3.5 hours.  Based on these limited  data,  and  on
general  observations  relating  molecular  structure  to ease of
biological oxidation, it is concluded that 2 4-DCP is-removed  to
a  high  degree  or  completely by biological treatment an POTWs.
Undegraded 2,4-DCP is-expected  to  pass  through; POTWs  to . the
effluent.  Some 2,4-DCP may be formed in POTWs by chlorination of
effluents containing phenol.             '  ;•
                                    i     >        „-,,,',.
1 3-dichloropropylene (33).   1,3-dichloropropylene  (CHC1:CHCH2C1)
is  a  colorleisTIquIdT" The boiling point of its cis-isomer is
104°C  (219°F), while the boiling point  of  its  trans-isomer  is
112°C  (234°F).  It is derived from the chlorination of propylene.
While  it  is  soluble   in  acetone,  toluene,  and octane, it is
insoluble in water.  This chemical  is  used  in  various  organic
synthesis procedures.

The  available  data  indicate that acute and chronic  toxicity to
freshwater aquatic life  occur at concentrations as^  low   as   6.06
mq/1   and  0.244  mg/1 respectively.  The available  data for  this
pollutant indicate that  acute toxicity  to saltwater  aquatic_  life
occurs  at   concentrations  as   low  as   0.79  mg/1.   No data are
available concerning  the chronic toxicity of  this   pollutant to
saltwater aquatic  life.

For  the protection  of  human health  from  the toxic properties^of
 this pollutant,  ingested through   aquatic   organisms  alone,   the
 ambient  water  criterion  is  determined to be 14.1  mg/1.

With respect to  treatment in  *POTWs,  laboratory  studies have shown
 that    1,3-dichloropropylene    is   only  moderately  amenable  to
 treatment via biochemical oxidation.   The optimum expected 30-day
 average  treated  effluent  concentration  for  this  pollutant  is
 0.100  mg/1.

 2.4-dimethylphenol(34).     2,4-dimethylphenol    (2,4-DMP),   also
 called 2,4-xylenol,  is  a colorless,  crystalline^ solid  at  room
 temperature  (25oC),   but  melts  at  27  to  28°C  (81to82°F.
 2,4-DMP is slightly soluble  in water and,   as  a  weak  acid,  is
 soluble in alkaline solutions.   Its vapor pressure is less than 1
 mm Hg at room temperature.

 2 4-DMP  is  a  natural  product,  occurring in coal and petroleum
 sources.  It is used commercially  as  an  intermediate  for  the
 manufacture  of  pesticides,   dyestuffs,  plastics,  resins,  and
 surfactants.  It is  found   in  the  water  runoff  from  asphalt
 surfaces.   It  can  find  its  way  into  the  wastewater  of  a
 manufacturing plant from any of several sources.
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 Analytical procedures specific to this compound are used for  its
 identification  and quantification in wastewaters.  This compound
 does  not  contribute  to  "Total  Phenols"  determined  by   the
 4-aminoantipyrene method.

 Three  methylphenol  isomers  (cresols)  and  six  dimethylphenol
 isomers (xylenols) generally occur together in natural  products,
 industrial  processes,  commercial products, and phenolic wastes.
 Therefore, data are not available for human exposure  to  2,4-DMP
 alone,  in addition to this,  most mammalian tests for toxicity of
 individual   dimethylphenol  isomers  have  been  conducted  with
 isomers other than 2,4-DMP.

 In  general,   the  mixtures   of   phenol,    methylphenols,    and
 dimethylphenols  contain compounds which produced acute poisoning
 in laboratory animals.   Symptoms were difficult breathing,   rapid
 muscular   spasms,   disturbance   of   motor  coordination,   and
 assymetrical  body  position.    In  a  1977   National   Academy  of
 Science publication,  the conclusion was reached that,  "In view of
 the    relative    paucity   of    data   on   the  mutagenicity,
 carcinogenicity,  teratogenicity,  and long term oral   toxicity  of
 2,4  dimethylphenol,   estimates   of  the  effects of  chronic  oral
 exposure at low levels  cannot be made with  any  confidence."    No
 ambient  water  quality  criterion  can  be set at this time.   In
 order to protect  public health,  exposure to this compound should
 be minimized  as soon  as possible.

 Toxicity  data  for fish  and  freshwater  aquatic life  are  limited
 Acute   toxicity    to    freshwater    aquatic   life    occurs   at
 2,4-dimethylphenol  concentrations  of 2.12  mg/1.   For  controlling
 undesirable taste  and odor  quality  of ambient  water,  due  to   the
 organoleptic    effects    of   2,4-dimethylphenol   in   water,   the
 estimated  level  is  0.4 mg/1.

 The behavior  of 2,4-DMP  in  POTWs has  not  been  studied.  As a weak
 acid  its behavior may be  somewhat dependent  on  the   pH  of   the
 i^J1,"61^ ,to  the POTW>  However, over the normal limited  range of
 POTW pH, little effect of pH would be expected.

 Biological  degradability of 2,4-DMP,  as determined in  one  study
 ?™?   92'5  Percent  removal,  based  on chemical oxygen demand
 (COD).  Thus, substantial removal is  expected for this  compound
Another  study  determined  that  persistence  of  2,4-DMP in the
environment is low, thus any of the compound  which  remained  in
 the  sludge or passed through the POTW into the effluent would be
degraded within a moderate  length of  time (estimated as 2  months
 in the report).
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2, 4-dinitrotoluene  ( 35 ) -..;.   2, 4-dinitrotoluene [ (N02) 2C6H3CH3], a
yellow crystalline compound, is manufactured as a co-product with
the 2,6-isomer by nitration of nitrotoluene.  It melts  at  71°C.
2,4-dinitrotoluene . is  insoluble in water  (0.27 g/1 at 22°C) and
soluble in a number of organic solvents.  Production data for the
2,4-isomer alone are not available.  The 2,4-and 2,6-isomers  are
manufactured in an 80:20 or 65:35 ratio, depending on the process
used.  Annual U.S. commercial: production .is about 150,000 tons of
the  two  isomers.   Unspecified amounts are produced by the U.S.
government and further  nitrated  to  trinitrotoluene   (TNT)  for
military use.

The  major use of the dinitrotoluene mixture is for production of
toluene diisocyanate used to make polyurethanes.  Another use  is
in production of dyestuffs.

The  toxic  effect  of  2,4-dinitrotoluene  in humans is primarily
methemoglobinemia  (a blood  condition hindering  oxygen  transport
by  the  blood).  Symptoms  depend on severity of the disease, but
include cyanosis, dizziness, pain in joints, headache,  and  loss
of   appetite  in  workers  inhaling  the   compound.    Laboratory
animals, fed oral doses of  2,4-dinitrotoluene, exhibited many  of
the  same  symptoms.   Aside from the effects in red blood cells,
effects are observed in the nervous system  and testes.

Chronic exposure to 2,4-dinitrotoluene may  produce   liver  damage
and  reversible  anemia.  No data were found on teratogenicity of
this compound.  Mutagenic data are limited  and  are, regarded  as
confusing.   Data  resulting , from  studies of carcinogenicity of
2,4-dinitrotoluene point to a need for further testing  for  this
property.

For  the  maximum  protection  of human health from  the potential
carcinogenic effects of exposure to  2,4-dinitrotoluene,  through
ingestion  of  water  and   contaminated  aquatic  organisms,   the
ambient  water  concentration    is   zero.    Concentrations   of
2,4-dinitrotoluene  estimated  to  result   in additional  lifetime
cancer risk at risk levels  of  TO-7, 10-*,   and   10~s  are  0..0074
mg/1, 0.074 mg/1,  and 0.740 mg/1, respectively.

Data  on  the  behavior  of  2,4-dinitrotoluene   in  POTWs are  not
available.  However, biochemical oxidation  of   2,4-dinitrophenol
was   investigated  on  a   laboratory   scale.   At   100  mg/1  of
2,4-dinitrophenol, a concentration considerably  higher  than   that
expected  in  municipal  wastewaters, biochemical oxidation  by an
acclimated,  phenol-adapted  seed  culture  produced 52  percent
degradation   in   three  hours.   Based on this  limited information
and  general observations relating molecular structure to  ease  of
degradation   for   all  the  organic  priority  pollutants,  it  was
                               307

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 concluded   that   biological   treatment   in   POTWs    removes
 2,4-dinitrotoluene   to   a   high   degree  or  completely.    No
 information  is  available  regarding  possible  interference  by
 2,4-dinitrotoluene   in  POTW  treatment  processes,   or  on  the
 possible detrimental effect on sludge  used  to  amend  soils  in
 which food crops are grown.

 2,6-dinitrotoluene (36).   2, 6-dinitrotoluene [ (N02)2C
-------
pressure of 7 mm Hg at 20°C.  It is  slightly  soluble  in  water
(0.14 g/1 at 15°C) and is very soluble in organic solvents.

About  98  percent  of the ethylbenzene produced in the U.S. goes
into the production of styrene, much of  which  is  used  in  the
plastics  and  synthetic  rubber  industries.   Ethylbenzene is a
constituent of xylene mixtures used as  dilutents  in  the  paint
industry, agricultural insecticide sprays/ and gasoline blends.

Although  humans  are  exposed  to ethylbenzene from a variety of
sources in the environment,  little  information  on  effects  of
ethylbenzene  in  man  or  animals  is available.  Inhalation can
irritate eyes, affect the respiratory tract,  or  cause  vertigo.
In  laboratory  animals,  ethylbenzene  exhibited  low  toxicity.
There are no data available on teratogenicity,  mutagenicity,  or
carcinogenicity of ethylbenzene.

Criteria  are  based  on  data  derived  from inhalation exposure
limits.  For the  protection  of  human  health  from  the  toxic
properties   of   ethylbenzene,   ingested   through   water  and
contaminated  aquatic  organisms,  the  ambient   water   quality
criterion  is  1.4 mg/1.  If contaminated aquatic organisms alone
are consumed, excluding the consumption  of  water,  the  ambient
water  criterion  is  3.28  mg/1.   Available  data  show that at
concentrations of 0.43 mg/1,  adverse  effects  on  aquatic  life
occur.

The  behavior  of  ethylbenzene  in POTWs has not been studied in
detail.  Laboratory scale studies of the biochemical oxidation of
ethylbenzene at concentrations greater  than  would  normally  be
found  in municipal wastewaters have demonstrated varying degrees
of  degradation.   In  one  study  with  phenol-acclimated   seed
cultures,  27  percent  degradation was observed in a half day at
250 mg/1 ethylbenzene.  Another study, at unspecified conditions,
showed 32, 38, and 45 percent degradation after  5,  10,  and  20
days,   respectively.    Based   on. these  results  and  general
observations relating molecular structure to ease of degradation,
it is expected that ethylbenzene will be  biochemically  oxidized
to  a  lesser extent than domestic sewage, by biological treatment
in POTWs.

An EPA study of seven POTWs showed removals of 77 to 100  percent
in  five POTWs having influent ethyl benzene concentrations of 10
to  44  x  10~3  mg/1.   The  other  two   POTWs   had   influent
concentrations  of  2 x  10~3 mg/1 or less.  Other studies suggest
that most of the ethylbenzene entering a POTW is removed from the
aqueous stream to the sludge.  The ethylbenzene contained  in  the
sludge removed from the POTW may volatilize.
                              309

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Fluoranthene(39).    Fluoranthene (1,2-benzacenaphthene)  is  one  of
the  compounds  called polynuclear aromatic  hydrocarbons  (PAH).    A
pale yellow solid  at room  temperature,  it melts  at  111°C  (232°F)
and  has  a  negligible vapor  pressure  at  25°C.   Water  solubility  is
low  (0.2 mg/1).   Its molecular  formula  is  C16H10.

Fluoranthene,  along with many other  PAHs,  is  found throughout the
environment.   It  is produced by pyrolytic  processing of  organic
raw  materials,   such  as coal  and petroleum,  at  high temperature
(coking  processes).   It occurs  naturally as a product  of   plant
biosynthesis.   Cigarette   smoke contains  fluoranthene.  Although
it is not  used as the pure  compound   in  industry,   it  has been
found  at  relatively higher concentrations (0.002 mg/1) than most
other PAHs in  at  least one  industrial effluent.   Furthermore,   in
a  1977  EPA   survey  to determine levels  of  PAH  in  U.S. drinking
water supplies, none of the 110 samples  analyzed  showed  any PAH
other than fluoranthene.

Experiments  with   laboratory   animals  indicate that fluoranthene
presents a relatively low degree of  toxic   potential from   acute
exposure,  including oral administration.   Where death occured,  no
information was reported concerning  target organs or the specific
cause of death.

There  is   no  epidemiological   evidence  to   prove  that PAHs  in
general, and fluoranthene,  in   particular,  present  in  drinking
water are  related to the development of  cancer.  The only studies
directed   toward determining carcinogenicity  of fluoranthene have
been skin  tests on  laboratory animals.   Results  of  these   tests
show  that  fluoranthene has no activity as a  complete carcinogen
(i.e., an  agent which  produces  cancer when applied  by  itself),
but  exhibits  significant cocarcinogenicity (i.e., in combination
with a carcinogen,  it  increases the  carcinogenic activity).

Based  on  the  limited  animal   study   data,  and   following   an
established   procedure,    the    ambient   water   criterion for
fluoranthene,  through  water and contaminated   aquatic  organisms,
is determined  to be  0.042 mg/1  for the protection of human  health
from  its  toxic   properties.   If contaminated aquatic organisms
alone are  consumed,   excluding   the  consumption  of  water,  the
ambient  water criterion is 0.054 mg/1.  Available data show that
adverse effects on  aquatic  life  occur at concentrations of   0.016
mg/1.

Results   of   studies   of  the  behavior  of  fluoranthene,   in
conventional sewage  treatment processes  found  in POTWs, have been
published.   Removal  of fluoranthene during primary   sedimentation
was  found  to  be   62  to  66  percent  (from  an initial value of
0.00323 to 0.0435 mg/1 to a final" value   of   0.00122  to   0.0146
                              310

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mg/1),  and  the  removal  was  91
0.00028 to  0.00026  mg/1)  after
activated sludge processes.
to 99 percent (final values of
biological  purification  with
A review was made of data on biochemical oxidation of many of the
organic  priority  pollutants  investigated  in  laboratory scale
studies at concentrations higher than would normally be  expected
in municipal wastewater.  General observations relating molecular
structure  to  ease of degradation have been developed for all of
these pollutants.  The conclusion reached by study of the limited
data  is  that  biological  treatment ^produces  little   or -  no
degradation  of  fluoranthene.   The same study however concludes
that fluoranthene would be readily removed by filtration and  oil
water   separation   and   other  methods  which  rely  on  water
insolubility, or adsorption on other particulate surfaces.   This
latter  conclusion  is  supported  by  the previously cited study
showing significant removal by primary sedimentation.

No studies were  found  to  give  data  on  either  the  possible
interference   of  fluoranthene  with  POTW  operations,  or  the
persistence of fluoranthene in sludges on POTW  effluent  waters.
Several  studies  have documented the ubiquity of fluoranthene in
the environment, and it cannot  be  readily  determined  if  this
results  from  persistence  of  anthropogenic fluoranthene or the
replacement of degraded fluoranthene by natural processes such as
biosynthesis in plants.

Bis(2-Ghloroethvoxv)methane   (43).   Bis(2-chloroethoxy)  methane
[CH2(OCH2CH2Cirz1isacolorless  liquid.  It boils at 218.1°C
(424°F), flashes at 110°C (230°F), and has a vapor pressure of   1
mm  Hg  at  53°C.   Slightly  soluble  in water, this chemical is
decomposed by mineral acids.  This chemical is used as a  solvent
and as an intermediate for polysulfide rubber.

The  available data indicate  that this pollutant is acutely toxic
to freshwater aquatic life at!concentrations as low as 0.36 mg/1,
and that chronictoxicity occurs  at  concentrations  as  low  as
0.122  mg/1.  No data are available to determine acute or chronic
toxicity levels for saltwater;aquatic life.

With respect to human health  effects,  a  satisfactory  criterion
cannot  be  derived at this time, due to the insufficiency  in the
available data.                                              T

Concerning treatment in POTWs,  laboratory studies have shown that
this pollutant  is  only  moderately  amenable  to  treatment  via
biochemical  oxidation.   It  should  be noted, however,  that the
optimum estimated  30-day average  treated  effluent   concentration
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of   0.10 mg/1  is  greater  than  the  level  at  which  this  contaminant
was  found  in any  foundry  process wastewater.

Methylene   chloride(44).     Methylene    chloride,    also    called
dichloromethane   (CH2C12),   is a colorless  liquid manufactured  by
chlorination of methane or methyl  chloride  followed  by separation
from the   higher   chlorinated   methanes   formed   as  co-products.
Methylene   chloride   boils   at 40°C,  and has  a vapor  pressure  of
362  mm Hg  at 20°C.   It  is slightly soluble  in  water  (20  g/1   at
20PC),  and very soluble   in organic   solvents.   U.S.   annual
production is  about  250,000  tons.

Methylene  chloride  is  a common  industrial  solvent found   in
insecticides,  metal  cleaners,  paint,   and   paint  and   varnish
removers.

Methylene  chloride is not generally   regarded as   being  'highly
toxic  to   humans.    Most human toxicity  data  are for  exposure  by
inhalation.  Inhaled  methylene chloride acts as a central  nervous
system depressant.  There is   also evidence   that   the  compound
causes heart failure  when large amounts are inhaled.

Methylene   chloride   does produce mutation   in  tests  for this
effect.  In addition, a bioassay   recognized   for  its extremely
high sensitivity  to strong and weak carcinogens, produced  results
which  were marginally significant.  Thus, potential carcinogenic
effects of  methylene  chloride  are  not  confirmed  or  denied,  but
are  under  continuous study.   Difficulty in conducting tests and
interpreting data  results from the low boiling point   (40°C)   of
methylene  chloride.   This increases the difficulty of  maintaining
the  compound  in  growth media   during  incubation at 37°C.   In
addition,   it is difficult to remove all impurities,  some of which
might themselves  be carcinogenic.

For the protection of human health from the toxic  properties   of
methylene   chloride,  ingested through   water  and  contaminated
aquatic organisms, the ambient water criterion is 0.002 mg/1.

The behavior of methylene chloride in POTWs has not  been   studied
in  any  detail.    However,   the   biochemical  oxidation   of this
compound  was  studied  in  one    laboratory   scale   study    at
concentrations higher than those expected to be contained  by most
municipal  wastewaters.    After  five  days,   no  degradation   of
methylene chloride was observed.   The conclusion reached is  that
biological  treatment produces  litte or no removal by  degradation
of methylene chloride in  POTWs.

The high vapor pressure of  methylene  chloride  is  expected   to
result  in  volatilization of  the  compound from aerobic treatment
                              312

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steps in POTWs.  It has been  reported  that  methylene  chloride
inhibits  anaerobic  processes  in POTWs.  Any methylene chloride
that is not volatilized in the POTW is expected to  pass  through
into the effluent.

Methyl  chloride  (45).    Methyl chloride (CH3C1) is a colorless,
noncorrosive liquifiable gas which is  transparent  in  both  the
gaseous  and  liquid  states.   It  has a faintly sweet, ethereal
odor.  It boils at -23.7°C (-11°F).  It is  slightly  soluble  in
water  (by  which  it  is  decomposed)  and  soluble  in alcohol,
chloroform, benzene, carbon  tetrachloride,  and  glacial  acetic
acid.   It  is  derived by:  (a) the chlorination of methane; and,
(b) the action of hydrochloric acid on methanol, either in  vapor
or  liquid  phase.  It is used as an extractant and solvent, as a
pesticide,  in  the  synthesis  of  organic  chemicals,  and   in
silicones.

The  available  data  for  this  pollutant  indicate  that  acute
toxicity to freshwater aquatic life occurs at  concentrations  as
low  as  11.0  mg/1.   No  data  are  available  concerning  this
pollutant's chronic  toxicity  to  sensitive  freshwater  aquatic
life.   The available data for this pollutant indicate that acute
and  chronic  toxicities  to  saltwater  aquatic  life  occur  at
concentrations  as  low  as  12.0 mg/1 and 6.40 mg/1 respectively.
With respect to saltwater aquatic life, a decrease in algal  cell
numbers was found to occur at concentrations as low as 11.5 mg/1.

For  the  maximum  protection  of human health from the potential
carcinogenic effects due to  exposure to this  pollutant,  through
the  ingestion  of  contaminated water and aquatic organisms, the
ambient water concentration  should be  zero.   Concentrations  of
this  pollutant estimated to result in additional lifetime cancer
risks at risk  levels of 10-», 10-«, and  10~7  are  0.0019  mg/1,
0.00019 mg/1, and 0.000019 mg/1 respectively.

Concerning treatment  in POTWs, laboratory studies have shown that
methyl  chloride  is  not  amenable  to treatment via biochemical
oxidation.  It should be noted that the optimum treated  effluent
level  of  0.100  mg/1  is   greater than the levels ,at which this
pollutant was  found in any foundry sampled.

Bromoform  (47).'  Brombform  (CHBr3) is a colorless,  heavy   liquid
whose  odor  "and  taste are similar to those of chloroform.  It  is
soluble in alcohol, ether, chloroform, benzene, solvent  naphtha,
and  fixed and  volatile oils, while being only slightly soluble  in
water.    It melts at  9°C  (48°F), boils at  151°C  (304<>F) and has  a
vapor pressure of 5 mm Hg of 22°C.  This chemical is derived from
the  heating of acetone or ethyl alcohol with bromine  and   alkali
hydroxide,  with  recovery by distillation.  This product  is used
                               313

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as an intermediate  in organic synthesis
waxes, greases and  oils.
                                         and  as  a  solvent  for
Available  freshwater data indicate that acute toxicity occurs at
concentrations  as  low  as   11  mg/1 .   No  data  are  available
concerning chronic toxicity to sensitive freshwater aquatic life.
The  available  data  indicate that acute and chronic toxicity to
saltwater aquatic life occur  at concentrations  as  low  as   12.0
mg/1 and 6.4 mg/1 respectively.

For  the  maximum  protection  of human health from the potential
carcinogenic  effects  due  to  exposure  to  bromoform,  through
contaminated   water  and  contaminated  aquatic  organisms,  the
ambient water concentration should be  zero.   Concentrations  of
this  pollutant estimated to  result in additional lifetime cancer
risk at risk levels of 10~5,  10~6,  and  10~7  are  0.0019  mg/1,
0.00019 mg/1, and 0.000019 mg/1 respectively.

With respect to treatment in  POTWs, laboratory studies have shown
that   bromoform  is  not  amenable  to  treatment  incorporating
biochemical oxidation.
Dichlorobromomethane
colorless  liquid  which
data was available for this chemical.
an additive in certain organic synthesis processes.
                            Dichlorobromomethane (CHCl2Br)  is  a
                          boils at 90.1°C (194°F).   No solubility
                                       This chemical is  used  as
Available  freshwater data indicate that acute toxicity occurs at
concentrations  as  low  as  11  mg/1.   No  data  are  available
concerning chronic toxicity to sensitive freshwater aquatic life.
The  available data indicate that acute and chronic toxicities to
saltwater aquatic life occur at concentrations  as  low  as  12.0
mg/1 and 6.4 mg/1 respectively.

For  the  maximum  protection  of human health from the potential
carcinogenic effects due  to  exposure  to  dichlorobromomethane,
through  contaminated  water  and contaminated aquatic organisms,
the ambient water concentration should be  zero.   Concentrations
of  this  pollutant  estimated  to  result in additional lifetime
cancer risk at risk levels of 10~s, 10~6,  and  1 0~7  are  0.0019
mg/1, 0.00019 mg/1, and 0.000019 mg/1 respectively.

With  respect  to treatment in POTWs, laboratory studies indicate
that this pollutant is not amenable to treatment via  biochemical
oxidation.

Trichlorof luoromethane (49) .
            	   Trichlorofluoromethane (CC13F)  is a
            nearly odorless,  volatile liquid.   It boils at 23.7°C
                                                 23.7°C.    It  is
colorless,
(75°F) and has a vapor pressure of 760 mm Hg at
                              314

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derived  from  the  reaction of carbon tetrachlpride and hydrogen
fluoride in the presence of fluorinating agents such as  antimony
tri-  and  penta-fluoride.   It is used as a solvent and chemical
intermediate.

The  available  data  for  this  pollutant  indicate  that  acute
toxicity  to  freshwater aquatic life occurs at concentrations as
low  as  11.0  mg/1.   No  data  are  available  concerning  this
pollutant's  chronic  toxicity  to  sensitive  freshwater aquatic
life.  The available data for this pollutant indicate that  acute
and  chronic  toxicities  to  saltwater  aquatic  life  occur  at
concentrations as low as 12.0:mg/1 and6.40  mg/1  respectively.
With  respect to saltwater aquatic life, a decrease in algal cell
numbers was found to occur at concentrations as low as 11.5 mg/1.

For the maximum protection of human  health  from  the  potential
carcinogenic, effects  due to exposure to this pollutant, through
the ingestion of contaminated water and  aquatic  organisms,  the
ambient  water  concentration:  should be zero.  Concentrations of
this pollutant estimated to result in additional lifetime  cancer
risks  at  risk  levels  of 10-*, 10-*, and 10~7 are 0.0019 mg/1,
0.00019 mg/1, and 0.000019 mg/1 respectively.

With respect to  treatment  in  POTWs,  laboratory  studies  have
indicated  that  this  pollutant is not amenable to treatment via
biochemical oxidation.

Chlorodibromomethane  (51).  Chlorodibromomethane (CHBr2Cl)  is  a
clear, colorless, heavy liquid.  It boils at 116°C (24T°F).  This
pollutant is used in the synthesis of various organic compounds.

The  available  data  for  this  pollutant  indicate  that  acute
toxicity to freshwater aquatic life occurs at  concentrations  as
low  as  11.0  mg/1.   No  data  are  available  concerning  this
pollutant's chronic  toxicity  to  sensitive  freshwater  aquatic
life.   The available data for this pollutant indicate that acute
and  chronic  toxicities  to  saltwater  aquatic  life  occur  at
concentrations  as  low  as 12.0 mg/1 and 6.40 mg/1 respectively.
With respect to saltwater aquatic life, a decrease in algal  cell
numbers was found to occur at concentrations as low as 11.5 mg/1.

For  the  maximum  protection  of human health from the potential
carcinogenic effects due to exposure to this  pollutant,  through
the  ingestion  of  contaminated water and aquatic organisms, the
ambient water concentration should be  zero.   Concentrations  of
this  pollutant estimated to result in additional lifetime cancer
risks at risk levels of 10~s, 10-«-, 10~7 are 0.0019 mg/1, 0.00019
mg/1, and 0.000019 mg/1 respectively.
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With respect to treatment  in POTWs,  laboratory  studies   indicate
that  this pollutant  is not amenable to treatment via biochemical
oxidation.  It should be noted that  the optimum expected  treated
effluent  level  of 0.100  mg/1 for this pollutant is greater than
the level at which  this   pollutant  was  found  in  any  foundry
sampled.

Isophorone(54).  Isophorone is an industrial chemical produced at
a  level  of tens of millions of pounds annually in the U.S.  The
chemical name for isophorone  is  3,5,5-trimethy2-cyclo-hexene-l-
one   and  it  is  also  known  as   trimethyl  cyclohexanone  and
isoacetophorone.  The formula is C6H5(CH3)30.   Normally,   it  is
produced  as  the  gamma-isomer; technical grades contain about 3
percent of the beta-isomer  (3,5-5-trimethyl-3-cyclohexen-l-one).
The  pure  gamma-isomer  is  a  water-white  liquid,  with  vapor
pressure less than 1 mm Hg at room   temperature,  and  a  boiling
point  of 215.2°C.  It has a camphor- or peppermint-like odor and
yellows upon standing.  It is slightly soluble (12 mg/1)  in water
and dissolves in fats and  oils.

Isophorone is synthesized  from acetone and is  used  commercially
as  a solvent or co-solvent for finishes, lacquers, polyvinyl and
nitrocellulose resins, pesticides, herbicides,  fats,  oils,  and
gums.  It is also used as  a chemical feedstock.

Because isophorone is an industrially used solvent, most toxicity
data   are  for  inhalation  exposure.   Oral  administration  to
laboratory animals in two  different  studies revealed no acute  or
chronic   effects   during  90  days,  and  no  hematological  or
pathological abnormalities were reported.  Apparently, no studies
have been completed on the carcinogenicity of isophorone.

Isophorone does undergo bioconcentration in the lipids of aquatic
organisms and fish.

Based on subacute data, the ambient  water quality  criterion  for
isophorone,   ingested  through  consumption of water and fish, is
set at 460 mg/1 for the protection of human health from its toxic
properties.

Studies  of  the  effects  of  isophorone  on  fish  and  aquatic
organisms  reveal relatively low toxicity, compared to some other
priority pollutants.

The behavior  of  isophorone  in  POTWs  has  not  been  studied.
However,  the  biochemical  oxidation  of  many  of  the  organic
priority pollutants has been  investigated  in  laboratory  scale
studies  at concentrations higher than would normally be expected
in municipal wastewater.  General observations relating molecular
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structure to ease of degradation have been.developed for  all  of
these  pollutants.   The  conclusion  reached by the study of the
limited data is that  biochemical  treatment  in  POTWs  produces
moderate  removal  of  isophorone.  This conclusion is consistent
with the findings of an  experimental  study  of  microbiological
degradation   of   isophorone   which  showed  about  45  percent
bio-oxidation in 15 to 20 days in domestic wastewater, but only 9
percent in salt water.  No data were found on the persistence  of
isophorone in sewage sludge.

Naphthalene(55).  Naphthalene is an aromatic hydrocarbon, with two
orthocondensed  benzene  rings  and a molecular formula of CioHg.
As such,  it  is  properly  classed  as  a  polynuclear  aromatic
hydrocarbon (PAH).  Pure naphthalene is a white crystalline solid
melting  at  80°C (176°F)..  For a solid, it has a relatively high
vapor  pressure  (0.05  mm  Hg  at  20°C),  and  moderate   water
solubility  (19  mg/1 at 20°C)...  Naphthalene is the most abundant
single component of coal tar.  Production is more than a third of
a million tons annually in the U.S.  About three fourths  of  the
production   is   used   as   feedstock  for  phthalic  anhydride
manufacture.  Most of the  remaining  production  goes  into  the
manufacture    of    insecticides,   dyestuffs,   pigments,   and
Pharmaceuticals.    Chlorinated   and   partially    hydrogenated
naphthalenes  are  used in some solvent mixtures.  Naphthalene is
also used as a moth repellent.

Naphthalene/ ingested by humans,  has  reportedly  caused  vision
loss  (cataracts),  hemolytic  anemia,  and  occasionally,  renal
disease.  These effects of naphthalene ingestion are confirmed by
studies on laboratory animals.,  No  carcinogenicity  studies  are
available  which can be used to:demonstrate carcinogenic activity
for naphthalene.   Naphthalene  does  bioconcentrate  in  aquatic
organisms.

The  available  data base is insufficient to establish an ambient
water criterion for the protection of human health from the toxic
properties of naphthalene.   Available  data  show  that  adverse
effects  in  aquatic  life occur at concentrations as low as 0.62
mg/1.

Only a limited number of studies have been conducted to determine
the effects of naphthalene on aquatic organisms.  The  data  from
those studies show only moderate toxicity.

Naphthalene  has  been  detected  in  sewage  plant  effluents at
concentrations up to 22 »/g/l in studies carried out by  the  U.S.
EPA.   Influent  levels  were  not  reported.   The  behavior  of
naphthalene in POTWs  has  not  been  studied.   However,  recent
studies  have  determined  that  naphthalene  will  accumulate in
                              317

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sediments at TOO times  the  concentration  in  overlying  water.
These results suggest that naphthalene will be readily removed by
primary   and   secondary   settling  in  POTWs,  if  it  is  not
biologically degraded.                    ;

Biochemical oxidation of many of the organic priority  pollutants
has   been   investigated   in   laboratory   scale   studies  at
concentrations  higher  than  would  normally  be   expected   in
municipal  wastewater.   General  observations relating molecular
structure to ease of degradation have been developed for  all  of
these pollutants.  The conclusion reached by study of the limited
data  is  that  biological  treatment  produces a high removal by
degradation of naphthalene.  One  recent  study  has  shown  that
microorganisms  can  degrade  naphthalene,  first  to  a  dihydro
compound, and ultimately to carbon dioxide and water.

Nitrobenzene   (56).    Nitrobenzene   (C6H5N02),   also   called
nitrobenzol-  and  oil  of mirbane, is a pale yellow, oily liquid,
manufactured by reacting benzene with nitric  acid  and  sulfuric
acid.   Nitrobenzene  boils  at  210°C  (410°F)  and  has a vapor
pressure of 0.34 mm Hg at 25°C.  It is slightly soluble in  water
(1.9  g/1  at  20°C), and is miscible with most organic solvents.
Estimates of annual U.S. production vary widely, ranging from 100
to 350 thousand tons.

Almost the entire volume of nitrobenzene produced (97 percent) is
converted  to  aniline,  which  is  used  in  dyes,  rubber,  and
medicinals.   Other  uses  for  nitrobenzene include: solvent for
organic synthesis, metal polish, shoe polish, and perfume.

The toxic effects of ingested or inhaled nitrobenzene  in  humans
are  related  to  its  action  in  blood:   methemoglobinemia and
cyanosis.  Nitrobenzene administered orally to laboratory animals
caused  degeneration  of  heart,  kidney,   and   liver   tissue;
paralysis;   and   death.    Nitrobenzene   has   also  exhibited
teratogenicity in laboratory animals, but  studies  conducted  to
determine  mutagenicity  or carcinogenicity did not reveal either
of these properties.

For the prevention of adverse effects  due  to  the  organoleptic
properties of nitrobenzene in water, the criterion is 0.030 mg/1.
                                          r
Data  on the behavior of nitrobenzene in POTWs are not available.
However,  laboratory  scale  studies  have  been   conducted   at
concentrations   higher  than  those  expected  to  be  found  in
municipal  wastewaters.   Biochemical   oxidation   produced   no
degradation  after  5,  10,  and  20  days.   A second study also
reported no degradation after  28  hours,  using  an  acclimated,
phenol-adapted seed culture with nitrobenzene at 100 mg/1.  Based
                               31S

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on  these  limited  data,  and  on  general observations relating
molecular structure  to  ease  of  biological  oxidation,  it  is
concluded that little or no removal of nitrobenzene occurs during
biological  treatment in POTWs.  The low water solubility and low
vapor pressure of  nitrobenzene  lead  to  the  expectation  that
nitrobenzene  will  be  removed from POTWs in the effluent and by
volatilization during aerobic treatment.
2-nitrophenol  (57).   2-nitrophenol  (NOzCgH^OH) ,  also   called
ortho-nitrophenol,   is   a   light   yellow  crystalline  solid,
manufactured commercially by hydrolysis of  2-chloro-nitrobenzene
with  aqueous  sodium  hydroxide.   2-nitrophenol  melts  at 45°C
(113°F)  and  has  a  vapor  pressure  of  1  mm  Hg   at   49°C.
2-nitrophenol  is slightly soluble in water (2.1 g/1 at 20°C) and
soluble in organic solvents.  This phenol does not react to  give
a color with 4-aminoantipyrene, and therefore does not contribute
to the non-conventional pollutant parameter "Total Phenols." U.S.
annual production is five thousand to eight thousand tons.

The   principle   use   of  ortho-nitrophenol  is  to  synthesize
ortho-aminophenol,   ortho-nitroanisole,   and   other   dyestuff
intermediates.

The  toxic  effects  of  2-nitrophenol  on  humans  have not been
extensively  studied.   Data  from  experiments  with  laboratory
animals indicate that exposure to this compound  causes kidney and
liver  damage.   Other  studies  indicate  that  the compound acts
directly on cell membranes, and  inhibits certain  enzyme  systems
in  vitro.  No information regarding potential teratogenicity was
found.  Available data indicate  that this compound does not  pose
a   mutagenic   hazard   to   humans.    Very  limited  data  for
2-nitrophenol do not reveal potential carcinogenic effects.

The available data base is  insufficient to establish  an  ambient
water  criterion for the protection of human health from exposure
to 2-nitrophenol.  No data are available on which to evaluate the
adverse effects of 2-nitrophenol on aquatic life.

Data   on   the  behavior  of   2-nitrophenol  in   POTWs  were   not
available.  However, laboratory  scale studies have been conducted
at  concentrations  higher  than those  expected  to be found  in
municipal  wastewater.   Biochemical  oxidation   using   adapted
cultures   from various sources produced 95 percent degradation  in
three  to six days  in one study.  Similar  results  were  reported
for    other  studies.   Based on   these  data,   and  on  general
observations relating molecular  structure to ease  of  biological
oxidation,    it    is   expected   that   2-nitrophenol   will   be
biochemically oxidized to  a lesser  extent than domestic sewage  by
biological treatment  in POTWs.
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 4-nitrophenol   (58).    4-nitrophenol   (NO2C6H4OH),   also   called
 para-nitrophenol,   is  a colorless to yellowish crystalline solid
 manufactured commercially by hydrolysis  of  4-chloro-nitrobenzene
 with   aqueous   sodium  hydroxide.   4-nitrophenol   melts at 114<>C
 (237°F).   Vapor pressure is  not  cited   in  the  usual   sources.
 4-nitrophenol   is   slightly soluble in water (15 g/1  at  25°C)  and
 soluble  in organic solvents.   This phenol  does  not  react to give
 a  color  with 4-aminoantipyrene,  and therefore does  not contribute
 to the   non-conventional  pollutant   parameter "Total  Phenols."
 U.S.  annual  production  is about  20/000 tons.

 Para-nitrophenol is used to prepare phenetidine,  aceta-phene-ti-
 dine,  azo and  sulfur  dyes,  photochemicals,  and  pesticides.

 The   toxic  effects  of   4-nitrophenol  on  humans  have not been
 extensively  studied.    Data  from experiments with laboratory
 animals   indicate   that   exposure   to this  compound results  in
 methemoglobinemia  (a  metabolic disorder  of blood),  shortness   of
 breath,   and  stimulation  followed by depression.  Other studies
 indicate  that  the  compound  acts  directly on cell  membranes,   and
 inhibits   certain enzyme   systems  in  vitro.   No  information
 regarding potential teratogenicity was  found.   Available data
 indicate   that  this  compound  does not pose a mutagenic  hazard  to
 humans.   Very   limited   data  for   4-nitrophenol  do  not  reveal
 potential  carcinogenic   effects,   although the compound has been
 selected  by  the national  cancer  institute  for testing under   the
 Carcinogenic Bioassay Program.

 No  U.S.  standards for exposure  to 4-nitrophenol in ambient water
 have been  established.

 Data on the  behavior of  4 nitrophenol  in POTWs  are not available.
 However,   laboratory  scale  studies   have   been   conducted    at
 concentrations   higher   than  those   expected  to  be   found   in
municipal  wastewater.   Biochemical   oxidation  using    adapated
 cultures   from  various sources produced  95  percent degradation  in
 three to six days  in one study.  Similar   results  were   reported
 for   other  studies.   Based  on   these  data,  and  on  general
observations relating molecular  structure  to  ease  of  biological
oxidation,   it  is  expected   that  complete  or  nearly  complete
removal of 4-nitrophenol occurs  during   biological  treatment   in
POTWs.

2,4-dinitrophenol   (59).   2,4-dinitrophenol   [(NO2)2C6H3OH],   a
yellow  crystalline  solid,  is  manufactured   commercially   by
hydrolysis  of  2,4-dinitro-l-chlorobenzene  with sodium hydroxide.
2,4-dinitrophenol sublimes at  114°C (237°F).  Vapor  pressure   is
not cited  in usual sources.  It  is slightly soluble in water (7.9
g/1  at  25°C)  and soluble in organic solvents.   This phenol does
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not  react  with  4-aminoantipyrene  and   therefore   does)(  not
contribute  to  the  non-conventional  pollutant parameter  Total
Phenols."  U.S.  annual production is about 500 tons.

2,4-dinitrophenol is used to manufacture  sulfur  and  azo  dyes,
photochemicals, explosives, and pesticides.

The  toxic  effects  of 2,4-dinitrophenol in humans are generally
attributed to this  pollutant's  ability  to  uncouple  oxidative
phosphorylation.    In   brief,   this   means   that  sufficient
2,4-dinitrophenol short-circuits cell  metabolism  by  preventing
utilization  of  energy  provided  by respiration and glycolosis.
Specific symptoms are  gastrointestinal  disturbances,  weakness,
dizziness,  headache,  and  loss of weight.  More acute poisoning
includes symptoms such as:  burning thirst, agitation,  irregular"
breathing,  and  abnormally  high  fever.    This  compound  also
inhibits other enzyme systems; and  acts  directly  on  the  cell
membrane,   inhibiting   chloride   permeability.   Ingestion  of
2,4-dinitrophenol also causes cataracts in humans.

Based   on   available   data,   it   appears    unlikely    that
2,4-dinitrophenol  poses a teratogenic hazard to humans.  Results
of  studies  of  mutagenic  activity   of   this   compound   are
inconclusive  as  far  as  humans  are concerned.  Available data
suggest that  2,4-dinitrophenol  does  not  possess  carcinogenic
properties.

To   protect   human   health   from   the   adverse  effects  of
2,4-dinitrophenol, ingested in contaminated water and  fish,  the
suggested water quality criterion is 0.0686 mg/1.

Data  on  the  behavior  of  2,4-dinitrophenol   in  POTWs are not
available.  However, laboratory scale studies have been conducted
at concentrations higher than  those  expected   to  be  found  in
municipal    wastewaters.     Biochemical   oxidation   using    a
phenol-adapted seed culture produced 92  percent  degradation  in
3.5  hours.   Similar  results  were  reported'  for other studies.
Based  on  these  data,  and  on  general  observations  relating
molecular  structure   to   ease  of  biological   oxidation,   it is
expected  that   complete   or   nearly    complete   removal   of
2,4-dinitrophenol occurs during biological treatment  in POTWs..

4.6-dinitro-o-cresol   (60).   4,6-dinitro-o-cresol   (DNOC)   is   a
yellow crystalline solid derived from o-cresol.   DNOC  melts  at
85.8°C   and has a vapor pressure of 0.000052 mm Hg at  20°C.  DNOC
is sparingly soluble in water  (100 mg/1 at  20°C),   while   it  is
readily  soluble  in   alkaline aqueous solutions, ether, acetone,
and  alcohol.   DNOC   is   produced  by  sulfonation  of  o-cresol
followed by treatment  with nitric acid.
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 DNOC is used primarily as a blossom thinning agent on fruit trees
 and  as  a  fungicide,   insecticide  and  miticide on fruit trees
 during the dormant season.   It is highly toxic to plants  in  the
 growing  stage.    DNOC  is  not  manufactured  in  the U.S. as an
 agricultural chemical.   Imports  of  DNOC  have  been  decreasing
 recently with only 30,000 Ibs being imported in 1976.

 While  DNOC  is   highly toxic to plants,  it is also very toxic to
 humans and  is  considered  to  be  one  of  the  more  dangerous
 agricultural  pesticides.    The  available  literature concerning
 humans indicates that  DNOC  may  be  absorbed  in  acutely  toxic
 amounts  through  the  respiratory and gastrointestinal tracts and
 through the skin,  and  that it accumulates in the blood.   Symptoms
 of  poisoning include profuse sweating,  thirst,   loss  of  weight,
 headache,  malaise,  and  yellow staining to the skin,  hair,  sclera,
 and conjunctiva.

 There  is   no evidence  to  suggest  that  DNOC  is teratogenic,
 mutagenic,  or carcinogenic.   The effects  of DNOC in the  human due
 to  chronic exposure are  basically  the  same  as  those  effects
 resulting   from   acute   exposure.    Although DNOC is considered a
 cumulative poison  in  humans,   cataract  formation  is  the  only
 chronic effect   noted  in  any human or experimental  animal  study.
 It  is believed that DNOC accumulates in the human body,  and  that
 toxic symptoms may  develop  when blood levels exceed 20 mg/kg.

 For   the   protection of human health from the toxic properties of
 dinitro-o-cresol,  ingested  through water  and contaminated  aquatic
 organisms,  the ambient  water  criterion is determined to  be  0.0134
 mg/1.   If  contaminated   aquatic  organisms  alone  are  consumed,
 excluding   the  consumption of  water,  the ambient water  criterion
 is determined to be 0.765 mg/1.   No data  are available concerning
 the adverse  effects of  4,6-dinitro-o-cresol  on  aquatic life.

 Some  studies  have been  reported regarding the behavior of DNOC in
 POTWs.  Biochemical oxidation of  DNOC under  laboratory conditions
 at a  concentration  of 100 mg/1  produced 22 percent  degradation in
 3.5 hours, using acclimated phenol   adapted   seed  cultures.    In
 addition,  the nitro group in  the  number  4  (para) position seems
 to impart  a destabilizing effect  on  the molecule.  Based on these
 data  and general  conclusions   relating   molecular   structure   to
 biochemical   oxidation,  it is  expected that  4,6-dinitro-o-cresol
will  be biochemically oxidized  to  a  lesser extent   than  domestic
 sewage by biological treatment  in  POTWs.

N-nitrosodipheny1amine  (62). N-nitrosodiphenylamine  [(C«H5)2NNO],
also  called  nitrous diphenylamide,  is a yellow crystalline solid
manufactured  by nitrosation of  diphenylamine.   It melts  at  66°C
 (151°F) and is insoluble in water, but soluble  in several organic
                              322

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solvents  other  than  hydrocarbons.   Production in the U.S. has
approached 1500 tons  per  year.   The  compound  is  used  as  a
retarder  for rubber vulcanization and as a pesticide for control
of scorch (a fungus disease of plants).

N-nitroso compounds are acutely toxic  to  every  animal  species
tested  and are also poisonous to humans.  N-nitrosodiphenylamme
toxicity in adult rats lies in the midrange of the values for   60
N-nitroso  compounds tested.  Liver damage is the .principal toxic
effect.     N-nitrosodiphenylamine,     unlike     many     other
N-nitrosoamines,    does    not    show    mutagenic    activity.
N-nitrosodiphenylamine   has    been    reported    by    several
investigations  to be non-carcinogenic.  However, the compound  is
capable of trans-nitrosation  and  could  thereby  convert  other
amines   to  carcinogenic  N-nitrosoamines.   Sixty-seven  of   87
N-nitrosoamines  studied  were  reported  to  have   carcinogenic
activity.   No  water  quality  criterion  has  been proposed for
N-nitrosodiphenylamine.

No data are available on the  behavior  of  N-nitrosodiphenylamine
in  POTWs.  Biochemical oxidation of many of  the organic priority
pollutants has been  investigated, at .least   in  laboratory  scale
studies,  at  concentrations  higher   than   those  expected to  be
contained in most municipal   wastewaters.    General  observations
have   been  developed  relating  molecular   structure   to ease  of
degradation  for  all  the  organic  priority pollutants.    The
conclusion   reached  by  study  of. the   limited data  is   that-
biological  treatment  produces    little   or  no   removal    of
N-nitrosodiphenylamine   in  POTWs.   No   information  is available
regarding possible  interference by  N-nitrosodiphenylamine  in  POTW
processes, or on  the possible detrimental  effects on sludge   used
to    amend   soils   in  which  crops  are   grown.   However,   no
interference  or  detrimental  effects  are    expected,    because
N-nitroso  compounds are widely distributed  in the  soil and  water-
environment, at  low concentrations,  as   a   result   of   microbial
action on nitrates  and nitrosatable compounds.

N-nitrosodi-n-propvlamine   (63).   No physical properties or  usage
data  could be  found for  this  pollutant.   It  can  be  formed   from
the  interaction  of  nitrite  with secondary and tertiary  amines.

The   available   data  for   this  pollutant  indicate  that  acute
toxicity to  freshwater aquatic  life occurs at  concentrations  as
 low   as  5.85   mg/1.   No   data  are  available  concerning  this
pollutant's  chronic toxicity to freshwater and saltwater  aquatic
 life.   The   available  data  indicate  that  acute  toxicity  to
 saltwater aquatic life occurs at concentrations as low  as  3,300
mg/1.      . ..- ••-- -•  -        •"   • '"_'"•"    ::'---'  -'-.  '"::'"r   •" -•"-
                               323

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 For  the  maximum  protection  of human health from the potential
 carcinogenic effects due to exposure to this  pollutant,  through
 the  ingestion  of  contaminated water and aquatic organisms, the
 ambient water concentration should be  zero.   Concentrations  of
 this  pollutant estimated to result in additional lifetime cancer
 risks at risk levels of 10-«,  10-«, and 10~7  are  0.00016  mg/1,
 0.000016 mg/1,  and 0.0000016 mg/1 respectively.

 With  respect  to treatment in POTWs,  laboratory studies indicate
 that this pollutant is not amenable to treatment via  biochemical
 oxidation.

 Pentachlorophenol(64).    Pentachlorophenol  (C6C15OH)   is a white
 crystalline solid produced commercially by chlorination of phenol
 or polychlorophenols.   U.S.  annual production  is  in   excess  of
 20,000   tons.    Pentachlorophenol  melts  at 190°C (374°F) and is
 slightly soluble in water (14  mg/1).    Pentachlorophenol  is.  not
 detected by the 4-aminoantipyrene method.

 Pentachlorophenol  is  a bactericide and fungicide and  is used for
 the preservation of wood and wood products.    It  is  competitive
 with creosote   in   that  application.    It   is  also   used  as a
 preservative in glues,  starches,  and photographic papers.   It  is
 an effective algicide  and herbicide.

 Although data   are available  on  the human toxicity effects of
 Pentachlorophenol,   interpretation   of  data   is   frequently
 uncertain.   Occupational  exposure observations must  be examined
 carefully,  because  exposure  to  pentachlorophenol  is   frequently
 accompanied    by   exposure  to  other    wood   preservatives.
 Additionally,   experimental  results   and  occupational   exposure
 observations must   be   examined   carefully,   to  make  sure  that
 observed effects are produced  by  the pentachlorophenol  itself and
 not   by    the     by-products    which    usually    contaminate
 pentachlorophenol.

 Acute  and   chronic  toxic effects  of pentachlorophenol  in  humans
 are  similar;  muscle  weakness,   headache,   loss  of    appetite,
 abdominal   pain,  weight  loss, and irritation  of skin,  eyes,  and
 respiratory   tract.    Available   literature    indicates    that
pentachlorophenol  does  not   accumulate   in  body  tissues  to any
significant   extent.    Studies   on    laboratory   animals   of
distribution  of  the compound in body tissues  showed  the highest
 levels of pentachlorophenol  in   liver,  kidney,   and  intestine,
while the lowest  levels were in brain,  fat, muscle, and  bone.

Toxic  effects of pentachlorophenol in aquatic -organisms are  much
greater at a pH of 6, where this weak acid  is  predominately  in
the  undissociated  form  than at a pH of  9,  where the ionic  form
                              324

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predominates.  Similar results were observed  in  mammals,  where
oral  lethal  doses  of  pentachlorophenol  were  lower, when the
compound was administered  in  hydrocarbon  solvents  (un-ionized
form)  than  when .it was administered as the sodium salt  (ionized
form) in water.

There appear to be  no  significant  teratogenic,  mutagenic,  or
carcinogenic effects of pentachlorophenol.

For  the  protection of human health from the toxic properties of
pentachlorophenol,   ingested   through   water    and    through
contaminated   aquatic   organisms,  the  ambient  water  quality
criterion is determined to be 1.01 mg/1.  If contaminated aquatic
organisms alone are consumed, excluding the consumption of water,
the ambient water  criterion  is  determined  to  be  29.4  mg/1.
Available data show that adverse effects on aquatic life occur at
concentrations as low as 0.0032 mg/1.

Only  limited  data  are available for reaching conclusions about
the behavior of pentachlorophenol  in  POTWs.   Pentachlorophenol
has been found in the influent to POTWs.  In a study of one POTW,
the  mean  removal was 59 percent over a 7 day period.  Trickling
filters removed 44 percent  of  the  influent  pentachlorophenol,
suggesting  that  biological degradation occurs.  The same report
compared removal of pentachlorophenol at the same plant   and  two
additional  POTWs  on  a  later date, and obtained values of 4.4,
19.5 and 28.6 percent removal, the last value being for the plant
which  achieved  59  percent  removal  in  the  original   study.
Influent  concentrations  of pentachlorophenol ranged from 0.0014
to 0.0046 mg/1.  Other studies, including the general  review  of
data   relating  molecular  structure  to  biological  oxidation,
indicate that pentachlorophenol   is  not  removed  by  biological
treatment  processes in POTWs,  Anaerobic digestion processes are
inhibited by 0.4 mg/1 of pentachlorophenol.

The  low water solubility and low  volatility of  pentachlorophenol
lead  to  the expectation that most of the compund will remain in
the  sludge  in..a POTW.  The effect on plants grown on land treated
with  sludge  containing  pentachlorophenol   is   unpredictable.
Laboratory   studies   show   that  this  compound  affects  crop
germination  at   5.4 mg/1.    However,   photodecomposition   of
pentachlorophenol occurs in sunlight.  The effects of the various
breakdown products which may remain in the soil were not  found in
the  literature.

Phenol(65).   Phenol,  also  called  hydroxybenzerie  and  carbolic
acid,   is   a   clear,   colorless,   hygroscopic,   deliquescent,
crystalline  solid at room temperature.   Its melting point is 43°C
(109°F) and  its vapor pressure at room temperature is 0.35 mm Hg.
                               325.

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 It   is  very  soluble  in  water  (67  gm/1  at  16°C)  and can be
 dissolved in benzene, oils,  and petroleum solids.   Its  formula is
 CeHgOH.

 Although a small  percent of the annual  production   of  phenol   is
 derived   from  coal   tar as a naturally occuring product,  most of
 the  phenol is synthesized.   Two of  the  methods  are  fusion   of
 benzene   sulfonate with sodium hydroxide,  and oxidation of cumene
 followed by cleavage with a catalyst.   Annual production  in  the
 U.S.   is  in  excess  of  one  million  tons.   Phenol  is generated
 during  the  distillation  of  wood   and   the   microbiological
 decomposition  of organic  matter  in   the  mammalian  intestinal
 tract.

 Phenol is used as a  disinfectant,  in the manufacture  of  resins,
 dyestuffs,   and  Pharmaceuticals,  and   in  the photo  processing
 industry.   In this discussion,  phenol is  the  specific compound
 which  is  separated  by  methylene   chloride  extraction   of   an
 acidified sample  and identified and  quantified by  GC/MS.    Phenol
 also   contributes to  the  pollutant   "Total Phenols",  discussed
 elsewhere,  which  are determined by the  4-AAP  colorimetric  method.

 Phenol exhibits  acute  and   sub-acute   toxicity  in  humans   and
 laboratory  animals.    Acute oral  doses of phenol  in  humans  cause
 sudden collapse and  unconsciousness  due to the action  of  phenol
 on  the   central   nervous system.   Death occurs  by respiratory
 arrest.   Sub-acute oral  doses in mammals  are  rapidly   absorbed,
 then quickly distributed to  various  organs, then cleared from  the
 body by  urinary excretion and metabolism.   Long term  exposure,  by
 drinking  phenol contaminated water,  has resulted in statistically
 significant  increases in reported  cases of diarrhea,  mouth sores,
 and  burning of the  mouth.   In  laboratory  animals,  long  term oral
 administration  at low levels produced   slight  liver  and  kidney
 damage.    No  reports were   found   regarding  carcinogenicity  of
 phenol administered  orally - all carcinogenicity studies involved
 skin tests.

 For the protection of human  health from phenol   ingested   through
 water  and   through   contaminated  aquatic organisms, the  ambient
 water  criterion is determined to be  3.5  mg/1.   If   contaminated
 aquatic  organisms   alone are consumed,   excluding the consumption
 of water,  the ambient water  criterion   is   769   mg/1.   Available
 data   show   that  adverse   effects  in  aquatic  life  occur   at
 concentrations  as  low as  2.56 mg/1.

Data have been developed  on  the  behavior   of   phenol   in  POTWs.
Phenol  is   biodegradable by  biota present  in  POTWs.  The ability
of  a  POTW  to   treat  phenol-bearing   influents  depends   upon
acclimation  of   the   biota   and  the   constancy  of  the  phenol
                              326

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concentration.   It appears that an induction period  is  required
to build up the population of organisms which can degrade Phenol.
Too large a concentration will result in upset or^pass through in
the  POTW   but  the  specific level causing upset depends on the
immediate past history of phenol concentrations in^the  influent,
Phenol  levels  as  high  as  200 mg/1  have been treated with 95
percent removal in POTWs, but more or less continuous presence of
phenol is necessary to maintain the population of  microorganisms
that degrade phenol.

Phenol which is not degraded is expected to pass thorugh the POTW
because  of  its  very  high water solubility.  However  in POTWs
whe?e ?hlorination isVacticed  for  disinfection  of  the  POTW
effluent, chlorination of phenol may occur.  The products of that
reaction may be priority pollutants.

The   EPA   has   developed   data   on    influent  and  effluent
concentrations  of  total  phenols   in  a  study  of   103  POTWs.
Sowever   the analytical procedure was the 4-AAP method mentioned
earlier  and  not  the  GC/MS  method  specif ically^  for  phenol.
SlscuSs'ion  of  the   study,  which   of course^ncludes phenol,  is
presented under the pollutant heading  "Total  Phenols.

Phthalate Esters  (66-71).         Phthalic      _  acid    ,-omer?c"
1,2-benzenedicarboxylic   acid,    is  one   of    three   ifomer ic
benzenedicarboxylic acids produced  by  the  chemical  industry.   The
otter So  isomeric  forms  a?e called isophthalic  and terephathalic
acids.   The formula for  all  three  acids   is   C«H*  5°OH)f'  ,^°me
esters   of  phthalic   acid  are  designated  as  priority ^"tants.
They will  be  discussed as a group here, and   specif ic properties
of individual  phthalate  esters  will be discussed afterwards.

Phthalic  acid  esters  are manufactured  in  the  U.S.  at  ah annual
rate  in  excess   of   1   billion  pounds.    They  are   used   as
DlaSticizers   - primarily in the production  of polyvinyl chloride
?P??) reSiSsY  The most widely used phthalate plasticizer is  bis
  2-ethylhexyl)  phthalate (66)  which accounts for nearly  one third
 of  the  phthalate  esters   produced.    This  particular ester is
 Commonly referred to as dioctyl phthalate (DOP)  ^ shouldnot^e
 confused with one of the less used esters,  di-n-octyl  Palate
 (69),  which  is also used as a plastcizer.   In addition to these
 two isomeric dioctyl phthalates, four .other  esters,  also  used
 primarily as plasticizers,  are designated asjprionty Poljut^s.
 They are: butyl benzyl phthalate (67), di-n-butyl phthalate (68),
 diethyl phthalate (70), and dimethyl phthalate (71).
 Industrially,   phthalate   esters  are  prepared  from
 anhydride and the specific  alcohol  to  form  the  ester.   Some
 evidence  is  available suggesting that phthalic acid esters also
                                327

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 may  be  synthesized  by  certain   plant   and   animal   tissues.    The
 extent  to which  this occurs  in  nature  is not  known.

 Phthalate   esters   used  as   plasticizers   can   be  present   in
 concentrations up to 60 percent of the total  weight  of   the   PVC
 plastic.  The plasticizer  is not  linked by primary chemical bonds
 to   the  PVC  resin.   Rather,  it is locked into the structure of
 intermeshing polymer molecules  and held by van der Waals  forces
 The   result   is   that  the  plasticizer  is  easily  extracted!
 Plasticizers are responsible for the   odor  associated  with   new
 plastic  toys  or   flexible  sheet  that  has been contained in a
 sealed package.

 Although the phthalate esters are not  soluble, or  are  only  verv
 slightly soluble in water, they do migrate into aqueous solutions
 P-fuef  "^.contact with the plastic.   Thus industrial facilities
 with tank linings,  wire and cable coverings,  tubing,   and  sheet
 flooring  of  PVC are expected to discharge some phthalate esters
 Xu4.u ?XE raw waste-   In addition to their  ,use  as  plasticizers
 phthalate  esters  are  used  in  lubricating  oils and pesticid4
 C^uX?r?'   These also can contribute to industrial   discharge  of
 phthalate esters.

 From the accumulated data on acute toxicity in animals,  phthalate
 esters  may   be  considered  as   having  a   rather   low  order  of
 toxicity.  Human  toxicity data are limited.   It  is   thought   that
 the  toxic  effects of the  esters  are  most likely  due to  one of the
 metabolic  products,,  in   particular   the   monoester.   Oral  acute
 toxicity in  animals  is  greater for  the  lower  molecular  weiaht
 esters than  for the  higher  molecular weight  esters.

 Orally administered  phthalate esters generally produced  enlarging
 of liver and kidney, and  atrophy of  testes  in  laboratory animals!
 Specific   esters   produced  enlargement  of  heart  and  brain,
 spleenitis,  and degeneration of  central nervous system tissue
Subacute doses administered orally to  laboratory animals
some decrease in growth and degeneration of the testes.
studies in animals showed similar effects to those found
and  subacute  studies,  but  to  a  much lower degree.
organs were enlarged, but pathological changes were  not
detected.
produced
 Chronic
in acute
The same
 usually
A recent study of several phthalic esters produced suggestive but
not conclusive evidence that dimethyl and diethyl phthalates have
a  cancer  liability.   Only  four  of the six priority pollutant
esters  were  included  in  the  study.   Phthalate   esters   do
bioconcentrate  in  fish.   The  factors,  weighted  for relative
consumption of various aquatic and marine food groups,  are  used
                              328

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to  calculate  ambient water quality ' criteria for four phthalate
esters.  The  values  are  included  in  the  discussion  of  the
specific esters.

Studies  of  toxicity  of phthalate esters in freshwater and salt
water  organisms  are  scarce.   A  chronic  toxicity  test  with
bis(2-ethylhexyl)  phthalate showed that significant reproductive
impairment occurred at  3  mg/1  in  the  freshwater  crustacean
Daphnia  maqna..  In  acute  toxicity studies, saltwater fish and
organisms~iho'wed sensitivity differences of up to  eight-fold  to
butyl  benzyl,  diethyl,  and dimethyl phthalates.  This suggests
that each ester must be evaluated individually for toxic effects.

The behavior of phthalate esters in POTWs has "not  been  studied.
However,  the  biochemical  oxidation  of  many  of  the  organic
priority pollutants has been  investigated  in   laboratory  scale
studies  at concentrations higher than would normally be expected
In municipal wastewater. , Three  of  the  phthalate. esters  were,
studied.   Bis(2-ethylhexyl)  phthalate  was found to be degraded
Slightly or not  at all, and  its removal by  biological  treatment
in a POTW  is expected to be  slight or  zero.  Di-n-butyl phthalate
and  diethyl   phthalate  were  degraded to a moderate degree,  and
their  removal  by biological  treatment  in a POTW   is  expected   to
occur   to  a   moderate  degree.   Based  on   these data and other
observations relating molecular structure to  ease of  biochemical
degradation  of  other  organic  pollutants,   it is  expected^that
butyl   benzyl   and  dimethyl  phthalate  will  be    biochemically
oxidized   to   a  lesser extent than  domestic  sewage  by  biological
treatment  in  a POTW.  An EPA study  of  seven  POTWs   revealed   that
for  all but  di-n-octyl  phthalate, which was  not  studied,  removals
ranged from  62 to  87  percent.

No   informations  was  found  on  possible  interference with  POTW
operation  or  the possible  effects   on   sludge  by  the   phthalate
esters    The water  insoluble phthalate esters - butyl  benzyl and
di-n-octyl phthalate  -  would tend  to remain  in   sludge,   whereas
the   other  four  priority  pollutant  phthalate  esters  with  water
solubilities ranging  from 50,mg/1  to 4.5  mg/1 would probably pass.
 through into the POTW effluent.

Bis  (2-ethylhexyl.)  phthalate(66).   In  addition  to  the  general
 FiHarks  and "discussion on phthalate esters,  specific information
 on bis (2-ethylhexyl)  phthalate is provided.    Little  ^^mation
 is  available  about the physical  properties of bis(2-ethylhexyl)
 phthalate.  It is a liquid boiling at 387°C  at  5mm  Hg  and  is
 insoluble  in  water.   Its  formula  is  C,H (COOC?H17)2-This
 priority pollutant constitutes about one third of  the  phthalate
 ester  production  in  the  U.S.    It  is commonly referred to as
 dioctyl phthalate, or DOP, in the plastics industry, where it  is
                               329

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 the  most  extensively  used  compound  for the plasticization of
 polyvinyl chloride  (PVC).  Bis(2-ethylhexyl) phthalate  has  been
 approved  by  the   FDA  for use in plastics in contact with food.
 Therefore, it may be found in wastewaters coming in contact  with
 discarded  plastic  food  wrappers  as  well as the PVC films and
 shapes  normally  found  in  industrial  plants.   This  priority
 pollutant  is  also  a  commonly used organic diffusion pump oil,
 where its low vapor pressure is an advantage.

 For the protection of human health from the toxic  properties  of
 bis(2-ethylhexyl)  phthalate,   ingested through water and through
 contaminated  aquatic  organisms,   the  ambient   water   quality
 criterion  is  determined to be 15 mg/1.   If contaminated aquatic
 organisms alone are consumed,  excluding the consumption of water
 the ambient water criterion is determined to be 50 mg/1.

 Although the behavior of bis(2-ethylhexyl)  phthalate in POTWs has
 not  been  studied,   biochemical   oxidation  of   -this   priority
 pollutant   has   been   studied    on   a   laboratory  scale  at
 concentrations  higher  than  would  normally   be   expected   in
 municipal  wastewater.   In  fresh water with a  non-acclimated seed
 culture,  no biochemical  oxidation  was observed after 5,   10,   and
 20  days.    However,  with  an  acclimated  seed  culture,  biological
 oxidation occurred to the extents  of  13,  0,  6,  and 23  percent  of
 theoretical   oxidation after 5,  10,  15 and  20  days,  respectively.
 Bis(2-ethylhexyl)  phthalate concentrations  were  3   to   10  mg/1
 Little  or no  removal of  bis(2-ethylhexyl) phthalate  by biological
 treatment in  POTWs is  expected.

 Butyl benzyl  phthalate(67).    In   addition  to  the  general  remarks
 and discussion on  phthalate esters, specific information on  butyl
 benzyl phthalate  is  provided.  No  information  was  found   on   the
 physical properties  of this compound.

 Butyl  benzyl  phthalate  is  used as  a plasticizer  for PVC.   Two
 special  applications  differentiate   it  from  other   phthalate
 esters.    It   is   approved  by  the  U.S. FDA  for food contact  in
 wrappers and  containers; and it  is  the  industry  standard   for
 plasticization  of   vinyl   flooring,   because   it  provides stain
 resistance.
No ambient water quality criterion is proposed for
phthalate.
butyl  benzyl
      .         phthalate  removal,  by  biological treatment in a
POTW, is expected to occur to a moderate degree.

Di-n-butvl phthalate (68).  In addition to  the  general  remarks
and  discussion  on  phthalate  esters,  specific  information on
                              330

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di-n-butyl phthalate (DBF) is provided.  DBF.is a colorless, oily
liquid,  boiling  at  340°C.    Its .water  solubility   at   room
temperature  is  reported  to : be  0.4  g/1  and  4.5  g/1 in two
different    chemistry    handbooks.      The     formula     for
DBF, C6H4(COOC^H9)2  is  the  same as for its isomer, di-isobutyl
phthalate.  DCP production is one to two percent  of  total  U.S.
phthalate ester production.

Dibutyl  phthalate  is  used to a limited extent as a plasticizer
for polyvinyl chloride (PVC).  It is  not  approved  for  contact
with  food.  It is used in liquid lipsticks and as a dilutent for
polysulfide dental  impression  materials.   DBF  is  used  as  a
plasticizer  for  nitrocellulose  in  making gun powder, and as a
fuel  in  solid  propellants - for  rockets.   Further  uses   are
insecticides,   safety  glass  manufacture,  textile  lubricating
agents,  printing  inks,  adhesives,  paper  coatings  and  resin
solvents.                       .

For  protection  of  human  health  from  the toxic properties'of
dibutyl   phthalate,   ingested   through   water   and   through
contaminated   aquatic   organisms,  the  ambient  water  quality
criterion is determined to be 34 mg/1.  If  contaminated  aquatic-
organisms  are  consumed, excluding the consumption of water, the
ambient water criterion is 154 mg/1.

Although  the behavior of di-n-butyl phthalate in  POTWs  has  not
been  studied,  biochemical   oxidation of this priority pollutant
has been  studied on a laboratory scale at  concentrations   higher
than   would  normally  be  expected  'in  municipal  wastewaters.
Biochemical oxidation of  35,  43, and 45  percent  of  theoretical
oxidation were  obtained after  5,  10, and 20 days,  respectively,
using sewage microorganisms   as  an  unacclimated  seed  culture.
Based  on these  data,   it  is expected that di-n-butyl phthalate
will be biochemically oxidized to a lesser extent  than  domestic
sewage by biological treatment in POTWs.  Biological treatment  in
POTWs  is expected  to remove di-n-butyl phthalate  to  a moderate
degree.

Di-n-octvl phthalate(69).  In addition to  the general remarks and
discussion   on  phthalate    esters,    specific    information    on
di-n-octyl phthalate  is provided,   Di-n-octyl phthalate  is  not  to
be  confused  with  the  isomeric  bis(2-ethylhexyl) phthalate which
is  commonly  referred  to   in   the plastics   industry  as  DOP.
Di-n-octyl phthalate  is a liquid which boils at  220°C at  5  mm Hg.
It    is    insoluble    in   water.     Its   molecular formula  is
C6H4(COOC8H17)2.   Its production constitutes about one  percent  of
all phthalate ester production  in  the  U.S.
                               331

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 Industrially,  di-n-octyl  phthalate
 polyvinyl chloride (PVC) resins.
is   used   to   plasticize
 No  ambient  water  quality  criterion is proposed for di-n-octyl
 phthalate.   Biological treatment in POTW is expected to  lead  to
 little or no removal of di-n-octyl phthalate.

 Diethyl  phthalate  (70).   In addition to the  general remarks and
 discussion  on phthalate esters,  specific information  on  diethyl
 phthalate is provided.  Diethyl  phthalate,  or  DEP,  is a colorless
 liquid  boiling  at  296°C,   and  is  insoluble  in  water.    Its
 molecular  formula  is  C6H4(COOC2H5)2.    Production  of  diethyl
 phthalate  constitutes  about  1.5  percent of  phthalate  ester
 production  in the U.S.

 Diethyl phthalate is approved for use in plastic food  containers
 by  the U.S.  FDA.   In addition to its use as a polyvinyl chloride
 (PVC)  plasticizer,  DEP is  used to  plasticize   cellulose  nitrate
 for    gun   powder,    to   dilute  polysulfide   dental  impression
 materials,  and as an accelerator for  dyeing  triacetate  fibers.
 An  additional   use,  which   would  contribute   to  its   wide
 distribution in  the  environment,   is  as   an  approved  special
 denaturant   for  ethyl alcohol.   The alcohol-containing products,
 for  which DEP is  an  approved  denaturant,  include a  wide range  of
 personal  care items  such as bath preparations,  bay  rum,  colognes,
 hair  preparations,   face  and  hand  creams,  perfumes and toilet
 soaps.  Additionally,  this denaturant  is  approved  for  use  in
 biocides,    cleaning   solutions,    disinfectants,   insecticides,
 fungicides,  and room deodorants  which have  ethyl  alcohol as   part
 of   the  formulation.   It  is  expected,  therefore, that people and
 buildings would  have   some   surface  loading   of  this  priority
 pollutant which would  find its way  into  raw wastewaters.

 For  the  protection of human  health from the  toxic properties of
 diethyl   phthalate,    ingested    through   water   and   through
 contaminated    aquatic  organisms,   the  ambient  water  quality
 criterion  is  determined to be 350  mg/1.  If contaminated aquatic
 organisms alone are  consumed,  excluding  the consumption  of water,
 the  ambient water criterion is 1800  mg/1.

 Although  the behavior  of diethyl  phthalate  in  POTWs has  not   been
 studied,  biochemical  oxidation  of   this  priority pollutant  has
 been studied on a laboratory scale  at  concentrations  higher   than
would normally  be expected in  municipal wastewaters.   Biochemical
oxidation  of   79, 84, and 89  percent  of  theoretical  was  observed
after 5,  5,  and 20 days, respectively.  Based on  these   results,
 it   is  expected  that  diethyl   phthalate   will  be  biochemically
oxidized to a  lesser extent than  domestic   sewage   by  biological
treatment in POTWs.
                              332

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Dimethyl phthalate (71).   In addition to the general remarks^and
discussion on pntnaiate esters, specific information on  dimethyl
phthalate (DMP) is provided.  BMP has the lowest molecular weight
of the phthalate esters - M.W. of 194 compared to M.W. of 391 for
bis(2-ethylhexyl)phthalate.   DMP  has  a boiling point of 2820C.
It is a colorless liquid, soluble in water to  the  extent  of  5
mg/1.  Its molecular formula is C6H4(COOCH3)2.

Dimethyl  phthalate  production  in  the  U.S.  is just under one
percent of total phthalate ester production.  DMP is used to some
extent as a plasticizer in cellulosics.  However   its  principle
specific use is for dispersion of polyvinylidene fluoride (PVDF).
PVDF  is  resistant to most chemicals and finds use as electrical
insulation, chemical process equipment  (particularly  pipe),  and
as a base for  long-life finishes for exterior metal siding.  Coil
coating techniques are used to apply PVDF dispersions to aluminum
or galvanized  steel siding.

For  the  protection of human  health from the toxic properties  of
dimethyl  phthalate,    ingested   through   water   and   through
contaminated   aquatic   organisms,  the  ambient  water  quality
criterion is determined to  be  313 mg/1.  If contaminated  aquatic
organisms alone are consumed,  excluding the consumption of water,
the  ambient water criterion  is 2800 mg/1.

Based   on  limited  data   and observations  relating  molecular
structure to ease of biochemical  degradation   of  other  organic
pollutants,  it   is  expected  that  dimethyl   phthalate  will  be
biochemically  oxidized  to  a lesser extent than  domestic sewage  by
biological  treatment in POTWs.

Polvnuclear  Aromatic    Hydrocarbons(72-84).     The   polynuclear
aromatic  hydrocarbons  (PAH)  selected  as priority pollutants  are a
group of  13 compounds  consisting  of  substituted and  unsubstituted
polycyclic  aromatic   rings.   The general  class of  PAHs  includes
heterocyclics, but   none  of  those   were   selected   as   priority
pollutants.     PAHs  are  formed  as   the   result  of  incomplete
combustion  when organic compounds are  burned  with   insufficient
oxvqen.    PAHs  are  found  in  coke  oven   emissions,   vehicular
emissions,  and volatile products  of  oil  and  gas  burning.    The
 compounds  chosen  as   priority   pollutants are listed  with their
structural  formulas  and melting  points (m.p.).   All  are insoluble
 in water.

      72   Benzo(a)anthracene (1,2-benzanthracene)*

                                  m.p.  162°C (324°F)

      73   Benzo(a)pyrene (3,4-benzopyrene)*

                       ;     T'-~i  m.p. '17.6DC (349°F)
                               333

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 74   3,4-benzofluoranthene*
                             m.p. 168°C (334°F)
 75   Benzo(k)fluoranthene (11,12-benzofluoranthene)
                             m.p.  217°C (391°F)
 76   Chrysene (1,2-benzophenanthrene)*
 77   Acenaphthylene*
           HC=CH
 78    Anthracene*
                             m.p.  255°C
                             m.p.  92°C (198°F)
                             m.p.  216°C (421°F)
                                                           HC=CH
 79    Benzo(ghi)perylene  (1,12-benzoperylene)
                             m.p.  not  reported
80   Fluorene  (alpha-diphenylenemethane)*
81   Phenanthrene*
                            m.p.  116°C  (241<>F)
                            m.p.  101°C  (214°F)
82   Dibenzo(a,h)anthracene  (1,2,5,6-dibenzoanthracene)
                            m.p. 269°C  (516°F)

83   Indenod,2,3-cd)pyrene  (2,3-o-phenylenepyrene)
                            m.p. not available
84   Pyrene*
                            m.p.  156°C  (313°F)
                         334

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Note; An asterisk indicates that the pollutant is known to be present
in metal molding and casting process wastewaters.


Some of these priority pollutants have commercial  or  industrial
useL   Benzo (a) anthracene, benzo(a)Pyrene, chrysene  anthracene,
dibenzo(a,h)anthracene, and pyrene are all used a^  jntioxidants.
Chrysene, acenaphthylene, anthracene, fluorene, phenanthrene, and
pyrene  are  all used for synthesis of dyestuffs or other organic
chemicals.  3,4-benzof luoranthrene,  benzo(k)f luoranthene,  benzo
(qhi)   perylene,  and  indeno   (1,2,3-cd) pyrene  have  no  known
industrial uses/ according to the results of a recent  literature
search .

Several of the  PAH priority pollutants are found in smoked^meats,
in   smoke  flavoring  mixtures,  in vegetable oils, and in coffee.
They  are  found  in  soils  and  sediments   in   river   beds.
Consequently,   they  are  also  found   in  many  drinking  water
sSppliel   The  widedistribution of  these pollutants   in  complex
mixtures, with  the many other PAHs which have not b^n designated
as   priority  pollutants,  results   in   exposures  by  humans  that
cannot be associated with  specific  individual compounds.
 The screening and verification analysis procedures used  for  the
 organic priority pollutants are based on gas chromatography (GC) .
 Three  pairs  of  the  PAHs  have  identical elution times on_the
 columnipecified in the protocol, which means that the parameters
 of the pair  are  not  differentiated.   For  these  three  pairs
 [anthracene  (78) - phenanthrene (81); 3,4-benzof luoran thene (74^
 -  benzo(k)fluoranthene  (75);  and  benzo (a) anthracene  (72)   ^
 chrysene  (76)] results are obtained and reported as  either-or.
 Either both are present in the combined  concentration  reported,
 or one is present in the concentration reported.  When detections
 below  reportable  limits  are  recorded,  ™f "r^V"3^3,1;3. ^
 reauired   For samples  where  the  concentrations  of  coeluting
 pairs   have  ..... I   significant  value,  additional  analyses  are
 Conducted, using different procedures that resolve the particular
 pair.

 There are no studies to document the possible carcinogenic  risks
 to humans by direct  ingest ion.  Air pollution studies  indicate an
 excess  of   lung  cancer mortality among workers exposed to large
 amounts of PAH containing materials such as  coal gas,  tars,  and
 coke-oven  emissions.  However, no definite  proof exists that the
 PAH present  in these materials are responsible  for  the   cancers
 observed.
 Animal  studies have demonstrated the toxicity of PAH by.b
 dermal administration.   The  carcinogenicity  of  PAH  has  been
                               335

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  traced   to   formation   of  PAH metabolites which,  in  turn,  lead  to
  tumor formation.  Because  the levels of  PAH which  induce   cancer
  are  very   low,  little  work has been done on other health  hazards
  resulting from exposure.   It  has  been  established   in   animal
  studies  that tissue damage and systemic toxicity can result  from
  exposure to  non-carcinogenic PAH compounds.

  Because there were no studies available  regarding   chronic   oral
  exposures  to  PAH mixtures, proposed water quality  criteria  were
  derived using data on exposure to a single compound.   Two  studies
  were selected, one involving  benzo(a)pyrene  ingestion  and  one
  involving   dibenzo(a,h)anthracene  ingestion.    Both  are  known
  animal carcinogens.

 For the maximum protection of human  health  from  the  potential
 carcinogenic   effects   of   exposure  to  polynuclear  aromatic
 hydrocarbons (PAH),  through ingestion of water   and  contaminated
 aquatic  organisms,   the  ambient  water  concentration  is zero
 Concentrations of PAH estimated  to result in additional  lifetime
 ?an«Sr ^isk  °f 10~7'  10~62'  and 10~S  are 2-8  x lO-^ mg/1, 2,8 x
 10-'  mg/1 and 2.8 x   1 o-  mg/1   respectively.    If  contaminated
 aquatic  organisms  alone are consumed,  excluding the consumption
 of water,  the water  concentration should be  less than 3 11  x 10-*
 mg/1  to keep the  increased  lifetime  cancer   risk  below  10-s
 Available data  show the adverse  effects on  aquatic life occur at
 concentrations higher  than  those  cited  for human health risk.

 The behavior of  PAHs  in  POTWs has  received only  a limited  amount
 of study.    It   is  reported  that   up  to 90 percent of the PAHs
 entering  a POTW will be   retained   in  the   sludge  generated   by
 ?°2?u"!:1unai   Sewa9e   treatment  processes.  Some of  the PAHs  can
 inhibit bacterial  growth when they are present at  concentrations
 as low  as  0.018  mg/1.   Biological  treatment in activated  sludge
 units has been shown to  reduce the concentration of   phenanthrene
 and anthracene   to some extent.  However, a study of biochemical
 oxidation of  fluorene on a  laboratory scale showed no degradation
 after 5, 10,  and  20 days.   On the basis of that  study and studies
 of other organic priority pollutants, some  general   observations
 were  made  relating  molecular structure to ease of  degradation.
 Those observations lead  to  the  conclusion  that  the   13  PAHs
 selected  to represent that^ group as priority pollutants, will be
 removed only slightly or  not  at  all  by  biological  treatment
methods in POTWs.  Based on their water insolubility  and tendency
*£ ?n™o h0S?1Sedime"t Partifles,  very little pass through of PAHs
to POTWs effluents is expected.
        r?cent  Agency  study,  Fate  of  Priority  Pollutants in
         Owned Treatment Works, the poI7uti[Ht~~c^ncentrations  IK
the influent, effluent and sludge of 20 POTWs were measured.  The
                              336

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results  show  that  indeed  the  PAHs  are  concentrated -in.-the
sludges, and that  little  or  no  PAHs  are  discharged  in  the
effluent  of  POTWs.   The  differences in average concentrations
from influent to effluent range from 50 to . TOO  percent  removal
with all but one PAH above 80;percent removal.  The data indicate
that  all  or  nearly  all  of  the , PAHs are concentrated in the
sludge.

No data are available at this time  to  support  any  conclusions
about PAH contamination of land on which sewage sludge containing
PAH is spread.        .

Tetrachloroethvlene(85).   Tetrachloroethylene  (CCl.2CClz),  also
called perchloroethylene and PCE,  is  a  colorless  nonflammable
liquid   produced  mainly  by  two  methods  -  chlonnation  and
pyrolysis  of  ethane  and  propane,   and   oxychlorination   of
dichloroethane.   U.S.  annual  production  exceeds 300,000 tons.
PCE boils at  121°C  (250°F) and has a vapor pressure  of  19 mm Hg
at  20°C.    It   is   insoluble  in  water  but  soluble in organic
solvents.

Approximately two-thirds of'the U.S. production pf  PCE  is  used
for  dry  cleaning.   Textile processing and metal degreasing, in
equal  amounts consume about one-quarter of the U.S. production.

The principal toxic  effect of PCE on humans   is   central  nervous
system depression,   when  the  compound   is   inhaled.  Headache,
fatigue, sleepiness,  dizziness and sensations of  intoxication  are
reported.     Severity   of   effects    increases    with    vapor
concentration.    High   integrated  exposure   (concentration times
duration) produces  kidney  and  liver damage.   Very limited data on
PCE  ingested by  laboratory animals   indicate   that   liver  damage
occurs when PCE  is  administered   by  that  route.   PCE tends to
distribute  to fat in mammalian bodies.

One  report   found  in  the  literature  suggests,   but  does   not
conclude,   that  PCE is  teratogenic.   PCE  has  been demonstrated to
be a liver  carcinogen in  B6C3F1 mice.

For  the maximum  protection of  human   health   from  the  potential
 carcinogenic  effects of  exposure to  tetrachloroethylene,  through
 ingestion   of  water  and  contaminated  aquatic   organisms,   the
 ambient   water    concentration    is    zero.    Concentrations  of
 tetrachloroethylene estimated to  result  in  additional   lifetime
 cancer risk levels of TO-7,  10-«,  and 10-* are 8  x 10-s  mg/1,  8  x
 10-*  mg/1,   8   x 10-3mg/l respectively.   If  contaminated aquatic
 organisms  alone are consumed,  excluding the consumption of water,
 the water  concentration should be less than 0.088  mg/1   to  keep
 the  increased  lifetime  cancer risk below 10~».  Available data
                             :: -337

-------
 show that adverse effects on aquatic  life occur at  concentrations
 higher than those cited for human health risks.

 No data were found regarding the behavior of PCE  in POTWs.   Many
 of  the  organic  priority  pollutants have been  investigated, at
 least in laboratory scale studies, at concentrations higher  than
 those  expected  to  be  contained by most municipal wastewaters.
 General  observations  have  been  developed  relating  molecular
 structure  to ease of degradation for all of the organic priority
 K 1U »r*S'  -?fSud u" Study of the limited data, it  is  expected
 that  PCE  will be biochemically oxidized to a lesser extent than
 domestic sewage by biological treatment in POTWs.   An  EPA  studv
 of  seven  POTWs  revealed removals of 40 to 100 percent.  Sludqe
 concentrations of tetrachloroethylene ranged from 1  x 10-3 to 16
 mg/1.    Some  PCE  is  expected  to  be  volatilized  in  aerobic
 treatment  processes  and  little,   if  any,   is expected to pass
 through into the effluent from the POTW.

 Toluene(86).    Toluene  is  a  clear,   colorless  liquid  with  a
 benzene-like  odor.    It is  a naturally occuring compound derived
 primarily  from  petroleum  or  petrochemical   processes.     Some
 toluene  is   obtained from the manufacture  of  metallurgical coke.
 Toluene is  also referred to  as totuol, methylbenzene,   methacide,
 and  phenymethane.   It is an  aromatic  hydrocarbon with  the formul4
 LgH5CH3.    It  boils  at llioc and has  a vapor pressure  of 30 mm Hq
 at room temperature.   The  water  solubility  of  toluene  is  535
 TSm.ai    x,  1J-  1S   "Jscible  with  a  variety of  organic  solvents.
 Annual  production of  toluene  in the   U.S.  is  greater  than  2
 million   metric tons.  Approximately  two-thirds  of the  toluene is
 converted to benzene  and the  remaining   30  percent  is  divided
 approximately   equally   into  chemical manufacture, and use as  a
 paint solvent and aviation gasoline additive.  An  estimated 5,000
 metric  tons  is   discharged   to   the  environment   annually  as   a
 constituent  in  wastewater. ,

 Most  data  on  the effects of toluene  in humans and  other  mammals
 have been based  on inhalation exposure or dermal contact studies
 There appear to  be no reports of oral  administration  of   toluene
 to  human  subjects.   A  long  term toxicity study on female  rats
 revealed no adverse effects on  growth, mortality, appearance  and
 behavior   organ  to  body  weight  ratios,  blood-urea  nitrogen
 levels,  bone  marrow  counts,  peripheral   blood   counts,   or
morphology  of  major  organs.  The effects of inhaled toluene on
 the central nervous system, both at high and low  concentrations
 have  been  studied  in  humans  and  animals.   However, inaested
toluene is expected  to  be  handled  differently  by  the  body
because  it  is  absorbed more slowly and must first pass through
the  liver  before  reaching  the  nervous  system.   Toluene  is
extensively  and  rapidly  metabolized  in the liver.  One of the
                              338

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principal metabolic products- of toluene is  benzoic  acid,  which
itself seems to have little potential to produce tissue injury.

Toluene  does  not appear to be teratogenic in laboratory animals
or man.  Nor is there any conclusive  evidence  that  toluene  is
mutagenic.   Toluene  has not been demonstrated to be positive in
any iH vitro mutagenicity or carcinogenicity bioassay system, nor
to be carcinogenic in animals or man.

Toluene has been found in fish caught in  harbor  waters  in  the
vicinity of petroleum and petrochemical plants.  Bioconcentration
studies  have  not  been  conducted, but bioconcentration factors
have been calculated on the basis of the octanol-water  partition
coefficient.
For  the
toluene, i
organisms,
mg/1.   If
excluding
criterion
on aquatic
protection of human health from the toxic properties of
ngested through water and through contaminated  aquatic
  the  ambient water criterion is determined to be 14.3
contaminated  aquatic  organisms  alone  are  consumed,
 the  consumption  of  water, the ambient water quality
is 424 mg/1.  Available data show that adverse  affects
 life occur at concentrations as low as 5 mg/1.
Acute  toxicity  tests  have  been  conducted  with toluene and  a
variety of freshwater fish and Daphnia maqna.  The latter  appears
to be significantly more resistant than fish.   No  test   results
have  been  reported  for  the  chronic  effects  of   toluene  on
freshwater fish or invertebrate species.

Only one  study  of  toluene  behavior  in   POTWs  is   available.
However,  the  biochemical  oxidation  of  many  of  the priority
pollutants has been investigated  in laboratory scale   studies  at
concentrations  centrations   greater  than   those  expected to be
contained   by   most   municipal   wastewaters.    At    toluene
concentrations  ranging from  3 to 25.0 mg/1,  biochemical oxidation
proceeded to fifty percent of theoretical or greater.   The  time
period  varied  from a few hours  to 20 days, depending on  whether
or  not  the  seed  culture   was  acclimated.    Phenol   adapted
acclimated  seed  cultures  gave  the  most  rapid  and extensive
biochemical oxidation.  Based on  study of the  limited  data,  it  is
expected that toluene will be biochemically  oxidized to a   lesser
extent  than  domestic  sewage by biological treatment in  a POTW.
The volatility and relatively low  water  solubility   of   toluene
lead  to  the  expectation  that  aeration   processes  will remove
significant quantities of toluene from the  POTW.  The  EPA  studied
toluene removal  in seven POTWs.   The removals  ranged from   40   to
100  percent.    Sludge concentrations of  toluene ranged from  54  x
10-3 to  1.85 mg/1.
                               339

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 Trichloroethvlene(87).     Trichloroethylene     (1,1,2-trichlor-
 ethylene  or  TCE)  is a clear colorless boiling at 87°C (189°F).
 It has a vapor pressure of 77 mm Hg at room  temperature  and  is
 slightly  soluble  in water (1 gm/1).   U.S. production is greater
 than 0.25 million metric tons  annually.   It  is  produced  from
 tetrachloroethane  by  treatment  with  lime  in  the presence of
 water.

 TCE is used for vapor phase degreasing of metal  parts,   cleaning
 and  drying  electronic components, as a solvent for paints, as a
 refrigerant,  for extraction of oils,  fats,  and waxes,  and for dry
 cleaning.   Its widespread  use  and  relatively  high   volatility
 result in detectable levels in many parts of the environment.

 Data  on  the effects produced by ingested TCE are limited.   Most
 studies have   been  directed  at  inhalation  exposure.    Nervous
 system  disorders  and  liver   damage   are  frequent  results  of
 inhalation exposure.   In the short term exposures, TCE acts  as  a
 central  nervous system depressant -  it was used as  an anesthetic
 before its other long term effects were defined.

 TCE has been  shown to induce transformation in a highly  sensitive
 iH vitro Fischer rat  embryo cell system (F1706)  that is  used  for
 identifying  carcinogens.    Severe and persistent toxicity to the
 liver  was  recently demonstrated when TCE  was  shown  to produce
 carcinoma   of  the  liver  in mouse strain B6C3F1.  One systematic
 study  of TCE  exposure and  the  incidence of  human cancer  was  based
 on  518  men exposed to TCE.   The authors of  that   study  concluded
 that,   although   the   cancer  risk to  man  cannot  be ruled out,
 exposure to low  levels of  TCE  probably does  not  present  a   very
 serious and general cancer  hazard.

 TCE  is  bioconcentrated in  aquatic  species,  making  the  consumption
 of   such  species  by  humans  a  significant source  of  TCE.  For the
 protection of   human   health   from the  potential  carcinogenic
 effects of  exposure   to  trichloroethylene,  through ingestion  of
 water and   contaminated  aquatic   organisms,   the  ambient   water
 concentration    is  zero.    Concentrations  of   trichloroethylene
 estimated  to  result in  additional  lifetime  cancer risk  of   1   in
 100,000  corresponds  to an ambient  water  concentration of 0.00021
mg/1.

Only a  very limited amount of  data  on  the   effects  of  TCE   on
freshwater  aquatic  life  are  available.    One  species of  fish
 (fathead minnows) showed a loss of  equilibrium at  concentrations
below   those  resulting  in  lethal  effects.   The limited data for
aquatic  life show that adverse effects  occur  at  concentrations
higher  than those cited for human health risks.
                              340

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For  a  recent  Agency  study,  Fate  of  Priority  Pollutants in.
Publicly Owned Treatment Works, the pollutant  concentrations  in
the influent, effluent, and sludge of 20 POTWs were measured.  No
conclusions  were made; however, trichloroethylene appeared in 95
percent of the influent stream samples but only in 54 percent  of
the    effluent    stream    samples.     This   indicates   that
trichloroethylene either is concentrated in the sludge or escapes
to the atmosphere.  Concentration? in 5.0 percent  of  the  sludge
samples   indicate   that   much   of  the  trichloroethylene  is
concentrated there.

Aldrin (89).  Aldrin (C12H8C16) is a brown to  white  crystalline
solid  whTcV is used as an insecticide.  It melts at -104-1 05.5°C
(219-222°F).  While soluble in most organic solvents,  aldrin  is
insoluble  in  water.   It  is not affected by alkalies or dilute
acids, and   is  compatible  with  most  herbicides,  fertilizers,,
fungicides,  and insecticides.

For  freshwater  aquatic life, the concentration of aldrin should
not  exceed  0.003  mg/1.   For  saltwater  aquatic   life,   the
concentration  of this pollutant should not exceed 0.0013 mg/1 at
any time.  No data  are  available  concerning  this  pollutant's
chronic toxicity.

For  the  maximum  protection  of human health from the potential
carcinogenic effects of exposure to this pollutant,  through  the
ingestion  of  contaminated  water  and  aquatic  organisms,  the
ambient water concentration should be  zero.   Concentrations, of
this  pollutant estimated  to result  in additional lifetime cancer
risks at risk levels of 10-5,  10-*, and TO-7 are 0.00000074 mg/1,
0.000000074  mg/1, and  0.0000000074 mg/1 respectively.         . ,

With respect to discharges to  a POTW,  it must be noted that   this
pollutant   is  toxic   to biological organisms.  As this pollutant
can interfere with the biological treatment processes  in  a  POTW,
its discharge to  a POTW must  be carefully controlled.

Chlordane   (91_).   Chlordane  (C10H6C18) is a colorless, odorless,
viscous  liquid."   It  boils  at  175°C  (347°F) and. decomposes in  weak
alkalies.   This chemical is soluble   in  many  organic  solvents,
insoluble   in  water,  and miscible   in deodorized  kerosene.   In
addition to  its use  as an  insecticide,  this  chemical  is also  used
in oil emulsions  and dispersible  liquids.

The criterion to  protect freshwater   aquatic   life   is  0.0000043
mg/1  as  a  24 hour average  and the concentration should not exceed
0.0024   mg/1 at   any  time.    The  criterion to protect saltwater
aquatic  life is  0.000004 mg/1   as   a  24  hour  average   and   the
concentration should not exceed 0.00009 mg/1 at any  time.
                               341

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 For   the  maximum  protection  of human health from the potential
 carcinogenic  effects due to exposure to  chlordane,   through  the
 ingestion  of    contaminated   water  and  contaminated  aquatic
 organisms,  the   ambient  water  concentration  should  be  zero.
 Concentrations    of   this   pollutant   estimated  to  result   in
 additional  lifetime cancer risk at risk levels of TO"5,  TO"6/  and
 1077  are 0.0000046  mg/1,  0.00000046 mg/1,   and  0.000000046  mg/1
 respectively.

 With    respect    to   treatment   in POTWs,   this  substance   is
 biodegradable, but  can also accumulate   in  biological  organisms
 and   exert  a  toxic  effect.    Therefore,   the discharge  of this
 pollutant to  a   POTW  must  be  carefully  controlled  to  avoid
 inhibitory  effects  on the POTW  treatment process.

 4,4'-DDT(92).  4,4'-DDT (C1C€H4)2CHCC13 is a  colorless crystal  or
 a  slightly off-white  powder   which  is   odorless   or  slightly
 aromatic.   It is  soluble  in  acetone,   ether,   benzene,  carbon
 tetrachloride,  kerosene,  dioxane,  and  pyridine,  but insoluble  in
 water.   It  is  not   compatible   with alkaline  materials.   This
 compound is derived by condensing chloral  or  chloral hydrate with
 chlorobenzene  in   the  presence  of fuming sulfuric acid.   It  is
 used  as  an  insecticide.

 For this pollutant,   the   criterion  to protect   freshwater and
 saltwater  aquatic   life   is  0.0000010  mg/1 as a  24  hour average.
 The concentrations  which  should not be  exceeded at any  time are
 0.0011 mg/1 for fresh  waters  and 0.00013 mg/1  for  saltwaters.

 For   the maximum   protection   of human health from  the  potential
 carcinogenic effects  due  to exposure to this   pollutant,   through
 the   ingestion  of   contaminated water  and  aquatic organisms, the
 ambient  water concentrations  should be  zero.    Concentrations   of
 this  pollutant estimated  to  result in  additional  lifetime cancer
 risks at risk levels  of  10-5, 10~6,  and 10~7 are  0.00000024  mg/1,
 0.000000024 mg/1, and  0.0000000024  mg/1  respectively.

 With  respect to discharge  to  a  POTW,  it must be noted  that  this
 pollutant   is  toxic   to  biological  organisms.  As this  pollutant
 can interfere with  the biological  treatment process   in  a   POTW,
 its discharge to a  POTW must  be  carefully  controlled.

 4,4'-DDE  (93).   4,4'-DDE  (C1C6H4)2  CHCC13  is  a colorless crystal
 or slightly off-white powder which   is  odorless   or   exhibits  a
 slight   aromatic odor.   It  is soluble in acetone,  ether, benzene,
 carbon tetrachloride, kerosene,   dioxane,   and  pyridine  but   is
 insoluble   in   water.    It  is  not   compatible  with  alkaline
materials.  This pollutant  is derived by  condensing   chloral  or
                               342

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chloral  hydrate  with  chlorobenzene  in  the presence of fuming
sulfuric acid.  It is used as a pesticide.

For this pollutant/  'the  criterion  to  protect  freshwater •  and
saltwater  aquatic  life  is 0.0000010 mg/1 as a 24-hour average.
The concentrations which should not be exceeded at any  time  are
0.0011  mg/1 for freshwaters and 0.00013 mg/1 for saltwaters.

For  the  maximum  protection  of human health from the potential
carcinogenic effects due to exposure to this  pollutant,  through
the  ingestion  of  contaminated water and aquatic organisms,  the
ambient water concentration should be  zero.   Concentrations  of
this  pollutant estimated to result in additional lifetime cancer
risks at risk levels of 10~s, TO-*/ and 10~7 are 0.00000024 mg/1,
0.000000024 mg/1, and 0.0000000027 mg/1 respectively.

With respect to discharges to,a POTW, it must be noted that  this
pollutant  is  toxic  to biological organisms.  As this pollutant
can interfere with the biological treatment processes in a  POTW,
its discharge, to a POTW must be carefully controlled.

Endrin  Aldehyde  (99).   Endrin  aldehyde  is  a  biodegradation
product of endirin.  While known to be toxic  no  additional  data
pertaining  to  aquatic toxicity, ambient water quality criteria,
and cancer risk levels are available.

Heptachlor epoxide (101).  Heptachlor epoxide  (C10H9C170)  is  a
degradation  product  of heptachlor and subsequently also acts as
an insecticide.

The criteria to protect fresh water and  saltwater  aquatic  life
are   0.0000053   mg/1  and  0.0000050  mg/1  respectively.   The
concentrations which should not  be  exceeded  at  any  time  are
0.00052 mg/1 for freshwaters and 0,0000053 mg/1 for saltwaters.

For  the  maximum  protection  of human health from the potential
carcinogenic effects due to exposure to this  pollutant,  through
the  ingestion  of  contaminated water and aquatic organisms, the
ambient water concentration should be  zero.   Concentrations  of
this  pollutant estimated to result in additional lifetime cancer
risks at risk levels of 10~s, 10~«, and 10~7 are 0.00000278 mg/1,
0.000000278 mg/1, and 0.0000000278 mg/1 respectively.

With respect to discharge to a POTW, it must be noted  that  this
pollutant  is  toxic  to biological organisms.  As this pollutant
can interfere with the biological treatment processes in a  POTW,
its discharge to a POTW must be carefully controlled.
                              343

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Hexachlorocyclohexanes  (102, 103, 104 and  105).  The alpha, beta,
gamma,  and  delta  BHC  isomers  (C«H6C16) are white, crystalline
powders with slightly musty odors.  These  isomers melt  at  about
"M2°C  (234°F)  and  are:  freely soluble  in acetone, benzene and
chloroform; soluble in  alcohol;  slightly  soluble  in  ethylene
glycol;  and  practically insoluble in water.  These products are
derived from the chlorination  of  benzene  in  the  presence  of
ultraviolet  light.  The mixture of stereoisomers is separated by
fractional  crystallization.    These   isomers   are   used   as
insecticides.

The  available data for a mixture of isomers of BHC indicate that
acute   toxicity   to   freshwater   aquatic   life   occurs   at
concentrations  as  low  as  0.1  mg/1  and  would occur at lower
concentrations among species more sensitive  than  those  tested.
The  available  data  for  a mixture of BHC isomers indicate that
acute toxicity to saltwater aquatic life occurs at concentrations
as low as 0.00034 mg/1.  No data are available concerning chronic
toxicity to freshwater or saltwater species.

For  maximum  protection  of  human  health  from  the  potential
carcinogenic  effects due to exposure to the BHC isomers, through
the ingestion of contaminated  waters  and  contaminated  aquatic
organisms,  the  ambient  water concentrations for alpha and beta
BHC should be zero.  Using the present guidelines, a satisfactory
criterion for delta BHC cannot be derived at this time, due to an
insufficiency of data.  Concentrations  estimated  to  result  in
additional  lifetime cancer risk at risk levels of 1 0~5 10~6, and
10~7 are 0.000092 mg/1, 0.0000092 mg/1, and 0.00000092  mg/1  for
alpha BHC, and 0.000163 mg/1, 0.0000163 mg/1, and 0.00000163 mg/1
for  beta  BHC.   For  the  protection  of  human health from the
ingestion  of  contaminated  water  and  aquatic  organisms,  the
ambient  water  criterion  for  gamma  BHt  is  determined  to be
0.000625 mg/1.  At this time, a satisfactory criterion for  delta
BHC cannot be derived.

With  respect  to the acceptability of these pollutants to POTWs,
it must be noted that they are pesticides and therefore toxic  to
the  biological  organisms  which  accomplish treatment in POTWs.
Subsequently, the discharge of these substances to POTWs must  be
controlled.

Polychlorinated  biphenyls  (106-112).  Polychlorinated biphenyls
(C12Hi0nCln,H,0-nCln where n can range from 1 to 10),  designated
PCB's,  are chlorinated derivatives of biphenyls.  The commerical
products are complex mixtures  of  chlorobiphenyls,  but  are  no
longer  produced in the U.S.  The mixtures produced formerly were
characterized   by   the   percentage    chlorination.      Direct
chlorination  of biphenyl was used to produce mixtures containing
                              344

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from 21  to 70 percent chlorine.
selected as priority pollutants;
               Six of these mixtures have  been
  Priority
  Pollutant
Number   Name
Percent  Distillation  Pour      25°C Water
Chlorine  Range(°C)  Point(°C)  Solubility ,/g/l
106
107
108
109
110
111
112
PCB
PCB
PCB
PCB
PCB
PCB
PCB
1
1
1
1
1
1
1
242
254
221
232
248
260
016


20.
31 .



42
54
5-21 .
4-32.
48
60
41


5
5



325-366
365-390
275-320
290-325
340-375
385-420
323-356
                                            -19
                                            10
                                             1
                                            -35,
                                            -7
                                            31
                                        240
                                         12
                                       >200  .

                                         54
                                        2.7
                                      225-250
The  PCBs  1221,  1232,  1016,  1242, and 1248 are colorless oily
liquids; 1254 is a viscous liquid; 1260 is a sticky resin at room
temperature.  Total annual U.S. production of PCBs averaged about
20,000 tons in 1972-1974.

Prior to 1971, PCBs were used in several  applications  including
plasticizers,    heat   transfer   liquids,   hydraulic   fluids,
lubricants, vacuum pump and compressor fluids; and capacitor  and
transformer  oils.   After  1970,  when PCB use was restricted to
closed systems, the latter two  uses  were  the  only  commercial
applications.

The  toxic  effects of PCBs ingested by humans have been reported
to range from acne-like skin eruptions and  pigmentation  of  the
skin  to  numbness  of  limbs,  hearing  and vision problems, and
spasms.  Interpretation of results is  complicated  by  the  fact
that  the very highly toxic polychlorinated dibenzofurans (PCDFs)
are found in many commercial  PCB  mixtures.   Photochemical  and
thermal  decomposition appear to accelerate the transformation of
PCBs to PCDFs.  Thus the specific effects of PCBs may  be  masked
by  the  effects  of  PCDFs.   However,  if  PCDFs are frequently
present to some extent in any PCB mixture, then their effects may
be properly included in the effects of PCB mixtures.

Studies of effects of PCBs in laboratory  animals  indicate  that
liver and kidney damage, large weight losses, eye discharges, and
interference  with  some  metabolic  processes  occur frequently.
Teratogenic effects of  PCBs  in  laboratory  animals  have  been
observed,  but  are  rare.  Growth retardations during gestation,
and reproductive failure are  more  common  effects  observed  in
studies of PCB teratogenicity.  Carcinogenic effects of PCBs have
been  studied  in  laboratory animals with results interpreted as
positive.  Specific reference has been made to  liver  cancer  in
rats in the discussion of water quality criterion formulation.
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 For  the  maximum  protection  of human health from the potential
 carcinogenic effects of exposure to PCBs,  through  ingestion  of
 water  and  contaminated  aquatic  organisms,  the  ambient water
 concentration should be zero.  Concentrations of  PCBs  estimated
 to  result  in  additional lifetime cancer risk at risk levels of
 10-*, TO-6,  and 10~5 are 0.0000000026 mg/1,  0.000000026 mg/1, and
 0.00000026 mg/1,  respectively.

 The behavior of PCBs in POTWs has received limited  study.    Most
 PCBs  will  be removed with sludge.   One study showed removals of
 82 to 89 percent,  depending on  suspended solid removal.  The PCBs
 adsorb onto  suspended  sediments  and  other  particulates.   In
 laboratory  scale  experiments   with  PCB  1221,   81   percent was
 removed by degradation in an activated sludge system in 47  hours.
 Biodegradation can form polychlorinated dibenzofurans  which  are
 more  toxic than  PCBs (as noted earlier).   PCBs at concentrations
 of 0.1  to 1,000 mg/1 inhibit or enhance bacterial   growth  rates,
 depending on the  bacterial culture and the percentage chlorine in
 the PCB.   Thus, activated sludge may be inhibited  by PCBs.   Based
 on  studies   of  bioaccumulation  of  PCBs in food crops grown on
 soils amended with  PCB-containing  sludge,   the   U.S.    FDA  has
 recommended  a limit of 10 mg PCB/kg  dry weight of  sludge used for
 application  to soils bearing food crops.

 Antimony(114).   Antimony  (chemical  name  - stibium,  symbol Sb)
 classified as a non-metal or metalloid,   is   a silvery  white  ,
 brittle,   crystalline  solid.    Antimony  is  found  in small ore
 bodies  throughout  the world.  Principal  ores are oxides of   mixed
 antimony   valences,   and   an' oxysulfide  ore.  Complex ores with
 metals  are important,  because the antimony   is recovered   as  a
 by-product.    Antimony melts at 631°C,  and is a poor  conductor of
 electricity  and heat.

 Annual  U.S.  consumption of primary antimony  ranges from 10,000 to
 20,000  tons.   About  half  is consumed in  metal  products   -   mostly
 antimonial   lead   for  lead acid storage  batteries,  and  about half
 in  nonmetal  products.   A  principal compound  is  antimony  trioxide
 which   is  used  as   a flame   retardant   in   fabrics,   and as an
 opacifier  in  glass,   ceramics,   and   enamels.   Several   antimony
 compounds  are  used  as catalysts  in organic  chemicals  synthesis,
 as  fluorinating agents  (the antimony fluoride), as  pigments,   and
 in   fireworks.    Semiconductor   applications  are economically
 significant.

Essentially   no  information  on   antimony-induced  human   health
effects,  has  been  derived from  community epidemiology studies.
The available data are  in  literature  relating  effects  observed
with  therapeutic  or  medicinal   uses  of antimony compounds  and
 industrial  exposure  studies.   Large   therapeutic    doses   of
                              346

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antimonial compounds, usually used to treat schistosomiasis, have
caused  severe  nausea,  vomiting,, convulsions,  irregular heart
action,  liver  damage,  and  skin  rashes.   Studies  of   acute
industrial  antimony  poisoning  have  revealed loss of appetite,
diarrhea, headache, and dizziness in  addition  to  the  symptoms
found in studies of therapeutic doses of antimony.

For  the  protection of human health from the toxic properties of
antimony, ingested through water and through contaminated aquatic
organisms, the ambient water criterion is determined to be  0.146
mg/1.   If  contaminated  aquatic  organisms  alone are consumed,
excluding the consumption of water, the ambient  water  criterion
is  determined  to  be 45 mg/1.  Available data show that adverse
effects on aquatic life occur at concentrations higher than those
cited for human health risks.                                ;

Very little information is available regarding  the  behavior  of
antimony  in, POTWs.   The  limited solubilities of most antimony
compounds expected  in  POTWs,  i.e.  the  oxides  and  sulfides,
suggest  that  at least part of the antimony entering a POTW will
be precipitated and incorporated into the sludge.  However,  some
antimony  is  expected  to  remain dissolved and pass through the
POTW into the effluent.   Antimony  compounds  remaining  in  the
sludge  under  anaerobic  conditions  may be connected to stibine
(SbH3), a very soluble and very toxic  compound.   There , are  no
data  to  show antimony inhibits any POTW processes.  Antimony is
not known to be essential to the growth of plants, and  has  been
reported  to  be  moderately toxic.  Therefore, sludge containing
large amounts of antimony could be detrimental to plants,  if  it
is applied in large amounts to croplands.

Arsenic(115).   Arsenic  (chemical symbol As), is classified as a
non-metal or metalloid.  Elemental arsenic normally exists in the
alpha-crystalline metallic form which is steel gray and  brittle,
and  in  the beta form which is dark gray and amorphous.  Arsenic
sublimes  at  6T5°G  (1139°F).   Arsenic  is  widely  distributed
throughout  the  world  in  a large number of minerals.  The most
important commercial source of arsenic is as  a  by-product  from
treatment  of  copper,  lead,  cobalt, and gold ores.  Arsenic is
usually marketed as the trioxide (As203).  Annual U.S. production
of the trioxide approaches 40,000 tons.

The  principal  use  of _ arsenicis  in  agricultural  chemicals
(herbicides)  for controlling weeds in cotton fields. , Arsenicals
have various applications in medicinal  and  veterinary  use,  as
wood preservatives, and in semiconductors.

The effects of arsenic in humans were known by the ancient Greeks
and  Romans.   The  principal  toxic effects are gastrointestinal
                              347

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disturbances.  Breakdown of red  blood  cells  occurs.  Symptoms  of
acute  poisoning   include  vomiting,   diarrhea,   abdominal  pain,
lassitude, dizziness, and  headache.   Longer  exposure  produced
dry, falling hair, brittle, loose nails,  eczema,  and exfoliation.
Arsenicals  also   exhibit  teratogenic and  mutagenic effects in
humans.   Oral  administration   of  arsenic  compounds  has  been
associated  clinically  with  skin  cancer   for   nearly a hundred
years.  Since 1888, numerous  studies  have  linked  occupational
exposure to, and therapeutic administration  of, arsenic compounds
to increased incidence of respiratory  and skin cancer.

For  the  maximum  protection  of human health from the potential
carcinogenic effects of exposure to arsenic, through ingestion of
water and  contaminated  aquatic organisms,  the ambient  water
concentration  is  zero.   Concentrations of arsenic estimated to
result in additional lifetime cancer risk levels  of  10~7,  10~*,
and  10-5  are  2.2 x 10-*° mg/1, 2.2  x lO-» mg/1, and 2.2 x 10-«
mg/1, respectively.  If contaminated aquatic organisms alone  are
consumed,   excluding   the   consumption of  water,  the  water
concentration should be less than 2.7  x 10~4 mg/1  to  keep  the
increased  lifetime  cancer risk below 10~5.  Available data show
that adverse effects on  aquatic life occur  at concentrations
higher than those  cited for human health  risks.

A few studies have been made regarding the behavior of arsenic in
POTWs.    One   EPA   survey   of   9   POTWs  reported  influent
concentrations ranging from 0.0005 to  0.693  mg/1; effluents  from
3 POTWs having biological treatment contained 0.0004 - 0.01 mg/1;
2  POTWs showed arsenic removal  efficiencies of 50 and 71 percent
in biological treatment.  Inhibition of   treatment  processes  by
sodium  arsenate   is  reported   to occur  at  0.1 mg/1 in activated
sludge,  and  1.6 mg/1  in  anaerobic  digestion  processes.   In
another  study  based  on  data  from  60  POTWs, arsenic in sludge
ranged from 1.6 to 65.6 mg/kg and the  median value was 7.8 mg/kg.
Arsenic in sludge spread on cropland may  be  taken up  by  plants
grown  on  that  land.   Edible  plants   can take up arsenic, but
normally their growth is inhibited before the  plants  are  ready
for harvest.

Beryl1jump 17).    Beryllium  is  a dark gray  metal of the alkaline
earth family.  It  is relatively  rare,  but because of  its  unique
properties   finds   widespread   use  as an  alloying  element,
especially  for  hardening  copper  which is  used  in  springs,
electrical contacts, and non-sparking  tools.  World production is
reported  to be in the range of  250 tons  annually.  However, much
more reaches the  environment  as  emissions from  coal  burning
operations.   Analysis  of  coal  indicates  an average beryllium
content of 3 ppm and 0.1 to 1.0  percent in coal ash or fly ash.
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The principal ores are beryl (3BeO»Al2Os»6Si02)  and  bertrandite
[Be4Si2O7(OH)2],    Only   two   industrial   facilities  produce
beryllium in the U.S.  because of limited demand and  the  highly
toxic  character.  About two-thirds of the annual production goes
into alloys, 20 percent into heat  sinks,  and  10  percent  into
beryllium oxide  (BeO) ceramic products.

Beryllium  has a specific gravity of 1.846 making it the lightest
metal with a high melting point (1350°C).  Beryllium  alloys  are
corrosion   resistant,   but   the   metal  corrodes  in  aqueous
environments.  Most"T:ommohberyllium  compounds  are  soluble  in
water,  at  least  to  the  extent  necessary  to produce a toxic
concentration of beryllium ions.

Most data on toxicity of beryllium is for inhalation of beryllium
oxide dust.  Some studies on  orally  administered  beryllium  in
laboratory  animals have been reported.  Despite the large number
of studies implicating beryllium as a  carcinogen,  there  is  no
recorded  -instance   of  cancer  being  produced  by  ingestion.
However,  a  recently  convened  panel  of   uninvolved   experts
concluded   that   epidemiologic   evidence  is  suggestive  that
beryllium is a carcinogen in man.

In the aquatic3environment, beryllium is acutely toxic to fish at
concentrations as low as 0.087 mg/1, and chronically toxic to  an
aquatic  organism  at  0.003 mg/1.   Water  softness  has a large
effect on beryllium toxicity to fish.  In soft  water,  beryllium
is reportedly  TOO times as toxic as in hard water.

For  the  maximum  protection  of human health from the potential
carcinogenic effects of exposure to beryllium, through  ingestion
of  water  and   contaminated aquatic organisms., The ambient water
concentration  is zero.  Concentrations of beryllium estimated  to
result  in  additional lifetime cancer risk levels of TO-7, 10~«,
and TO-5 are 0.00000087 mg/1, 0.0000087 mg/1, and 0.000087  mg/1,
respectively.

Information  on  the  behavior  of  beryllium in POTWs is scarce.
Because beryllium hydroxide is  insoluble in water, most beryllium
entering POTWs will probably be in the form of suspended  solids.
As  a  result,,   most  of the beryllium will settle and be removed
with sludge.   However,  beryllium  has  been  shown  to  inhibit
several  enzyme  systems,  to   interfere  with  DNA metabolism in
liver, and to  induce chromosomal and mitotic abnormalities.  This
interference in  cellular processes may extend to  interfere  with
biological treatment processes.  The concentration and effects of
beryllium  in  sludge which could be applied to cropland have not
been studied.
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Cadmium(118).   Cadmium  is  a  relatively  rare  metallic  element  that
is  seldom  found in  sufficient   quantities   in   a  pure   state  to'
warrant  mining  or  extraction  from the  earth's surface.   It  is
found  in trace  amounts  of  about  1  ppm throughout   the  earth's
crust.   Cadmium is,   however,   a  valuable  by-product  of  zinc
production.

Cadmium  is used primarily  as an electroplated  metal,  and is  found
as  an  impurity  in the  secondary refining  of zinc,   lead,  and
copper.    Cadmium    appears   at a  significant  level  in  raw
wastewaters from only one  of  the three   subcategories  of   coil
coating  - galvanized.  The  presence of cadmium in the  wastewater
is  attributed to its  presence  as an impurity in the zinc used  to
produce  galvanized  coil  stock.  Some of the zinc is  removed  by
the cleaning and conversion  coating steps.

Cadmium  is an extremely dangerous cumulative   toxicant,   causing
progressive  chronic  poisoning   in  mammals,   fish,  and probably
other organisms.  The metal  is not excreted.

Toxic  effects   of  cadmium  on   man  have  been  reported    from
throughout the  world.   Cadmium may be a factor in the development
of   such   human  pathological   conditions  as kidney  disease,
testicular   tumors,    hypertension,    arteriosclerosis,   growth
inhibition,  chronic  disease  of old age,  and  cancer.   Cadmium  is
normally ingested by  humans  through food and water, as  well as  by
breathing  air   contaminated  by cadmium    dust.    Cadmium    is
cumulative  in  the  liver,  kidney, pancreas,  and thyroid of humans
and other animals.  A severe bone and kidney  syndrome   known  as
itai-itai disease has been documented in Japan as being caused  by
cadmium  ingestion  via  drinking  water and  contaminated  irrigation
water.  Ingestion of  as little as 0.6  ing/day   has  produced  the
disease.  Cadmium acts  synergistically  with  other metals.  Copper
and zinc substantially  increase  its toxicity.

Cadmium   is    concentrated  by   marine organisms,  particularly
molluscs, which  accumulate cadmium in calcareous tissues  and  in
the viscera.  A concentration factor of 1000  for cadmium  in  fish
muscle has been  reported as  having concentration factors of   3000
in  marine plants  and  up to 29,600 in certain marine animals.  The
eggs  and larvae  of fish are apparently more sensitive  than adult
fish to poisoning by  cadmium,  and crustaceans  appear to be   more
sensitive than  fish eggs and larvae.

For  the  protection of human  health from  the  toxic properties  of
cadmium, ingested through  water  and through  contaminated  aquatic
organisms,   the  ambient water  criterion is determined to be 0.01.0
mg/1.   Available  data show that  adverse effects on  aquatic   life
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occur  at  concentrations  in  the  same range as those cited for
human health, and they are highly dependent on water hardness.

Cadmium is not destroyed when it is introduced into a  POTW,  and
will  either pass through to the POTW effluent or be incorporated
in the POTW sludge.  In addition, it can interfere with the  POTW
treatment process.

In  a  study  of  189 POTWs, 75 percent of the primary plants, 57
percent of  the  trickling  filter  plants,  66  percent  of  the
activated  sludge  plants and 62 percent of the biological plants
allowed over 90 percent of the influent cadmium to  pass  through
to  the POTW effluent.  Only 2 of the 189 POTWs allowed less than
20 percent pass through, and  none  less  than  10  percent  pass
through.   POTW  effluent  concentrations  ranged  from  0.001 to
1.97 mg/1 (mean 0.028 standard deviation 0.167).

Cadmium not passed through the  POTW  will  be  retained  in  the
sludge, where it is likely to build up in concentration.  Cadmium
contamination  of  sewage sludge limits its use on land, since it
increases the level of cadmium  in  the  soil.   Data  show  that
cadmium  can be incorporated into crops, including vegetables and
grains, from contaminated soils.  Since the crops themselves show
no adverse  effects  from  soils  with  levels  up  to  100 mg/kg
cadmium, these contaminated crops could have a significant  impact
on  human  health.   Two Federal agencies have already recognized
the potential adverse human health effects posed by  the  use  of
sludge  on  cropland.   The FDA recommends that sludge containing
over 30 mg/kg of cadmium should not be used on agricultural land.
Sewage sludge contains 3 to  300 mg/kg  (dry  basis)  of  cadmium
 (mean  =  10 mg/kg; median = 16 mg/kg).  The USDA also recommends
placing limits on  the total  cadmium  from  sludge  that  may  be
applied to land.

Chromium(119).  Chromium is an elemental metal usually found  as  a
chromite  (FeO*Cr203).  The metal is normally produced by reducing
the  oxide  with   aluminum.   A  significant  proportion  of  the
chromium used  is   in  the  form  of  compounds  such  as   sodium
dichromate    (Na?CrO4),  and  chromic  acid   (CrO3)  -  both  are
hexavalent chromium compounds.

Chromium and  its  compounds  are  used  extensively  in  the  coil
 coating   industry.   As  the  metal,  it   is  found as an alloying
 component of  many  steels.

 The  two  chromium forms   most  frequently   found  in    industry
 wastewaters   are   hexavalent  and trivalent chromium.  Hexavalent
 chromium  is  the form  used  for metal treatments.  Some  of   it  is
 reduced   to   trivalent   chromium as part of the process reaction.
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 The  raw  wastewater  containing   both   valence  states  is  usually
 treated    first   to  reduce  remaining  hexavalent  to  trivalent
 chromium,  and  second  to  precipitate  the   trivalent  form  as  the
 hydroxide.   The  hexavalent form is not removed by lime treatment.

 Chromium,  in its various valence states,  is  hazardous  to man.   It
 can   produce    lung   tumors   when   inhaled,   and  induces   skin
 sensitizfations.   Large doses of chromates have corrosive  effects
 on   the   intestinal  tract  and  can  cause   inflammation of the
 kidneys.   Hexavalent chromium  is   a  known   human  carcinogen.
 Levels   of   chromate  ions that  show  no effect  in  man appear  to be
 so low as  to prohibit determination,  to  date.
                                          i
 The  toxicity of  chromium salts  to fish  and  other  aquatic   lif-e
 varies   widely  with  the species, temperature,  pH,  valence of the
 chromium, and  synergistic or antagonistic effects,  especially the
 effect of water  hardness.   Studies   have shown   that  trivalent
 chromium  is  more  toxic to fish of  some  types than is hexavalent
 chromium.  Hexavalent chromium  retards growth  of  one fish species
 at 0.0002 mg/1.   Fish food organisms  and   other  lower  forms  of
 aquatic  life  are  extremely   sensitive  to  chromium.   Therefore,
 both hexavalent  and trivalent chromium must  be considered harmful
 to particular  fish  or organisms.

 For the  protection  of human health from the  toxic  properties  of
 chromium (except  hexavalent chromium), ingested through  water  and
 contaminated  aquatic organisms,  the recommended water quality
 criterion is 0.050  mg/1.

 For the  maximum protection of human   health  from  the  potential
 carcinogenic  effects of  exposure to  hexavalent chromium,  through
 ingestion  of  water  and  contaminated   aquatic   organisms,   the
 ambient  water concentration is  zero.  The estimated levels  which
would result in  increased lifetime cancer risks  of 10~7,   10-*,
 and  10-s  are   7.4   x IO-« mg/1, 7.4  x 10~7 mg/1,  and 7.4 x  10-*
mg/1 respectively.  If contaminated aquatic organisms  alone   are
 consumed,    excluding   the   consumption  of   water,  the   water
 concentration should  be  less than 1.5  x 10~5  mg/1   to  keep   the
 increased lifetime  cancer risk below  10~5.

Chromium  is  not  destroyed  when treated by POTWs  (although  the
oxidation state may change),  and will  either pass  through to   the
POTW  effluent  or  be   incorporated   into the  POTW sludge.  Both
oxidation states  can  cause POTW  treatment inhibition and  can also
limit the usefulness  of municipal sludge.

Influent concentrations of chromium to POTW facilities have  been
observed  by  EPA to  range from  0.005  to  14.0 mg/1, with a median
concentration of  0.1  mg/1.    The  efficiencies  for   removal  of
                              352

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chromium  by  the  activated  sludge  process  can  vary greatly,
depending on chromium concentration in the  influent,  and  other
operating  conditions  at  the  POTW.   Chelation  of chromium by
organic matter and dissolution due to the presence of  carbonates
can  cause  deviations  from  the predicted behavior in treatment
systems.

The  systematic  presence  of  chromium   compounds   will   halt
nitrification  in  a  POTW  for  short  periods,  and most of the
chromium will be  retained  in  the  sludge  solids.   Hexavalent
chromium  has  been reported to severely affect the nitrification
process, but trivalent chromium has  little  or  no  toxicity  to
activated sludge, except at high concentrations.  The presence or
iron,  copper,  and low pH will increase the toxicity of chromium
in a POTW by releasing the chromium  into solution to be  ingested
by microorganisms in the POTW.

The  amount of chromium which passes through to the POTW effluent
depends on the type of treatment processes used by the POTW. v  In
a  study  of  240  POTWs 56 percent  of the primary plants allowed
more than  80  percent  pass  through  to  POTW  effluent.^  More
advanced  treatment  results ;in less pass through.  POTW effluent
concentrations ranged from 0.003 to  3.2 mg/1 total chromium  (mean
=0.197, standard deviation = 0.48), and from  0.002  to  0.1 mg/1
hexavalent chromium  (mean = 0.017, standard deviation = 0.020).

Chromium  not  passed  through  the  POTW will be retained  in  the
sludge, where it is  likely to build  up in concentration.    Sludge
concentrations of total chromium of  over 20,000 mg/kg  (dry  basis)
have   been  observed.   Disposal of  sludges, containing very high
concentrations  of   trivalent  chromium,  can  potentially   cause
problems  in  uncontrollable  landfills.  Incineration, or similar
destructive oxidation processes can  produce  hexavalent  chromium
from   lower  valance states.  Hexavalent chromium  is potentially
more toxic than trivalent chromium.   In cases  where  high rates of
chrome sludge application  on  land   are  used,  distinct   growth
inhibition and plant tissue uptake have been noted.

Pretreatment    of    discharges     substantially    reduces   the
concentration of  chromium   in  sludge.    In  Buffalo,  New   York,
pretreatment  of  electroplating   waste resulted  in  a  decrease in
chromium concentrations   in   POTW    sludges    from   2,510   to
 1,040  mg/kg.   A  similar   reduction  occurred  in   Grand Rapids,
Michigan POTWs,  where   the   chromium  concentration   in   sludge
decreased from  11,000  to  2,700 mg/kg when pretreatment was  made  a
requirement.

Copper(120).    Copper   is   a   metallic  element that sometimes is
 found  free,  as  the  native metal,  and is  also  found  in   minerals
                               353

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 such   as  cuprite  (Cu20),  malachite  [CuC03»Cu(OH)2],  azurite
 [2CuC03»Cu(OH)2], chalcopyrite (CuFeS2), and  bornite  (CusFeS4).
 Copper  is  obtained  from  these ores by smelting, leaching, and
 electrolysis.   It is used in the plating,   electrical,  plumbing,
 and  heating equipment industries, as well as in insecticides and
 fungicides.

 Traces of copper are found in all forms of plant and animal life,
 and the metal   is  an  essential  trace  element  for  nutrition.
 Copper  is  not considered to be a cumulative systemic poison for
 humans,  as it  is readily excreted by the body, but it  can  cause
 symptoms   of    gastroenteritis,    with   nausea  and  intestinal
 irritations, at relatively low dosages.
 domestic  water  supplies  is  taste.
 The limiting  factor  in
To  prevent  this adverse
 organoleptic effect of copper in water,  a criterion of 1  mg/1 has
 been  established.
 The  toxicity of  copper to aquatic organisms varies significantly,
 not  only  with the  species,   but  also  with  the  physical  and
 chemical   characteristics  of   the  water,  including temperature,
 hardness,  turbidity,  and  carbon dioxide content.   In hard  water,
 the   toxicity of copper salts  may be reduced by the precipitation
 of copper carbonate  or other  insoluble compounds.    The  sulfates
 of   copper and zinc,  and  of copper and calcium are synergistic in
 their toxic effect on fish.

 Relatively high  concentrations of  copper  may  be  tolerated  by
 adult fish  for  short  periods  of time;  the critical effect of
 copper appears to  be  its  higher toxicity to  young  or  juvenile
 fish.   Concentrations of 0.02 to 0.031  mg/1 have  proved fatal to
 some  common fish species.   In  general,  the   salmonoids   are  very
 sensitive and the  sunfishes are less sensitive to  copper.

 The   recommended  criterion  to protect  saltwater  aquatic  life is
 0.00097 mg/1   as  a   24-hour   average,   and  0.018  mg/1   maximum
 concentration.

 Copper  salts  cause   undesirable  color  reactions  in  the food
 industry  and  cause pitting when deposited on  some   other   metals
 such  as aluminum and  galvanized steel.

 Irrigation  water,  containing   more  than   minute   quantities of
 copper,  can be detrimental to  certain  crops.   Copper appears   in
 all  soils,  and  its  concentration  ranges  from  10  to 80 ppm.   In
 soils, copper  occurs   in  association  with  hydrous   oxides   of
manganese   and   iron,  and also  as  soluble and  insoluble complexes
with organic matter.    Copper is  essential to the life of   plants,
and  the  normal range of concentration  in  plant tissue is  from 5
to 20 ppm.  Copper concentrations  in plants  normally do not  build
                              354

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up to  high  levels  when  toxicity  occurs.   For  example,  the
concentrations  of  copper  in snapbean leaves and pods were less
than 50 and 20 mg/kg, respectively, under  conditions  of  severe
copper  toxicity.  Even under conditions of copper toxicity, most
of the excess copper accumulates in the  roots;  very  little  is
moved to the aerial part of the plant.

Copper  is  not destroyed when treated by a POTW, and will either
pass through to the POTW effluent or  be  retained  in  the  POTW
sludge.   It  can interfere with the POTW treatment processes and
can limit the usefulness of municipal sludge.

The influent concentration of copper to POTW facilities has  been
observed  by  the  EPA  to  range  from 0.01 to  1.97 mg/1, with a
median concentration of 0.12 mg/1.  The copper   that  is  removed
from  the  influent stream of a POTW is adsorbed on the sludge or
appears in the sludge as the hydroxide of the metal.  Bench scale
pilot studies have shown that 25 percent to  75  percent  of  the
copper  passing  through  the activated sludge process remains in
solution in the final effluent.  Four hour slug  dosages of .copper
sulfate, in concentrations exceeding 50 mg/1,  were  reported  to
have  severe effects on the removal efficiency of an unacclimated
system, with the system returning  to normal  in about  100  hours.
Slug  dosages  of  copper  in  the  form  of  copper cyanide were
observed to have much more severe  effects on the activated sludge
system, but the total system returned to normal  in .24 hours.

In a recent study of 268 POTWs, the median pass  through was  over
80 percent for primary plants, and 40 to 50  percent for trickling
filter,  activated sludge, and biological treatment plants.  POTW
effluent concentrations of copper  ranged from 0.003  to   1.8 mg/1
(mean  0.126, standard deviation 0.242).

Copper  which  does  not pass through  the POTW will be retained in
the sludge,  where   it  will  build   up  in  concentration.   The
presence   of  excessive   levels of copper in sludge may  limit its
use on  cropland.  Sewage  sludge contains up  to   16,000 mg/kg  of
copper,  with  730 mg/kg  as the mean  value.  These concentrations
are significantly greater  than  those  normally   found   in  soil,
which   usually   range  from   18   to   80 mg/kg.   Experimental data
indicate that when dried  sludge is spread over tillable  land, the
copper  tends  to  remain  in  place down  to  the  depth  of   tillage,
except  for  copper which  is taken up  by plants grown  in  the soil.
Recent  investigation  has shown that  the  extractable  copper
content   of  sludge-treated   soil decreased  with   time,  which
suggests that a  reversion of  copper to   less  soluble   forms  was
occurring.
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 Cyanide(121).    Cyanides  are  among the most toxic of pollutants
 commonly observed in  industrial  wastewaters.    Introduction  of
 cyanide  into   industrial  processes is usually by dissolution of
 potassium cyanide (KCN)   or  sodium  cyanide  (NaCN)   in  process
 waters.    However,   hydrogen cyanide (HCN),  formed when the above
 salts are dissolved in water,  is probably the most acutely lethal
 compound.

 The  relationship of pH to  hydrogen  cyanide  formation  is  very
 important.   As pH  is lowered to below 7,  more  than 99 percent of
 the  cyanide  is present as HCN and less than  1 percent as  cyanide
 ions.    Thus,   at  neutral pH,  that of most  living organisms,  the
 more toxic form of  cyanide prevails.

 Cyanide  ions combine with  numerous  heavy  metal   ions  to  form
 complexes.  The complexes are in equilibrium with  HCN.   Thus,  the
 stability  of   the  metal-cyanide complex and the pH determine the
 concentration  of HCN.    Stability  of  the   metal-cyanide  anion
 complexes  is extremely variable.   Those formed  with zinc,  copper,
 and   cadmium   are  not  stable   -  they  rapidly dissociate,  with
 production of  HCN,  in near neutral or  acid waters.  Some  of   the
 complexes are  extremely  stable.   Cobaltocyanide is  very resistant
 to   acid  distillation in the  laboratory.  Iron cyanide complexes
 are  also stable,  but undergo photodecomposition to  give HCN  upon
 exposure to sunlight.  Synergistic effects have been  demonstrated
 for  the metal  cyanide complexes,  making zinc, copper,  and  cadmium
 cyanides  more  toxic than  an   equal   concentration  of   sodium
 cyanide.

 The  toxic mechanism  of cyanide is  essentially   an   inhibition   of
 oxygen  metabolism,   i.e.,  rendering   the  tissues   incapable  of
 exchanging oxygen.   The  cyanogen  compounds are  true noncumulative
 protoplasmic poisons.  They arrest  the  activity  of  all   forms   of
 animal life.    Cyanide shows a very  specific  type of toxic  action.
 It   inhibits   the  cytochrome oxidase system.   This system is  the
 one which facilitates electron transfer from reduced  metabolites
 to  molecular  oxygen.    The  human body can convert  cyanide  to a
 non-toxic thiocyanate and  eliminate it.  However,  if  the quantity
 of cyanide ingested  is too great at one time, the   inhibition   of
 oxygen  utilization   proves fatal  before the detoxifying reaction
 reduces the cyanide  concentration  to a  safe  level.

Cyanides are more toxic  to fish than to lower   forms  of   aquatic
organisms   such  as  midge  larvae,  crustaceans,   and  mussels.
Toxicity  to   fish   is   a   function    of    chemical    form   and
 concentration,   and   is   influenced  by  the  rate  of metabolism
 (temperature),   the   level  of  dissolved  oxygen,   and  pH.    In
 laboratory  studies free cyanide concentrations  ranging from 0.05
to 0.15 mg/1  have been proven  to  be   fatal  to  sensitive  fish
                               356

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species  including  trout, bl.uegi.il/ and fathead minnows.  Levels
above 0.2 mg/1 are rapidly fatal to most, fish species.  Long term
sublethal concentrations of cyanide, as low  as  0.01 mg/1,  have
been  shown  t,p  affect the ability of fish to function normally,
e.g., reproduce, grow, and swim.

For the protection of human health from the toxic  properties  of
cyanide,  ingested through water and through contaminated aquatic
organisms, the ambient water quality criterion is  determined  to
be  0.200 mg/1.  Available data show that effects on aquatic life
occur at concentrations as low as 3.5 x 10-3 mg/1.

Persistence of cyanide in water is highly  variable  and  depends
upon the chemical form of cyanide in the water, the concentration
of cyanide, and the nature of other constituents.  Cyanide may be
destroyed  by  strong  oxidizing  agents such as permanganate and
chlorine.  Chlorine is commonly used to  oxidize  strong  cyanide
solutions.   Carbon  dioxide  and  nitrogen  are  the products of
complete oxidation.  But  if the reaction  is  not  complete,  the
very  toxic  compound,  cyanogen  chloride,  may  remain  in  the
treatment system and subsequently be released to the environment.
Partial chlorination may  occur as part of a  POTW- treatment,  or
during  the  disinfection treatment of surface water for drinking
water preparation.

Cyanides can interfere with treatment processes in POTWs, or pass
through to ambient  waters.   At  low  concentrations,   and  with
acclimated     microflora,    cyanide   may   be   "decomposed   by
microorganisms in anaerobic and  aerobic  environments   or  waste
treatment  systems.   However,  data  indicate  that  much of the
cyanide introduced passes through to the POTW effluent.  The mean
pass through of  14 biological plants was 71 percent.   In a recent
study of 41 POTWs the effluent  concentrations ranged   from  0.002
to   100 mg/1   (mean = 2.518, standard deviation =  15.6).  Cyanide
also enhances  the toxicity  of  metals  commonly   found  in  POTW
effluents,  including   the priority pollutants cadmium,  zinc, and
copper.

Data for Grand Rapids,  Michigan, showed a significant  decline   in
cyanide    concentrations   downstream   from   the    POTW   after
pretreatment  regulations  were enforced.  Concentrations  fell from
0.66 mg/1  before, to  0.01 mg/1  after pretreatment  was  required.

Lead  (122).   Lead  is  a  soft,  malleable,  ductile,   blueish-gray,
metallicelement,  usually obtained from the mineral  galena  (lead
sulfide,  PbS), anglesite   (lead sulfate,   PbS04),   or  cerussite
 (lead   carbonate,,  PbC03).  Because it  is usually  associated with
minerals  of zinc,  silver, copper,  gold,  cadmium,   antimony,   and
arsenic,   special purification  methods  are  frequently used before
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 and after extraction of the metal  from
 smelting.
the  ore  concentrate  by
 Lead  is  widely  used  for  its  corrosion resistance,  sound and
 vibration absorption,  low melting point (solders),  and relatively
 high imperviousness to various forms of radiation.   Small  amounts
 of  copper,  antimony and other metals can be alloyed with lead  to
 achieve greater hardness,  stiffness,  or corrosion resistance than
 is  afforded by the pure metal.   Lead compounds are used  in glazes
 and  paints.   About one third of U.S.   lead consumption  goes into
 storage batteries.   About half of U.S.  lead consumption   is  from
 secondary  lead  recovery.    U.S.   consumption  of lead  is in the
 range of one million tons annually.

 Lead ingested by humans produces  a  variety  of  toxic  effects,
 including  impaired  reproductive  ability,  disturbances in blood
 chemistry,  neurological  disorders,  kidney   damage,   and  adverse
 cardiovascular  effects.   Exposure to  lead  in  the diet results in
 permanent increase  in  lead levels in  the body.   Most of  the  lead
 entering  the  body  eventually  becomes localized in the bones,
 where it accumulates.   Lead is  a carcinogen or   cocarcinogen  in
 some  species  of   experimental  animals.   Lead  is  teratogenic in
 experimental  animals.   Mutagenicity  data are  not  available  for
 1 ead.

 For   the protection of human health from the  toxic  properties of
 lead,  ingested through  water  and contaminated  aquatic  organisms,
 the   ambient   water criterion is 0.050  mg/1.   Available  data show
 that adverse  effects on aquatic life occur  at  concentrations  as
 low  as  7.5  x  10~4 mg/1.

 Lead  is  not  destroyed   in  POTWs, but is  passed  through  to the
 effluent  or retained in the POTW sludge.  It can   interfere  with
 POTW treatment  processes  and  can limit  the usefulness  of POTW
 sludge  for  application to   agricultural   croplands.    Threshold
 concentration  for   inhibition  of  the activated sludge process  is
 0.1  mg/1, and for the nitrification process  is 0.5   mg/1.    In  a
 study   of   214   POTWs,  median   pass  through  values were  over  80
 percent  for primary  plants and   over  60  percent  for   trickling
 filter,   activated   sludge,   and biological  process  plants.   Lead
 concentrations  in POTW  effluents ranged  from 0.003   to'  1.8   mg/1
 (mean »  0.106  standard  deviation = 0.222).

Application of  lead-containing  sludge to  cropland should not  lead
 to   uptake  by  crops under most  conditions,   because  normally  lead
 is strongly bound by soil.  However, under the unusual conditions
of low pH (less  than   5.5)   and   low  concentrations  of   labile
phosphorus,    lead   solubility    is  increased  and  plants  can
accumulate lead.
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Mercury (123).  Mercury is an elemental  metal Barely
nature  aTThe free metal.  Mercury is unique among metals, as j.t .
remains a liquid down to about -39°C.   It  is^ relatively  inert
chemically  and  is  insoluble  in  water.   The principal ore is
cinnabar (Hgj5) .

Mercury is used industrially as the metal and  as  mercurous  and
mlrcuric  salts  and  compounds.  Mercury released to_the aqueous
environment is subject to  biomethylation  -  conversion  to  the
extremely toxic methyl mercury.

Mercury  can be "introduced into the body through the skin and the
respiratory system as the elemental vapor.   Mercuric  salts  are
highly   toxic   to  humans  and  can  be  absorbed  through^ the
gastrointestinal tract.   Fatal doses can vary from '^30 grams..
Chronic toxicity of methyl  mercury  is  evidenced, primarily  by
neurological  symptoms.  Some mercuric  salts cause death by kidney
failure.

Mercuric  salts  are  extremely   toxic  to fish  and other  aquatic
life   Mercuric  chloride  is more  lethal  than   copper,   hexavalent
chromium,   zinc,   nickel,  and  lead  towards fish  and aquatic  life;
In  the food cycle,  algae,  containing mercury  up  to  TOO times  the
concentration  in   the  surrounding sea  water, are  eaten  by  f ish,
which further concentrates the mercury.   Predators  that  eat  the
fish  in  turn concentrate  the mercury even further.

For  the protection  of human  health from the toxic properties of
mercury,  ingested  through water and through  contaminated  aquatic
organisms,  the ambient  water  criterion is determined to be 0.0002
mg/1 .

Mercury   is not destroyed when treated by a POTW,  and will either
oass  through to the POTW  effluent or  be  incorporated  into  the
 POTW   slSdge    At low concentrations, it may reduce POTW removal
 efficiencies, and at high concentrations, it may upset  the  POTW
 operation.

 The  influent  concentrations  of "v mercury  to  POTWs  have  been
 oblervSd by the EPA to range  from  0.0002 to 0. 24 mg/1,  with  a
 melian concentration of 0.001  mg/1.   Mercury has been reported^n
 the  literature  to  have  inhibiting  effects  upon an activated
                   IS
  inhibitory effects being reported  at  1365 mg/1
                                359.

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  In a study of  22 POTWs  having  secondary  treatment,  the   range   of
  removal of mercury  from the  influent  to  the  POTW  ranged  from 4  to
  99  percent, with median removal of 41 percent.   Thus significant
  pass through of mercury may  occur.

  In sludges, mercury content  may be high,  if  industrial sources  of
  mercury contamination are present.  Little   is  known  about  the
  form  in  which  mercury occurs  in  sludge.  Mercury may undergo
  biological methylation  in sediments,  but  no methylation  has  been
  observed in soils, mud,  or sewage sludge.

  T.he  mercury  content   of  soils  not receiving additions of POTW
  sewage sludge lies in the range from  0.01 to 0.5 mg/kg.   In soils
  receiving POTW sludges  for protracted periods, the  concentration
 of mercury has been observed to approach  1.0 mg/kg.  In  the soil
 mercury  enters  into reactions with  the exchange complex of clay
 and organic fractions, forming both   ionic  and  covalent  bonds
 Chemical  and  microbiological degradation of mercurials can take
 place side by side in the soil,  and  the  products  -   ionic  or
 molecular  -  are  retained  by organic matter and clay  or may be
 volatilized if gaseous.   Because of  the  high  affinity  between
 mercury  and  the   solid  soil surfaces, mercury persists in the
 upper layer of soil.

 Mercury can enter plants through the roots,  it can  readily  move
 to other   parts   of the plant, and it has been reported to cause
 injury  to  plants.   In  many  plants,  mercury  concentrations  range
 from   0.01  to  0.20 mg/kg,  but  when  plants are supplied  with high
 levels  of  mercury,  these concentrations   can  exceed  0.5 mg/kg
 Bioconcentration  occurs  in  animals  ingesting  mercury in  food.

 Nickel(124).    Nickel   is  seldom   found   in   nature  as  the pure
 elemental  metal.   It is  a relatively   plentiful  element   a.nd   is
 widely   distributed  throughout the earth's  crust.  It occurs  in
 marine   organisms  and   is  found   in   the oceans.    The   chief
 commercial  ores  for  nickel are pentlandite  [(Fe,Ni)9Sa],  and  a
 lateritic  ore  consisting  of   hydrated   nickel-iron-magnesium
 silicate.

 Nickel  has  many  varied uses.  It is used  in alloys and as the
 pure metal.  Nickel salts are used for electroplating baths.
                                            t
 The toxicity of nickel to man is thought   to  be   very  low   and
 systemic  poisoning  of  human beings by nickel or  nickel  salts is
 almost unknown.  In non-human mammals,  nickel  acts  to  inhibit
 insulin  release,  depress growth, and  reduce cholesterol.  A hiqh
 incidence of cancer of the lung and nose  has  been  reported  in
humans engaged in the refining of nickel.
                              360

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Nickel  salts can kill fish at very low concentrations.  However,
      s
animals contain up to 0.4 mg/1 and marine plants  contain  up  to
Trng/l   Higher nickel concentrations have been reported to cause
reduction  in  photosynthetic  activity of the giant kelp.  A  low
concentration was found to kill oyster eggs.

For the protection of human health from the  toxic  properties  _ of
nickel   ingested  through water  and through contaminated  aquatic
Srgan sms  the ambient water criterion is determined to be 0  34
mg/1.   If contaminated aquatic organisms are consumed  excluding
consumption of water, the ambient water criterion   is  determined
to  be  1 01  mg/1.   Available data show that adverse effects on
aquatfc life occur for total recoverable nickel  concentrations as
low as 0.032 mg/1.

Nickel is not destroyed when treated  in a POTW,  but  will   either
oass  through  to  the  POTW   effluent or be retained  in  the  POTW
SlSdge?   It  can  interfere with POTW  treatment processes   and   can
.also  limit  the usefulness of municipal sludge.

Nickel  salts  have  caused  inhibition of  the biochemical  oxidation
of  sewage  in a POTW.   In a  pilot   plant,   slug  doses   of  nickel
sianif icantly  reduced   normal  treatment   efficiencies  for a few
houri but the plant  acclimated   itself   somewhat  to  the  slug
do^e   and  appeared  to   achieve  norma ^treatment e «-iencies
within  40   hours.    It   has  been  reported  that  the  anaerobic
diges?ion  process  is   inhibited  only  by high concentrations of
 nickel,   while  a  low  concentration  of   nickel  inhibits   the
 nitrification process.          .^r  ....  -     -.       •-

 The  influent concentration of nickel to POTW facilities  has. been
 observed by the EPA to range  from  0.01   to  3.19 mg/1,   with  a
 median  of  033 mg/1.    In  a  study  of   190 POTWs,  nickel pass
 through was greate? than 90 percent for 82 percent of the primary
 plants.   Median pass  through  for  trickling  filter,  activated
 lludge,   and  biological  process  plants  was  greater   than  80
 percent.   POTW  effluent  concentrations  ranged  from  0.002  to
 40 mg/1 (mean = 0.410, standard  deviation =3.279).

 Nickel  not passed through the POTW will be  incorporated  into the
 sludge.   !n-S recent two-year study of _ eight cities  four of  the
 cities  had  median  nickel concentrations  of over 350 mg/kg, and
 two were over   1,000 mg/kg.   The  maximum   nickel  concentration
 observed was 4,010 mg/kg.
                                361

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 Nickel   is found  in nearly all soils, plants, and waters.  Nickel
 has no known essential function   in  plants.    In  soils,  nickel
 typically  is  found  in the range from  10 to TOO mg/kg.  Various
 environmental  exposures  to  nickel  appear  to  correlate  with
 increased incidence of tumors in man.  For example, cancer in the
 maxillary  antrum  of  snuff  users  may  result from using plant
 material grown on soil high in nickel.

 Nickel toxicity may develop in plants from application of  sewage
 sludge  on acid soils.  Nickel has caused reduction of yields for
 a variety of crops including oats, mustard, turnips, and cabbage.
  I? ?n« study, nickel decreased the yields of  oats  significantly
 at 100 mg/kg.

 Whether nickel exerts a toxic effect on plants depends on several
 soil  factors,   the amount of nickel applied,  and the contents of
 other metals in the sludge.   Unlike copper and  zinc,   which  are
 more  available  from  inorganic sources than from sludge,  nickel
 uptake by plants seems to be promoted  by  the  presence  of  the
 organic  matter  in  sludge.    Soil  treatments,  such as liming,
                                   T°xicit* of  nickel  to plants L
 Selenium(125).   Selenium (chemical  symbol  Se)  is  a  non-metallic
 SJ®m^nu   existin9  in  several   allotropic forms.   Gray selenium,
 which  has a  metallic appearance,  is the  stable form  at  ordinary
 temperatures  and  melts at  220°C.   Selenium is a  major component
 or  38  minerals  and a  minor   component   of  37  others   found   in
 various   parts   of  the  world.   Most   selenium is obtained as a
 by-product of precious metals recovery from  electrolytic  copper
 refinery   slimes.   U.S.  annual production  at one time reached  one
 million pounds.

 Principal  uses  of   selenium   are  in  semi-conductors,   pigments,
 decoloring of glass,  zerography,  and metallurgy.   It also is used
 to  produce  ruby   glass  used in  signal  lights.  Several  selenium
 compounds  are important oxidizing  agents   in   the  synthesis   of
 organic chemicals  and drug products.

 While  results  of   some  studies suggest  that  selenium may be  an
 essential  element   in human  nutrition,   the   toxic effects   of
 selenium   in  humans   are  well   established.   Lassitude,  loss  of
 hair, discoloration  and   loss  of  fingernails   are   symptoms   of
 selenium  poisoning.   In  a  fatal case of  ingest ion of  a larger
dose of selenium acid, peripheral vascular   collapse,   pulumonary
edema,   and  coma  occurred.    Selenium  produces  mutagenic  and
teratogenic  effects,  but  it  has  not  been   established    as
exhibiting carcinogenic activity.
                              362

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For  the  protection of human health from the toxic properties of
selenium, ingested through water and through contaminated aquatic
organisms, the ambient water criterion is determined to be  0.010
ma/1    Available  data show that adverse effects on aquatic life
occur  at  concentrations  higher  than  that  cited  for   human
toxicity.

Very few data are available regarding the behavior of selenium in
POTWs.   One  EPA  survey  of  103  POTWs revealed one POTW using
biological treatment and having selenium in  the  influent.   The
influent   concentration  was  0.0025 mg/1,  while  the  effluent
concentration was 0.0016 mg/1 giving a  removal  of  37  percent.
Selenium  is  not  known  to be inhibitory to POTW processes.  In
another study, sludge from  POTWs  in  16  cities  was  found^to
contain   from  1.8  to  8.7 mg/kg  selenium,  compared to  0.01 to
2 mg/kg  in untreated soil.  These concentrations of  selenium  in
sludae  present  a  potential;hazard for humans or other mammuals
eating crops  grown  on  soil  treated  with  selenium-containing
sludge.

Silver(126).   Silver  is  a . soft, lustrous, white metal  that is
insoluble in water and alkali.  In nature, silver  is found in the
elemental state  (native silver) and  combined   in  ores  such  as
argentite  (Ag2S),  horn  silver  (AgCl), proustite/ (Ag3AsS3), and
pyrargyrite  (Ag3SbS3).  Silver  is  used  extensively   in   several
industries,  among them electroplating.

Metallic silver is   not considered to  be toxic,  but  most of  its
salts are toxic  to a  large number of organisms.    Upon  ingestion
by   humans,  many  silver  salts  are  absorbed  in  the  circulatory
system and   deposited   in various  body  tissues,   resulting   in
generalized  or  sometimes  localized gray pigmentation  of  the skin
and mucous  membranes  know as  argyria.   There is no  known   method
for  removing   silver   from  the tissues  once it is deposited,  and
the effect  is  cumulative.

Silver is recognized  as  a bactericide  and  doses from 1 x  10-«   to
 5  x  10-*'  mg/1  have  been  reported as  sufficient to sterilize
water.  The criterion for ambient water to protect  human  health
 from  the  toxic properties  of silver,  ingested through water and
 through contaminated  aquatic organisms,  is 0.05 mg/1.    Available
 data  show  that  adverse  effects on  aquatic life occur at total
 recoverable silver  concentrations as  low as 1.2 x 10 3 mg/1.

 The chronic toxic effects of silver on  the  aquatic  environment
 have not been given as much attention as many other heavy metals.
 Data  from  existing  literature  support the fact that silver is
 very toxic to aquatic organisms.   Despite the fact that silver is
 nearly the most toxic of the heavy metals, there are insufficient
                                363

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 data to adequately evaluate   even   the   effects  of  hardness  on
 silver  toxicity.  There are  no data available on the  toxicity of
 different forms of silver.

 There is no available literature on  the   incidental   removal  of
 silver  by  POTWs.   An incidental removal of about 50 percent is
 assumed as being representative.  This   is  the  highest  average
 incidental  removal  of  any  metal for which data are available.
 (Copper has been indicated to have a  median  incidental  removal
 rate of 49 percent).

 Bioaccumulation  and  concentration  of silver from sewage sludge
 has not  been  studied  to  any  great  degree.    There  is  some
 indication  that  silver could be bioaccumulated in mushrooms,  to
 the extent that there could be adverse physiological  effects  on
 humans  if  they  consumed large quantities of mushrooms grown in
 silver enriched soil.  The effect,   however,   would  tend  to  be
 unpleasant rather than fatal.

 There  is  little summary data available on the quantity of silver
 discharged to POTWs.   Presumably,  there would be  a  tendency  to
 limit  its discharge from a manufacturing facility because of its
 high intrinsic value.

 Thallium  (127).   Thallium (Tl) is  a   soft,   silver-white,   dense,
 malleable   metal.    Five  major  minerals contain  15  to  85  percent
 thallium,  but  they  are not  of  commerical importance,  because   the
 metal   is   produced   in   sufficient   quantity  as a  by-product  of
 lead-zinc  smelting of sulfide  ores.   Thallium melts   at   304°C.
 U.S.  annual production of  thallium and  its  compounds  is estimated
 to  be  1500 pounds.

 Industrial  uses  of   thallium include  the  manufacture  of  alloys
 electronic devices and special   glass.    Thallium catalysts  are
 used for industrial organic syntheses.
                                            I
 Acute  thallium  poisoning  in   humans has  been widely  described.
 Gastrointestinal pains and  diarrhea  are   followed  by  abnormal
 sensations  in  the legs and arms, dizziness,  and, later,  loss of
 hair.  The central nervous system is also affected.   Somnolence,
 delerium  or  coma  may  occur.  Studies on the teratogenicity of
 thallium appear inconclusive; no  studies   on  mutagenicity  were
 found;  and  no  published reports on carcinogenicity of thallium
were found.

For the protection of human health from the toxic  properties  of
thallium,    ingested   through  water  and  contaminated  aquatic
organisms,  the ambient water criterion is 0.004 mg/1.
                              364

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No reports were found  regarding  the  behavior  of  thallium  in
POTWs.   It  will not be degraded, therefore it must pass through
to the effluent or be removed with the  sludge.   However,  since
the  sulfide  (T1S)  is very insoluble, if appreciable sulfide is
present, dissolved thallium in  the  influent  to  POTWs  may  be
precipitated  into  the sludge.  Subsequent use of sludge bearing
thallium compounds, as a soil amendment to  crop  bearing  soils,
may  result  in  uptake  of this element by food plants.  Several
leafy garden crops (cabbage, lettuce, leek, and  endive)  exhibit
relatively  higher  concentrations  of  thallium than other foods
such as meat.                   ;

Zinc(128).   Zinc  occurs  abundantly  in  the   earth's   crust,
concentrated  in  ores.   It  is  readily  refined into the^pure,
stable, silvery-white metal.  In addition to its use  in  alloys,
zinc  is used as a protective coating,on steel.  It is applied by
hot dipping  (i.e.  dipping  the  steel  in  molten  zinc)  or  by
electroplating.  The resulting galvanized steel is used as one ol
the  basis  materials for coil coating.  Zinc  salts are also used
in conversion coatings in the coil coating industry.

Zinc can have an adverse effect on man and animals at  high  con-
centrations.   Zincat concentrations in excess of 5 mg/1 causes
an  undesirable  taste,  which  persists   through   conventional
treatment.   For   the  prevention of adverse effects due  to these
organoleptic properties of  zinc,  5 mg/1  was adopted   for   the
ambient water criterion.

Toxic   concentrations  of zinc compounds cause adverse  changes in
the morphology and physiology  of  fish.  Lethal concentrations   in
the   range  of  0.1 mg/1   have   been  reported.   Acutely  toxic
concentrations   induce  cellular  breakdown  of the   gills,   and
possibly   the  clogging  of  the  gills with mucous.   Chronically
toxic concentrations of zinc compounds cause general enfeeblement
and widespread histological changes  to many organs,  but   not   to
gills.     Abnormal  swimming   behavior   has   been  reported   at
0.04  mg/1.   Growth and maturation are  retarded by  zinc.    It   has
been  observed   that the effects  of  ziric poisoning may not  become
apparent  immediately,  so that  fish removed from zinc-contaminated
water may  die  as long  as 48  hours after  removal.

 In general,  salmonoids are  most sensitive  to   elemental   zinc   in
soft  water;   the  rainbow   trout  is   the most sensitive in  hard
waters.     A   complex   relationship    exists    between    zinc
concentration,  dissolved zinc  concentration,  pH,  temperature,  and
calcium  and  magnesium  concentrations.    Prediction   of harmful
effects has been less  than  reliable  and  controlled  studies  have
not been extensively documented.

-------
 The  major  concern  with  zinc compounds in marine waters is not
 with  acute  lethal  effects,  but  rather  with  the   long-term
 sublethal  effects of the metallic compounds and complexes.  Zinc
 accumulates in some marine species, and  marine  animals  contain
 zinc  in the range of 6 to 1500 mg/kg.  From the point of view of
 acute lethal effects, invertebrate marine animals seem to be  the
 most sensitive organism tested.

 To,xicities  of  zinc in nutrient solutions have been demonstrated
 for a number of plants.   A variety of fresh water  plants  tested
 manifested  harmful  symptoms at concentrations of 10 mg/1.  Zinc
 sulfate has also been found to be lethal to many plants,   and  it
 could impair agricultural uses of the water.

 Zinc is not destroyed when treated by POTWs,  but will either pass
 through  to  the POTW effluent or be retained in the POTW sludge.
 It can interfere with treatment processes in  the  POTW  and  can
 also limit the usefulness of  municipal sludge.

 In  slug  doses,   and particularly  in  the  presence of copper,
 dissolved zinc  can  interfere  with  or  seriously  disrupt  the
 operation  of   POTW  biological  processes  by  reducing   overall
 removal efficiencies,  largely as a result of  the toxicity of  the
 metal   to biological  organisms.   However,  zinc solids in  the form
 of hydroxides   or  sulfides   do  not  appear   to  interfere  with
 biological   treatment processes,  on the basis of available data.
 Such solids accumulate in the sludge.

 The influent concentrations of zinc to POTW  facilities have  been
 observed by   the  EPA   to range  from 0.017  to 3.91  mg/1,  with a
 median  concentration  of   0.33 mg/1.    Primary   treatment   is   not
 efficient  in   removing   zinc;   however,   the   microbial   floe of
 secondary treatment readily adsorbs zinc.

 In  a study  of  258  POTWs,  the  median pass  through  values  were  70
 to   88  percent  for primary plants,  50  to  60 percent for trickling
 filter  and  biological process plants,  and  30 to  40  percent   for
 activated  process plants.   POTW  effluent concentrations  of zinc
 ranged  from 0.003  to  3.6 mg/1  (mean =  0.330, standard  deviation =
 0.464).

 The  zinc  which  does not pass  through the POTW  is  retained  in  the
 sludge.   The   presence  of   zinc   in  sludge may  limit its use on
 cropland.   Sewage  sludge contains   72  to  over   30,000 mg/kg  of
 zinc,  with  3,366 mg/kg as the mean value.  These concentrations
 are significantly  greater  than  those  normally   found  in  soil,
which  range  from  0  to  195 mg/kg, with 94 mg/kg being a common
 level.  Therefore, application of   sewage  sludge  to  soil  will
generally   increase  the concentration of zinc  in the soil.  Zinc
                              366

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can be  toxic  to  plants,   depending  upon  soil  pH.    Lettuce,
?omatoes   turnips,  mustard,  kale,   and  beets  are  especially
sensitive to zinc contamination.

                              is  a  colorless  flammable  liquid
                                The boiling point ranges from 137
many other organic liquids.  Xylene  is  commonly  JJ  mixture  of
three  isomers,  ortho,  meta,  and  para-xylene,  with  m-xylene
predominating. ' Xylene' is manufactured from pseudocumene,  or  by
catalytic isomerization of a hydrocarbon fraction.

Xylene  is predominately used as a solvent, for the manufacure of
dveland other organics, and as a raw material -for production  of
benzotc  acid, phthalic anhydride and other acids and esters used
in the manufacture of  polyester fibers.

Xylene has been shown  to have a narcotic effect^on humans  exposed
to Mgh concentrations.  The chronic toxicity  of  xylene  has  not
been defined, however,  it  is less toxic than benzene.

      on  the behavior  of  xylene  in  POTWs are not available.
         the  methyl  groups in xylene tend  to   transfer   electrons
         benzeneTino,  anS  make If more -usceptible.to biochemical
oxidation.  This   observation,   in  addition  _to   the  low_ water
solubility  of   xylene,   leads   to  the expectation  that aeration
processes will remove  some xylene from the POTW.

Ammonia.  Ammonia (chemical  formula NH,)   is
the U.S.)
                               converted to ammonium compounds  or
                 Lronfad
 to 50 mg/1 ammonia.
 ThP   nrincinal  use  of  ammonia  and  its  compounds  is  as  a
 fertilizer? PHighSmounts are introduced into soils and the water
 runoff from agricultural land by this use.  Smaller quantities of
 ammonia are Jed as a  refrigerant.   Aqueous  ammonia  ( 2  to  5
 percent   solution)  is  widely  used  as  a  household  c leaner.
 Ammonium compounds find a variety of uses in various industries.
                                367

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 Ammonia  is toxic  to humans  by inhalation of the gas or  ingestion
 of  aqueous solutions.   The  ionized form (NH4+)  is less toxic than
 hone:  h"^"1^  -f0.m-    mgestion  of   as  little, as' one ounce of
 household  ammonia has  been  reported as   a  fatal   dose.    Whether
 inhaled    or  ingested,   ammonia   acts   destructively  on  mucous
 membrane with resulting  loss  of function.   Aside  from  breaks  in
 =m2!Ji-  amiponia   refrigeration  equipment,  industrial hazard from
 ammonia exists where   solutions   of ammonium   compounds  may  be
             trea^d Wlth a Stron9 alkali,  releasing  ammonia gas.
             as  15°  pm  ammonia   in air   is  reported  to  cause

                                              in alr  iS
            amb.ient water criteria for total ammonia  are  pH  and
 temperature  dependent; un-ionized ammonia criteria is 0.02 mg/1 .
 The reported odor threshold for ammonia in water is  0.037  mq/1
 Un-ionized  ammonia  is  acutely  or  chronically  toxic  to many
 important freshwater and  marine  aquatic  organisms  at  ambient
 water  concentrations  below  4.2  mg/1.   Salmonoid  fishes  are
 *?P™i   £ sensitive to the toxic effects of  un-ionized  ammoniJ
 at concentrations as low as 0.025 mg/1 during prolonged exposure
 Because   the   proportion  of  un-ionized  ammonia  varies  with
 environmental conditions,  and cannot be  directly  controlled  in
 controlled?       *"'  tOtal ammonia is the Pollutant which must be


 The behavior  of ammonia in POTWs is  well documented,   because  it
 is  a  natural  component of domestic wastewaters.   Only verv hiah
 concentrations  of ammonia  compounds  could  overload  POTWs    One
 ?£*ny SnS S/?Wn fcSat  concentrations  of un-ionized  ammonia greater
 than  90  mg/1   reduce  gasification   in   anaerobic  digesters,  and
 concentrations  of 140 mg/1  stop  digestion completely.    Cor?osiSn
 ™, ?°PPfr Plp.*n8 and excessive  consumption  of chlorine also
 ff^i-  frorohif1? ammonia  concentrations.    Interference   with
 aerobic     nitrification   processes   can  occur   when   larae
 concentrations  of ammonia suppress  dissolved  oxygen.    Nitrites
 are    then  produced  instead   of  nitrates.    Elevated   nitrite

                   drinking water  are   known   to
            Fluoride  ion   (F-)  is a non-conventional pollutant.
Fluorine is an extremely reactive,  pale  yellow,  gas  which  is
never  found free in nature.  Compounds of fluorine - fluorides -
are found widely distributed in nature.  The  principal  minerals
            fl°rine are fluorspar (CaF2) and
   hoi                            2             e   a
Although fluorine is produced commercially in small quantities by
electrolysis  of  potassium  bifluoride  in  anhydrous   hydrogen
fluoride,  the  elemental  form   bears  little  relation  to the
combined ion.  Total production of fluoride chemicals in the U S
                              368

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is difficult to estimate  because  of  the  varied ,  uses.   Large
volume  usage  compounds  «":.,„ calcium fluoride (est. 1,5.00,000
tons in U.S.) and sodium f luoroaluminate (est.  100,000  tons  in
5s )/   Some  fluoride  compounds  and  their  uses are:  sodium
f luoroaluminate  -  aluminum  production;  calcium   fluoride   -
steelmtking?  hydrofluoric acid production, enamel,  iron foundry;
boron Sif luoride - organic synthesis; antimony  Pe»taf luoride  -
f luorocarbon   production;   f luoboric  acid  and  f luoborates
ele?t?oplatinq.  perchloryl  fluoride  (C10.F)  -   rocket   fuel
oxidize?-  hydrogen  fluoride  -  organic  fluoride  manufacture,
PickUng'acid in stainless steel-making,, manufacture   of  alumium
fiSoride;   sulfur  hexaf luoride  -   insulator  in  high  voltage
transformers; polytetraf luoroethylene -  inert  plastic.   Sodium
f luSfide is used at a concentration of about  1 ppm in  many public
drinking water supplies to prevent tooth decay in children.

The   toxic   effects   of  fluoride  on   humans  include  severe
aastroenteritis, vomiting, diarrhea,  spasms,  weakness,  thirst,
failing  pulse  and delayed blood coagulation.  Most observations
of toxic effects are made on   individuals  who  intentionally  or
accidentally   ingest  sodium   fluoride   intended  for  use as  rat
poison "o?  insecticide.  Lethal doses .for adults are estimate^ to
be  as   low   as  2.5 g.  At  1.5  ppm  in drinking water, mot ling of
tooth enamel  is reported, and  14 ppm, consumed over a  period  of
ylars,   may   lead   to   deposition of  calcium fluoride  in bone  and
tendons.

Verv  few data are  available  on the  behavior  of  fluoride ; in  POTWs.
Under usual   operating   conditions   in   a   POTW,   fluorides   pass
S?ough  ?nto the  effluent.  Very  little of  the  fluoride entering
 conventional  primary   and   secondary  treatment    Presses   is
 removed     In  one  study of POTW  influents  conducted by _ the U.S.
 EPA  nine  POTWs reported concentrations  of fluoride ranging  from
 07   m~g/l   to 1.2  mg/1, which  is the range of concentrations used
 for  fluoridated drinking water.
Iron
        Iron is a non-conventional pollutant.  It is  an  abundant
               3oand tante      O>   Pros .    of en
 Sd in commSrcial use, but it is  usually  alloyed  with  other
 metals and minerals.  The most common of these is .carbon.

 Iron  is the basic element in the production of steel.   Iron with
 carbon is used for casting of major. parts of machines and it  can
 be  machined,  cast, formed, and welded.  Ferrous iron  is used in
 SlntSfihlle. powdered  iron' can be sintered and  used   in  powder.
 metallurgy.   Iron  compounds  are also used to precipitate other
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 metals  and  undesirable  minerals   from   industrial
 streams.
wastewater
 Corrosion  products  of  iron  in water cause staining of porcelain
 fixtures, and ferric iron combines with tannin to produce a  dark
 violet   color.    The   presence  of  excessive  iron  in  water
 discourages cows from drinking and thus reduces milk  production.
 High concentrations of ferric and ferrous ions in water kill most
 fish  introduced to the solution within a few hours.  The killing
 action is attributed to coatings of iron  hydroxide  precipitates
 on  the  gills.  Iron oxidizing bacteria are dependent on iron in
 water for growth.  These bacteria form slimes that can affect the
 aesthetic values of bodies of water and cause stoppage  of  flows
 in pipes.

 Iron is an essential nutrient and micro-nutrient for all forms of
 growth.    Drinking water standards in the U.S.  set a limit of 0 3
 mg/1 of iron in domestic water supplies,  based on  aesthetic  and
 organoleptic properties of iron in water.

 High  concentrations  of iron do not  pass through a  POTW into the
 effluent.   In some  POTWs  iron  salts  are  added  to  coagulate
 precipitates  and  suspended  sediments  into a  sludge.   In an EPA
 study of  POTWs the concentration of  iron  in the  effluent   of  22
 biological   POTWs  meeting secondary  treatment  performance levels
 ranged from  0.048 to 0.569 mg/1  with  a median  value  of  0.25  mq/1
 This represented removals of 76  to 97  percent with a median  of  87
 percent removal.

 Iron in sewage  sludge   spread  on land   used   for   agricultural
 purposes  is   not  expected  to have a  detrimental  effect on  crops
 grown  on  the  land.

 Manganese.  Manganese is  a non-conventional  pollutant.   It   is  a
 gray-white  metal   resembling   iron,   but more  brittle.  The pure
 metal does not occur in nature, but must be  produced  by reduction
 °t   B  , °?lde  Wlth  sodium,  magnesium,  or   aluminum,  or   by
 electrolysis.   The  principal  ores   are  pyrolusite   (MnO,) and
 psilomelane  (a complex mixture of  Mn02 and oxides  of  potassium
 barium  and other alkali and alkaline  earth metals).  The largest
 percentage of manganese used in the U.S.   is  in  ferro-manganese
 alloys.  A small  amount goes into dry batteries and chemicals.

 Manganese  is not often present in natural surface waters because
 its hydroxides and carbonates are only sparingly soluble.

Manganese is undesirable in domestic water  supplies  because  it
causes unpleasant tastes, deposits on food during cooking,  stains
and  discolors  laundry  and  plumbing  fixtures, and fosters the
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growth  of  some  microorganisms  in  reservoirs,  filters,   and
distribution systems.

Small concentrators of 0.2 to;0.3 mg/1 of manganese may cause the
formation  of heavy encrustations in piping.  Excessive manganese
is  also  undesirable  in  water  for  use  in  many  industries,
including textiles, dyeing, food processing, distilling, brewing,
ice, and paper.                             ,

The recommended limitation for manganese in drinking water in the
U.S.  is  0.05  mg/1.  The limit appears to be based on aesthetic
and economic factors rather  than  physiological  hazards.   Most
investigators   regard   manganese  to  be  of  no  toxicological
significance in drinking  water  at  concentrations  not  causing
unpleasant  tastes.   However,  cases of manganese poisoning have
been  reported  in  the  literature.    A   small   outbreak   of
encephalitis  - like disease, with early symptoms of lethargy and
edema, was traced to manganese, in the drinking water in a village
near Tokyo.  Three persons died as a result of poisoning by  well
water  contaminated  by manganese derived from dry-cell batteries
buried nearby.  Excess manganese in the drinking  water  is  also
believed  to be the cause of a rare disease  in Northeastern China.

No  data  were found  regarding the behavior  of manganese in POTWs.
However,  one sourcereports   that  typical  mineral  pickup  from
domestic   water   use   results  in  an  increase   in  manganese
concentration of 0.2 to 0.4 mg/1 in a  municipal  sewage   system.
Therefore,  it  is   expected  that  interference  in POTWs,  if  it
occurs,   would  not  be  noted  until  manganese    concentrations
exceeded  0 . 4, mg/1.                 .

Phenols(Total).    "Total Phenols" is  a non-conventional pollutant
parameter.  Total  phenols  is  the result  of  analysis   using  the
4-AAP   (4-aminoantipyrene)  method.   This  analytical  procedure
measures  the color development of reaction  products between  4-AAP
and some  phenols.  The results  are   reported  as   phenol.   Thus
"total  phenol"   is  not   total  phenols,   because   many   phenols
(notably  nitrophenols) do  not react.  Also, since   each  reacting
phenol  contributes  to   the  color   development  to  a different
degree, and each phenol has  a molecular  weight  different  from
others  and  from  phenol   itself,  analyses   of  several  mixtures
containing the same  total   concentration   in  mg/1   of   several
phenols will give  different  numbers,  depending on the  proportions
in  the.  particular  mixture.

Despite  these  limitations  of  the  analytical method, total  phenols
is   a  useful   parameter   when   the  mix  of phenols is relatively
constant  and  an inexpensive  monitoring  method is desired.   In  any
given plant  or even  in an  industry  subcategory,   monitoring   of
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 "total  phenols"  provides  an indication of the concentration of
 this group of priority pollutants, as well as those  phenols  not
 selected as priority pollutants.   A further advantage is that the
 method is widely used in water quality determinations.

 In  an  EPA  survey  of  103  POTWs  the  concentration of "total
 phenols" ranged grom 0.0001 mg/1  to 0.176 mg/1 in  the  influent,
 with a median concentration of 0.016 mg/1.  Analysis of effluents
 from  22  of  these  same  POTWs,   which had biological treatment
 meeting secondary treatment  performance  levels,  showed  "total
 phenols"  concentrations ranging  from 0 mg/1 to 0.203 mg/1 with a
 median of 0.007.   Removals were 64 to 100 percent with  a  median
 of 78 percent.

 It  must  be recognized,  however,  that six of the eleven priority
 pollutant phenols could be present in high concentrations and not
 be detected.   Conversely,  it is possible, but  not  probable,  to
 have  a  high  "total  phenol" concentration  without having any
 phenol itself or  any of the ten other priority pollutant  phenols
 present.     A  characterization of  the  phenol   mixture  to  be
 monitored to establish constancy of composition will allow "total
 phenols"  to be  used with  confidence.

 Sulfides

 Sulfides  are oxidizable and therefore can exert an oxygen  demand
 on  the  receiving   stream.    Their  presence,  in  amounts which
 consume oxygen  at a rate   exceeding  the  oxygen   uptake  of   the
 stream,   can  produce a condition of insufficient  dissolved oxygen
 in the receiving  water.  Sulfides  also impart  an  unpleasant taste
 and odor  to the water and  can  render  the water  unfit  for other
 uses.

 Sulfides  are  constituents  of many  industrial wastes  such as those
 from  tanneries,  paper  mills,  chemical plants,  and gas works;  but
 they are  also generated in  sewage  and  some natural waters  by   the
 anaerobic   decomposition of organic matter.  When  added  to water,
 soluble sulfide salts  such  as  Na2S  dissociate  into   sulfide  ions
 which,  in turn, react  with  the hydrogen  ions in the  water  to  form
 HS-   or   H2S, the proportion of each depending  upon  the  resulting
 pH  value.   Thus,  when  reference is  made  to sulfides  in water,  the
 reader should bear  in mind  that the sulfide  is  probably  in   the
 form  of HS- or H2S.

Owing  to   the  unpleasant  taste   and   odor  which   results  when
sulfides occur  in water, it is unlikely  that any person  or  animal
will  consume a harmful dose.   The thresholds of taste  and  smell
were  reported  to  be  0.2 mg/1 of sulfides in pulp mill wastes.
For  industrial uses, however,  even  small  traces of  sulfides  are
                              372

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often   detrimental.
irrigation waters.
                        Sulfides  are  of  little  importance  in
The toxicity of solutions of sulfides toward  fish  increases  as
the  pH  value  is." lowered, i.e., the HeS or HS- rather than the
sulfide ion, appears to be the principle toxic agent.   In  water
containing  3.2  mg/1  of sodium sulfide, trout overturned in two
hours at pH 9.0, in ten minutes at pH 7.8, and in four minutes at
pH 6.0.  Inorganic sulfides have proved to be fatal to  sensitive
fish  such as trout at concentrations between 0.5 and 1.0 mg/1 as
sulfide, even in neutral and somewhat alkaline solutions.
                       and  grease  are  taken  together  as  one
                        This is a conventional pollutant and some
Oil and .Grease.   Oil
pollutant  parameter.
of its components are:

1.   Light Hydrocarbons -  These  include  light  fuels  such  as
     gasoline,  kerosene,  and  jet  fuel, and miscellaneous sol-
     vents  used  for  industrial  processing,   degreasing,   or
     cleaning  purposes.   The  presence  of  these   light hydro-
     carbons may make the removal of  other  heavier  oil  wastes
     more difficult.

2.   Heavy Hydrocarbons, Fuels, arid  Tars  -  These   include  the
     crude  oils,  diesel  oils, #6 fuel oil, residual oils, slop
     oils, and in some cases, asphalt and road tar.

3.   Lubricants and Cutting Fluids - These  generally fall  into
     two  classes: non-emulsifiable oils such as lubricating oils
     and greases and emulsifiable  oils  such  as  water  soluble
     oils,  rolling  oils,  cutting  oils, and drawing compounds.
     Emulsifiable oils may contain  fat  soap  or  various  other
     additives.

4.   Vegetable  andAnimal  Fats  and  Oils  -  These  originate
     primarily from processing  of foods and natural products.

These  compounds  can  settle or float and may exist  as solids or
liquids depending upon factors  such as method of use, production
process, and  temperature of wastewater.

Oils   and  greases,  even  in small quantities,  cause troublesome
taste  and odor  problems.   Scum  lines,  from  these   agents  are
produced  on   water  treatment  basin walls and  other containers.
Fish and water fowl  are  adversely  affected  by   oils   in   their
habitat.   Oil  emulsions may adhere to the gills  of  fish causing
suffocation,  and  the flesh of fish  is tainted when microorganisms
that were exposed to waste oil  are  eaten.  Deposition of  oil   in

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 the bottom sediments of water can serve to inhibit normal benthic
 growth.   Oil and grease exhibit an oxygen demand.

 Many of  the organic priority pollutants will be found distributed
 between   the  oily  phase  and  the  aqueous  phase in industrial
 wastewaters.  The presence of phenols,  PCBs, PAHs,  and almost any
 other organic   pollutant   in   the   oil    and    grease   make
 characterization  of  this parameter almost  impossible.   However,
 all of these other organics add to the   objectionable  nature  of
 the oil  and grease.

 Levels   of  oil   and  grease which are  toxic to aquatic organisms
 vary greatly,   depending  on   the  type   and   the   species'
 susceptibility.   However,  it has been reported that crude oil,  in
 concentrations   as   low  as  0.3 mg/1,   is   extremely  toxic  to
 fresh-water fish.   It has  been  recommended  that   public  water
 supply sources be essentially free from oil  and grease.
                                          I
 Oil  and  grease in quantities of 100 1/sq km  show up as a sheen  on
 the  surface  of  a   body  of  water.   The presence of oil slicks
 decreases  the aesthetic  value of a waterway.

 Oil  and  grease is compatible with a POTW activated  sludge process
 in   limited   quantity.     However,   slug   loadings    or   high
 concentrations   of   oil   and  grease interfere with   biological
 treatment  processes.   The oils coat surfaces and solid particles,
 preventing access  of  oxygen,  and sealing in  some microorganisms.
 Land   spreading  of   POTW  sludge,   containing oil   and  grease
 uncontaminated by  toxic  pollutants,  is   not   expected   to  affect
 crops grown on the treated  land,  or animals  eating  those crops.

 p_H.   Although   not   a   specific  pollutant,  pH is  related to the
 acidity  or   alkalinity   of   a   wastewater  stream.    It   is  not,
 however,    a  measure  of  either.   The term pH is used  to describe
 the hydrogen  ion  concentration  (or  activity)  present  in   a  given
 solution.   Values  for  pH  range  from  0  to  14,  and  these numbers
 are the  negative  logarithms  of  the  hydrogen   ion concentrations.
A  pH of 7  indicates  neutrality.   Solutions  with a pH  above 7 are
alkaline, while  those solutions  with a pH  below 7  are  acidic.
The  relationship  of  pH  and   acidity   and   alkalinity  is  not
necessarily  linear or direct.    Knowledge  of   the  water   pH   is
useful   in  determining  necessary measures for  corrosion control,
sanitation, and disinfection.   Its  value  is  also necessary in the
treatment of  industrial  wastewaters,  to  determine   amounts   of
chemicals   required   to  remove  pollutants,  and to measure  their
effectiveness.   Removal  of  pollutants,  especially    dissolved
solids,   is  affected by the pH of the wastewater.
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Waters  with  a  pH  below  6.0  are  corrosive  to  water  works
structures, distribution lines, and household  plumbing  fixtures
and  can  thus  add  constituents to drinking water such as iron,
copper, zinc, cadmium, and lead.  The hydrogen ion  concentration
can  affect the taste of the water, and at a low pH, water tastes
sour.  The bactericidal effect of chlorine is weakened as the  pH
increases,  and  it  is advantageous to keep the pH close to 7.0.
This is significant for providing.safe drinking water.

Extremes of pH or rapid pH changes can exert stress conditions or
kill  aquatic  life  outright.   Even   moderate   changes   from
acceptable criteria limits of pH are deleterious to some species.
The  relative  toxicity  to  aquatic  life  of  many materials is
increased  by  changes   in   the   water   pH,    For   example,
metallocyanide complexes can increase a thousand-fold in toxicity
with a drop of 1.5 pH units.

Because  of  the  universal  nature of pH and its effect on water
quality and treatment, it is selected as  a  pollutant  parameter
for  all subcategories in the metal molding and casting industry.
A neutral pH range  (approximately  6-9)  is  generally  desired,
because either extreme beyond this range has a deleterious effect
on  receiving  waters or the pollutant nature of other wastewater
constituents.

Pretreatment for regulation of pH  is  covered  by  the  "General
Pretreatment   Regulations   for  Existing  and  New  Sources  of
Pollution," 40 CFR 403.5.  This section prohibits  the  discharge
to  a  POTW  of "pollutants which will cause corrosive structural
damage to  the POTW, but  in no case discharges with pH lower  than
5.0,  unless  the works  is specially designed to accommodate such
discharges."

Total Suspended Sol ids(TSS).   Suspended  solids    include   both
organic and  inorganic materials.  The inorganic compounds include
sand,  silt,  and  clay.   The  organic  fraction   includes  such
materials  as grease, oil, tar, and  animal  and  vegetable  waste
products.   These  solids  may  settle  out  rapidly,  and bottom
deposits  are often  a  mixture  of  both  organic   and   inorganic
solids.    Solids  may  be  suspended  in water for a time and then
settle to  the bed of  the stream or lake.  These solids discharged
with man's wastes may  be inert, slowly  biodegradable  materials,
or   rapidly   decomposable   substances.   While   in  suspension,
suspended  solids  increase  the   turbidity  of  the   water,  reduce
light  penetration,   and  impair   the  photosynthetic activity of
aquatic plants.

Suspended  solids   in  water   interfere  with   many    industrial
processes  and  cause  foaming   in  boilers  and encrustations on
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equipment  exposed  to  such water,  especially   as   the   temperature
rises.   They   are undesirable   in  process   water   used   in  the
manufacture of  steel,  in the  textile industry,  in laundries,   in
dyeing,  and in  cooling systems.

Solids   in suspension are aesthetically displeasing.   When they
settle to  form  sludge  deposits on the stream  or   lake  bed,  they
are  often damaging   to  the life  in  the  water.   Solids, when
transformed to  sludge  deposit,  may  do  a  variety   of damaging
things,  including blanketing the stream or  lake bed and  thereby
destroying the  living  spaces  for   those  benthic  organisms  that
would  otherwise   occupy the  habitat.  When of an organic  nature,
solids use a portion or all of the dissolved  oxygen available   in
the  area.   Organic   materials   also  serve  as a food source  for
sludgeworms and associated organisms.

Disregarding any toxic effect attributable to substances  leached
out  by  water,  suspended  solids may kill fish  and  shellfish  by
causing  abrasive  injuries   and   by  clogging  the    gills    and
respiratory  passages  of  various aquatic   fauna.    Indirectly,
suspended  solids are   inimical  to aquatic   life,  because  they
screen  out  light, and they  promote and maintain the development
of noxious conditions  through oxygen depletion.   This results   in
the  killing  of   fish and fish food organisms.   Suspended solids
also reduce the recreational  value of the water.

Total suspended  solids  is   a  traditional   pollutant   which   is
compatible  with   a  well-run  POTW.   This   pollutant   with   the
exception  of those components which are  described  elsewhere   in
this  section,  e.g.,   heavy  metal components, does not  interfere
with the operation of  a  POTW.    However,  since  a   considerable
portion  of  the   innocuous   TSS   may be inseparably  bound to  the
constituents which do  interfere with POTW operation,   or  produce
unusable sludge, or subsequently  dissolve to  produce  unacceptable
POTW effluent, TSS may be considered a toxic  waste hazard.

REGULATION OF SPECIFIC POLLUTANTS

Discussions of individual pollutants selected or  not  selected for
consideration for specific regulation are based on concentrations
obtained  from  sampling  and  analysis of raw wastewater streams
from six subcategories.
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Aluminum Casting Subcateqory

Pollutants Considered for Specific
Regulation in the Aluminum Casting Subcategory

Based on sampling results and examination of the aluminum casting
subcategory manufacturing processes and raw materials,  forty-one
pollutants   were   selected   for   consideration  for  specific
regulation through effluent limitations and  standards  for  this
subcategory.  These pollutants were found in raw wastewaters from
processes  in  this  subcategory  and  are amenable to control by
identified wastewater treatment practices (e.g. activated  carbon
adsorption,  chemical  precipitation-sedimentation).  Discussions
of each of these pollutants follow.

Acenaphthene (1) values were detected on 6  of  the  21  sampling
days  in  this  subcategory.   The  maximum concentration in this
subcategory was 0.38 mg/1.  Some of the concentrations are  above
the  treated  effluent  level  achievable with available specific
treatment methods.  This pollutant may be found in the  leakages,
which  subsequently  contaminate  process  wastewaters,  from die
casting operations.

Benzidine  (5) values were detected on 1 of the 21  sampling  days
in  this  subcategory.   The  concentration found on this day was
2.76  mg/1,  a  value  substantially  greater  than  the  treated
effluent levels achievable with available treatment methods.

Carbon  tetrachloride  (6)  values  were detected on 11 of the 21
sampling days in this  subcategory.   The  maximum  concentration
found   in   this   subcategory  was  0.25  mg/1.   Some  of  the
concentrations are above  the treated effluent  levels  achievable
with  available  specific  treatment  methods.  This, pollutant is
used in metal degreasing  and as  a  general  solvent   in  process
solutions.

Chlorobenzene   (7)  values  were detected on 2 of the  21 sampling
days in this subcategory.  The maximum  concentration  found  was
0.59  mg/1.   Some  of  the  concentrations are above  the treated
effluent levels  achievable  with  available  specific  treatment
methods.    This  pollutant's  presence  is , associated  with  the
process solutions used in this subcategory.

1,2-dichloroethane  (10) values were  detected  on   4   of  the  21
sampling   days   in. this  subcategory.  The maximum concentration
found was  0.33 mg/1.  Some of; the  concentrations  are  above  the
treated    effluent  levels  achievable  with  available  specific
treatment  methods.  This  pollutant  is  used  as  a  solvent  for
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 various  process solutions,  as a metal degreasing agent,  and as a
 wetting or penetrating agent.

 1,1t 1-trichloroethane (11)  values were detected on 9  of   the  21
 sampling  days  in  this  subcategory.  The maximum concentration
 found was 16.95 mg/1.   This  pollutant's  presence  is  associated
 with  the process solutions  used in this subcategory.

 l',1-dichloroethane  (13)  values  were  detected  on  1 of the 21
 sampling days in this  subcategory.    The  maximum  concentration
 found  was  0.105  mg/1.   This pollutant is used as a solvent in
 process solutions.

 2,4,6-trichlorophenol  (21)  values were detected on 13 of   the  21
 sampling  days  in  this subcategory.  The maximum concentration
 found was 2.0 mg/1.   Some of the  concentrations  are  above  the
 treated   effluent  levels   achievable  with  available  specific
 treatment methods.   This pollutant is  used as an agent to control
 biological growth in various process solutions.

 Parachlorometacresol (22) values were  detected on  7  of   the  21
 sampling  days  in  this subcategory.  The maximum concentration
 found was 0.925 mg/1.   Some  of  these  concentrations are   well
 above the optimum expected 30-day average treated effluent levels
 achievable  with  available  treatment  methods.   The presence of
 this  pollutant is associated with the   contamination  of   process
 waters with  process  equipment  lubricants and fluids.

 Chloroform  (23)   values were  detected on all  21  sampling days in
 this  subcategory.  The  maximum concentration found was 0.46  mg/1.
 Some  of the  concentrations are above the treated  effluent levels
 achievable  with  available  specific   treatment   methods.    This
 pollutant is  used   as   a  general  solvent   in   this  and  other
 subcategories.

 2,4-dichlorophenol   (31)  values   were  detected   on  8 of the 21
 sampling  days  in this   subcategory.    The maximum  concentration
 found   was   0.15  mg/1.  Some  of  the concentrations  are above  the
 treated  effluent  levels  achievable   with   available   specific
 treatment  methods.   This pollutant's presence  is related to  the
 solutions  used   in  processes   and  process   equipment   in   this
 subcategory.

 Fluoranthene   (39)   values were detected  on  15 of  the  21  sampling
 days  in this subcategory.  The maximum  concentration  found   was
 5.8 mg/1.  Some  of the  concentrations  are substantially above  the
 treated   effluent   levels   achievable with   available   specific
 treatment methods.   This pollutant's presence  is related   to   the
process solutions used  in this subcategory.
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Methylene  chloride  (44)  values  were  detected on 16 of the 21
sampling days in this  subcategory.   The  maximum  concentration
found  was 2.46 mg/1.  Some of these concentrations are above the
optimum  expected  30-day   average   treated   effluent   levels
attainable   with  available  specific  treatment  methods.   The
presence :of this pollutant is  related  to  its  use  in  various
process solutions.

Naphthalene  (55)  values  were  detected on 8 of the 21 sampling
days in this subcategory.  The maximum  concentration  found  was
2.87  mg/1.   Some  of  these ; concentrations  are well above the
optimum  expected  30-day   average   treated   effluent   levels
achievable  with  available  treatment methods.  This pollutant's
presence is related to the process solutions used.

4-nitrophenol (58) values were detected on 1 of the  21  sampling
days  in  this  subcategory.  The concentration found on this day
was 0.45 mg/1, a concentration above the optimum expected  30-day
average   treated   effluent   level  achievable  with  available
treatment methods.  The presence of this pollutant is related  to
the solutions used in the processes.

N-nitrosodi-n-propylamine  (63).  values were detected on 2 of the
21 sampling days' in this subcategory.  The maximum  concentration
found  was  0.078  mg/1.  This pollutant's presence is associated
with the process solutions used in this subcategory.

Pentachlorophenol (64) values  were  detected  on  2  of  the  21
sampling  days  in  this  subcategory.  The maximum concentration
found  was  3.05  mg/1.    Some   of   the   concentrations   are
substantially  above  the treated effluent levels achievable with
available specific treatment methods.  This pollutant is used  as
an agent to control biological growth in process solutions.  This
pollutant's  presence may also be related to the contamination of
process wastewaters with process equipment fluids and lubricants.


Phenol (65.)-. values were detected on 15 of the  21 sampling days in
this subcategory.  The maximum concentration found was 36.0 mg/1.
Some of these  concentrations  are  above  the  optimum  expected
30^day  average treated effluent levels achievable with available
treatment  methods.   This  pollutant  is  present  as  a   major
component  of  various process solutions and of process equipment
fluids.

Bis(2-ethylhexyl)phthalate (66) values were detected  on  all  21
sampling  days  in  this  subcategory.  The maximum concentration
found  was  482.4  mg/1.   Some   of   the   concentrations   are
substantially  above  the treated effluent levels achievable with
                              379

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available specific treatment methods.  This pollutant's  presence
can  be related to the solutions used  in the processes and to the
fluids used in process equipment.

Butyl benzyl phthalate (67) values were detected on  12 of the  21
sampling  days  in  this  subcategory.  The maximum  concentration
found was 2.0 mg/1.  Some of these concentrations are  above  the
optimum   expected   30-day   average   treated  effluent  levels
attainable  with  available  specific  treatment  methods.    The
presence  of  this  pollutant  can  also  be  associated with the
solutions used in the processes  and   with  the  fluids  used  in
process equipment.

Benzo(a)anthracene  (72)  values  were detected  on  6 of the 21
sampling days in this  subcategory.    The  maximum   concentration
found   was   22.54   mg/1.    Some  of  the  concentrations  are
substantially above the treated effluent levels  achievable  with
available  specific  treatment  methods.   This  pollutant can be
found in the solutions used in this subcategory's processes.

Benzo(a)pyrene (73) values were detected on 5 of the 21  sampling
days  in  this  subcategory.  The maximum concentration found was
0.16 mg/1.  Some of these concentrations are  above  the  optimum
expected  30-day  average treated effluent levels achievable with
available treatment methods.  As  with  b$nzo(a)anthracene,  this
pollutant can be found in process solutions.

Chrysene  (76)  values were detected on 9 of the 21 sampling days
in this subcategory.   The maximum concentration  found  was  19.0
mg/1.   Some of the concentrations are above the treated effluent
levels achievable  with  available  specific  treatment  methods.
This  pollutant's  presence  is  related to the process solutions
used in this subcategory.

Acenaphthylene (77) values were detected on 8 of the 21  sampling
days  in  this  subcategory.  The maximum concentration found was
1.64 mg/1.  Some of  these  concentrations  are  well  above  the
optimum   expected   30-day   average   treated  effluent  levels
achievable with available treatment  methods.   The  presence  of
this pollutant can be attributed to the process solutions used.

Anthracene (78)  values were detected on 9 of the 21 sampling days
in  this  subcategory.    The maximum concentration found was 1.35
mg/1.   Some  of  these  concentrations  are  above  the  optimum
expected  30-day  average treated effluent levels achievable with
available specific treatment  methods.   This  pollutant  can  be
found in process solutions used in this subcategory.
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Fluorene  (80) values were "detected on 10 of the 21 sampling days
in this subcategory.  The maximum concentration  found  was  7.27
mg/1.   Some  of  the  concentrations are substantially above the
treated  effluent  levels  achievable  with  available   specific
treatment  methods.   Fluorene  can  be  found in various process
solutions (e.g., die lubes).

Phenanthrene  (81) values were detected on 9 of  the  21  sampling
days  in  this  subcategory.  The maximum concentration found was
1.35 mg/1.  Some of the  concentrations  are  above  the  treated
effluent  levels  achievable  with  available  specific treatment
methods.  This pollutant's presence  in  process  wastewaters  is
attributable  to its presence in process solutions.

Pyrene  (84) values were detected on 15 of the 21 sampling days in
this subcategory.  The maximum concentration found was 0.69 mg/1.
Some  of  these  concentrations  are  above  the optimum expected
30-day average treated effluent levels achievable with  available
treatment  methods.   Pyrene  can be found in many of the process
solutions used by plants in this subcategory,

Tetrachloroethylene (85) values were detected on  14  of  the  21
sampling  days  in  this  subcategory.  The maximum concentration
found was 0.255 mg/1.  Some of the concentrations are  above  the
treated   effluent  levels  achievable  with  available  specific
treatment methods.   The  presence  of  this  pollutant  in  this
subcategory's  wastewaters  is related to its use as a solvent and
as a drying agent for metals.

Trichloroethylene  (87) values were  detected  on  14  of  the  21
sampling  days  in  this  subcategory.  The maximum concentration
found was 0.328 mg/1.  Some of the concentrations are  above  the
treated   effluent  levels  achievable  with  available  specific
treatment methods.  This pollutant's presence  results  from  its
use as  a solvent in process solutions and for metal degreasing.

Chlordane   (91) values were detected on 6 of the 13 sampling days
in this subcategory.  The maximum concentration  found  was  0.24
mg/1.   Some  of  these  concentrations  are  above  the  optimum
expected 30-day average treated effluent levels  achievable  with
available   treatment  methods.  Although most commonly known as  a
pesticide,  chlordane  is   also  used   in   oil   emulsions   and
dispersible   liquids.   These  latter two uses are related to the
process solutions of this subcategory.

Xylene  (130)  values were detected on 6  of the 21 sampling days in
this subcategory.   The  maximum  concentration  found  was  70.09
mg/1.   Some  of   the  concentrations are substantially above the
treated effluent   levels   achievable   with  available   specific
                              331

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treatment  methods.   This pollutant is used as both a protective
coating and a solvent in process solutions.

Copper (120) values were detected on all  14 sampling days  in this
subcategory.  The maximum  concentration  found  was  1.11  mg/1.
Some  of  these  concentrations  are  above  the optimum expected
30-day average treated effluent levels achievable with  available
treatment methods.  The presence of copper in process wastewaters
is  related to its use as an alloying material, as well as to  its
use in various items of process equipment (dies, etc.).

Lead (122) values were detected on all 20 sampling days  in  this
subcategory.  The maximum concentration found was 3.9 mg/1.  Some
of  the  concentrations  are  above  the  treated effluent levels
achievable  with  available  specific  treatment  methods.   Lead
contamination in process wastewaters results from the presence of
lead in process equipment and facilities.

Zinc  (128)  values were detected on all  20 sampling days  in this
subcategory.  The maximum concentration found was 9.1 mg/1.  Some
of these concentrations are above  the  optimum  expected  30-day
average   treated   effluent  levels  achievable  with  available
treatment methods.   Zinc's  presence  as  a  process  wastewater
contaminant  is  related  to  its use as  an alloying material, as
well as to its use in process equipment and facilities.

Total suspended solids (TSS) values were  found on all 20 sampling
days at  concentrations  as  high  as  1632.7  mg/1.   These  TSS
concentrations  are  above the treated effluent levels achievable
with available treatment technologies.  In addition, the  control
of  TSS in wastewater discharges will also result in the control,
to a certain extent, of several toxic pollutants.   Consequently,
TSS is considered for specific regulation in this subcategory.

Oil and grease values were detected on all 20 sampling days.  The
maximum  concentration  found was 23,273 mg/1.  Oils and greases,
as process wastewater pollutants,  originate  in  the  solutions,
products,  and  scrap  used  in this subcategory's processes.  As
many of the concentrations are greater than the treated  effluent
levels  typically  achievable,  oil  and grease is considered for
specific regulation in this subcategory.

pH can be controlled within  the  limits  of  7.5  to  10.0  with
available   specific   treatment   methods   and  is,  therefore,
considered for specific regulation in this subcategory.

Ammonia values were  detected  on  all  20  sampling  days.   The
maximum  concentration  found  was 25.2 mg/1.   As a number of the
concentrations are  greater  than  the  treated  effluent  levels
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attainable  with  available  treatment  technologies,  ammonia is
considered for specific regulation in this subcategory.   Ammonia
can   result   from   the   biological   degradation  of  organic
constituents in the process solutions.

Sulfide values were  detected  on  all  20  sampling  days.   The
maximum  level  detected  was:37.0 mg/1.   As many of these values
are greater than the  treated  effluent  levels  achievable  with
specific  available  treatment methods, sulfide is considered for
specific  regulation  in  this  subcategory.   Sulfide   can   be
generated  as  a  result of the biological degradation of process
solution organic compounds.

Phenols values were detected on all 20 of the  sampling  days  in
this  subcategory.   The  maximum  concentration  found was 88.41
mg/1.  Some of the concentrations  are  substantially  above  the
treated   effluent  levels  achievable  with  available  specific
treatment methods.  This pollutant,  detected  by  wet  chemistry
techniques  (4AAP),  encompasses  a  variety  of  the  individual
phenolic  compounds.   This  pollutant's  presence   in   process
wastewaters is related to the constituents of process solutions.

Pollutants Not Considered for Specific
Regulation in the Aluminum Casting Subcateqory

A  total  of  ninety-six  pollutants   that  were  evaluated  were
eliminated from further consideration  for specific regulation   in
the  aluminum casting subcategory.  Forty pollutants were dropped
from further consideration, because their presence in  raw process
wastewater  was  not  detected   in  this  subcategory.   Nineteen
pollutants  were  eliminated  from further  consideration,  because
the  concentrations  of  these   pollutants  were  less  than   the
analytically quantifiable  limits.

The  remaining  thirty-seven  pollutants were  found  to be  present
infrequently or found at levels  below those usually  achieved   by
end-of-pipe   treatment    technologies.     Discussions of   these
pollutants follow.

Benzene  (4) concentrations  appeared on 16 of  21  process  sampling
days   in  the  aluminum subcategory.  The  maximum  concentration  was
0.335  mg/1.  Eleven  concentrations are lower  than the  analytical
quantification  limit.   Three  of  the remaining  five  concentrations
are   lower  than   the   level   considered to   be achievable with
available specific   treatment   methods.    However,  all   five
concentrations  are   lower  than  the  level  considered  likely to
cause   toxic  effects   in   humans.    Therefore,   benzene   is  not
considered  for  specific regulation  in this  subcategory.
                               383

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 1,1,2,2-tetrachloroethane (15)  concentrations appeared on 3 of 21
 process  sampling  days in the  aluminum subcategory.   The maximum
 concentration was 0.013 mg/1.   One  concentration  is  below  the
 analytically  quantifiable  limit.    The maximum concentration is
 less  than the  concentration achievable  by  specific  treatment
 methods.     Therefore,   this pollutant  is  not  considered  for
 specific  regulation in  this subcategory.

 Bis(2-chloroethyl)ether (18) concentrations appeared  on 1   of   21
 process   sampling   days   in   the  aluminum  subcategory.    The
 concentration was 0.024 mg/1.   Because this toxic  pollutant  was
 found  at   only   one  plant,   bis(2-chloroethyl)ether  is  not
 considered for specific regulation  in this subcategory.

 2-chlorophenol (24)  concentrations  appeared on 4  of   21   process
 sampling    days   in   the  aluminum  subcategory.    The  maximum
 concentration was 0.235 mg/1.   Two  concentrations are  below  the
 analytically  quantifiable limit.   Another concentration is  lower
 than  the  level considered to be achievable by specific  treatment
 methods.    Because   this  toxic  pollutant  was found on only  one
 process sampling  day at a level  considered to be achievable  with
 available  specific   treatment   methods,   2-chlorophenol   is  not
 considered for specific regulation  in  this subcategory.

 2,4-dimethylphenol   (34)   concentrations   appeared  on  9  of   21
 process  sampling days in the  aluminum subcategory.   The  maximum
 concentration was 0.13  mg/1.  Five  concentrations are  below  the
 analytical   quantification  limit.    Two  other concentrations  are
 lower than  the level  considered   to  be  achievable   by   specific
 treatment  methods.   The  two  remaining  concentrations  are  lower
 than  trie  level  considered  to   cause   toxic   effects   in   humans.
 Therefore,   2,4-dimethylphenol   is   not  considered   for specific
 regulation  in this subcategory.

 Ethylbenzene (38) concentrations  appeared  on   6  of   21   process
 sampling    days   in    the  aluminum   subcategory.    The   maximum
 concentration  was 0.033 mg/1.  Five  concentrations are below  the
 analytically   quantifiable  limit.   The maximum  concentration  is
 below the level considered to be  achievable  by specific  treatment
methods.  Therefore,  ethylbenzene is not considered for  specific
 regulation  in  this subcategory.

Dichlorobromomethane  (48)   concentrations^  appeared   on   7  of  21
process sampling days in  the aluminum  subcategory.    The   maximum
 concentration  was 0.017 mg/1.  Five concentrations are below the
analytically   quantifiable    limit.      The     remaining    two
 concentrations   are  lower  than  the  level   considered  to   be
achievable   by   specific   treatment     methods.     Therefore,
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dichlorobromornethane is not considered "for specific regulation in
this subcategory.

2-nitrophenol  (57)  concentrations  appeared  on 3 of 21 process
sampling  days  in  the  aluminum   subcategory.    The   maximum
concentration  was  1.0  mg/1.    One  concentration  is below the
analytically quantifiable limit.  Another concentration is  below
the  level  considered  to  be achievable with available specific
treatment methods.  Because this toxic  pollutant  was  found  on
only  one  process  sampling  day  at  a  level  considered to be
achievable   with   available   specific    treatment    methods,
2-nitrophenol  is  not considered for specific regulation in this
subcategory.

2,4-dinitrophenol  (59) concentrations appeared on 2 of 21 process
sampling  days  in  the  aluminum   subcategory.    The   maximum
concentration  was  0.41  mg/1.   One  concentration is below the
analytically quantifiable limit.  Because  this  toxic  pollutant
was  found  on  only one sampling day at a level considered to be
achievable   with   available   specific    treatment    methods,
2,4-dinitrophenol  is  not  considered for specific regulation in
this subcategory.

4 6-dinitro-o-cresol  (60) concentrations  appeared  on   3  of  21
process  sampling  days in the aluminum subcategory.' The maximum
concentration was  0.285 mg/1.  Two concentrations are  below  the
analytically  quantifiable  limit.   Because  this toxic  pollutant
was found on only  one  sampling day at a level   considered  to  be
achievable  with specific treatment methods,  4,6-dinitro-o-cresol
is not considered  for  specific regulation; in  this subcategory.

Di-n-butyl phthalate  (68) concentrations appeared  on  18  of  21
process  sampling  days in the aluminum subcategory.  The maximum
concentration was  23.6 mg/1.  Eight concentrations are below  the
analytically  quantifiable  limit.  Many other  concentrations are
lower than the  level  considered to be achievable with   available
specific  treatment   methods.  Therefore, di-n-butyl phthalate is
not considered  for specific regulation  in this  subcategory.

Diethyl phthalate   (70)   concentrations  appeared  on   11  of  21
process  sampling  days in the  aluminum subcategory.  The maximum
concentration was  9.09 mg/1.   Five concentrations  are  below  the
analytically  quantifiable   limit.  Many other  concentrations are
at  levels that  are considered  achievable with available   specific
treatment methods.   However, all  of the concentrations were  below
the   human  toxicity  level  for  this pollutant.   Therefore, diethyl
phthalate  is  not  considered   for specific   regulation   in   this
subcategory.                                         ,
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 Dimethyl   phthalate  (71)   concentrations  appeared  on  5   of  21
 process sampling days in  the aluminum subcategory.    The maximum
 concentration  was 0.035  mg/1.   Four concentrations are below the
 analytically quantifiable limit.   The  maximum  concentration  is
 slightly   above  the  level   that   is  considered achievable with
 available   specific  treatment   methods.     Therefore,    dimethyl
 phthalate   is  not  considered   for  specific   regulation in this
 subcategory.


 Toluene (86)  concentrations  appeared on 14  of  21  process sampling
 days  in the aluminum subcategory.   The maximum concentration was
 1.02  mg/1.    Eleven  concentrations  are  below the analytically
 quantifiable limit.   One  other  concentration is  lower   than the
 level   considered  to be   achievable  wi|th  available  specific
 treatment  methods.   Therefore,   toluene  is not  considered for
 specific regulation in this  subcategory.

 Aldrin  (89)   concentrations appeared on  6  of  13  process sampling
 days  in the aluminum subcategory.   The maximum concentration was
 0.018  mg/1.   Five concentrations  are below that  level  achievable
 with  end-of-pipe  treatment   technologies.   Because this   toxic
 pollutant   appeared  on  only  one  process sampling   day   at an
 analytically  quantifiable limit, aldrin  is not  considered for
 specific regulation in this  subcategory.

 4,4'-DDT (92)  concentrations appeared on  9  of  13  process  sampling
 days  in the  aluminum subcategory.   The maiximum concentration was
 0.017 mg/1.   Eight  of  the   nine   concentrations  are   below the
 analytically   quantifiable   level.   Because only  one quantifiable
 value  was  found,   4,4'-DDT is   not  considered  for    specific
 regulation  in  this  subcategory.

 4,4'-DDE (93)  concentrations  appeared on  6  of  13  process  sampling
 days  in the  aluminum  subcategory.   The maximum concentration was
 0.013 mg/1.    Five   concentrations   are  below   the  analytically
 quantifiable    limit.    Because   only  one  quantifiable   value
 appeared,  4,4'-DDE  is  not considered  for  specific  regulation  in
 this subcategory.

Heptachlor  epoxide   (101)   concentrations   appeared  on  4  of 13
process sampling days  in the  aluminum subcategory.   The  maximum
 concentration  was  0.028 mg/1.  Three  concentrations  are  below the
analytically   quantifiable   limit.    Because this toxic pollutant
was found on only one process sampling  day  at   an  analytically
quantifiable   level,  heptachlor  epoxide   is   not considered for
specific regulation  in this  subcategory.
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a-BHC-Alpha (102) concentrations appeared  on  8  of  13  process
sampling   days   in   the  aluminum  subcategory.   The  maximum
concentration was 0.071 mg/1.   Seven concentrations are below the
analytically quantifiable limit.  Because  this  toxic  pollutant
was  found  on  only  one process sampling day at an analytically
quantifiable level, a-BHC-Alpha is not  considered  for  specific
regulation in this subcategory.

b-BHC-Beta  (103)  concentrations  appeared  on  6  of 13 process
sampling  days  in  the  aluminum   subcategory.    The   maximum
concentration  was 0.151 mg/1.  Four concentrations are below the
analytically quantifiable limit.  Because  this  toxic  pollutant
was  found  on  only two process sampling days at an analytically
quantifiable level, b-BHC-Beta is  not  considered  for  specific
regulation in this subcategory.
                                                 11 of 13 process
                                                    The   maximum
r-BHC-Gamma  (104)  concentrations  appeared  on
sampling  days  in  the  aluminum   subcategory.
concentration  was 0.024 mg/1.  Nine concentrations are below the
analytically quantifiable limit.  Because  this  toxic  pollutant
was  found  on  only two process sampling days at an analytically
quantifiable level, r-BHC-Gamma is not  considered  for  specific
regulation in.this subcategory.

g-BHC-Delta  (105)  concentrations  appeared  on  7 of 13 process
sampling  days  in  the  aluminum   subcategory.    The   maximum
concentration  was 0.039 mg/1,  Five concentrations are below the
analytically quantifiable limit.  Because  this  toxic  pollutant
was  found  on  only two process sampling days at an analytically
quantifiable level, 6-BHC-Delta is not  considered  for  specific
regulation in this subcategory.

Polychlorinated    biphenols    (PCB-1242,   PCB-1254,   PCB-1221,
PCB-1232, PCB-1248, PCB-1260, PCB-1016) (106-112)  concentrations
appeared  at  one plant in the aluminum subcategory.  The maximum
concentration was 0.013 mg/1.  This concentration  is  above  the
level  considered to be achievable by specific treatment methods.
The appearance of these PCBs can be traced,to plants which at one
time used PCS bearing hydraulic fluids.  Hydraulic fluids  are  a
necessity  in  the  operation of die casting machinery.  Prior to
1971, PCBs were used extensively in hydraulic fluids.  Commercial
products containing PCBs are no longer produced  in the U.S:,  and
the   use  of  these  materials  in  hydraulic   fluids  has  been
eliminated.  However, PCB residuals can still be  detected  after
extensive  cleaning  and  flushing of hydraulic  oil systems which
once contained them.  Because PCBs are artifacts of one time use,
and because they are no longer  used, PCBs are not considered  for
specific regulation in this subcategory.
                               387.

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Arsenic   (115)   concentrations  appeared  on  all  4  process  sampling
days  in  the  aluminum  subcategory.   The maximum  concentration   was
0.01  mg/1.   Three   concentrations are  lower than  the  analytical
quantification  limit.  The maximum   concentration  is   below   the
level    considered  to   be   achievable   with  available  specific
treatment methods.  Therefore,   arsenic   is not  considered   for
specific regulation in this  subcategory.

Chromium (119)  concentrations appeared on all 11  process  sampling
days  in the aluminum subcategory.   The  maximum concentration  was
0.01 mg/1.   Ten concentrations   are  lower  than  the   analytical
quantification   limit.   The maximum concentration is below  the
level  considered  to be  achievable with available    specific
treatment  methods.   Therefore,  chromium  is  not  considered  for
specific regulation in this  subcategory.

Cyanide  (121) concentrations appeared on all 20 process  sampling
days  in the aluminum subcategory.   The  maximum concentration  was
0.05  mg/1.   All  concentrations   are   lower   than   the  level
considered   to   be  achievable   by   specific  treatment  methods.
Therefore, cyanide is not considered for specific  regulation   in
this subcategory.

Mercury  (123)  concentrations appeared on all 14  process  sampling
days in  the  aluminum  subcategory.   The maximum  concentration   was
0.0014   mg/1.    All   concentrations   are lower  than   the  level
considered   to   be  achievable   by   specific  treatment  methods.
Therefore,   mercury   is  not  considered for  specific regulation in
this subcategory.

Nickel (124) concentrations  appeared on  all 14  process  sampling
days  in the aluminum subcategory.   The  maximum concentration  was
0.04 mg/1.   This concentration  is below  the level   considered   to
be  achievable   by specific  treatment methods.  Therefore, nickel
is not considered for specific  regulation in this subcategory.

Fluoride concentrations  appeared on  all  20  process sampling  days
in  the  aluminum subcategory.   The  maximum concentration was  3.4
mg/1.  This  concentration is below  the   level   considered  to   be
achievable by specific treatment methods.   Therefore, fluoride is
not considered  for specific  regulation in this  subcategory.

Manganese concentrations appeared on all 20 process sampling days
in  the  aluminum subcategory.   The maximum  concentration  was 0.56
mg/1.    Four    concentrations   are  below    the     analytical
quantification  limit.   Fourteen  concentrations  are lower  than  the
level  considered to be  achievable by specific  treatment  methods.
Because  this pollutant was found on  only   two  process   sampling
days  at  a  concentration   above  the   level   considered  to   be
                              388

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achievable  by  specific  treatment  methods,  manganese  is  not
considered for specific regulation in this subcategory.

Iron  concentrations  appeared on all 12 process sampling days in
the aluminum casting subcategory.  The maximum concentration  was
4.2  mg/1.  Three of the concentration values are below the level
considered to be analytically quantifiable.  Nine of  the  twelve
concentration  values  are  below  the  level  considered  to  be
achievable by specific treatment methods.  Therefore, iron is not
considered for specific regulation in this subcategory.

Copper Casting Subcateqory

Pollutants Considered for Specific
Regulation in the Copper Casting Subcateqory

Based on sampling results and a careful examination of the copper
casting subcategory manufacturing processes  and  raw  materials,
thirteen  pollutants were selected for consideration for specific
regulation through effluent limitations and  standards  for  this
subcategory.  These pollutants were found  in raw wastewaters from
processes  in  this  subcategory  and  are amenable  to control by
identified wastewater treatment practices  (e.g., activated carbon
adsorption,  oxidation,  chemical   precipitation-sedimentation).
Discussions of these pollutants follow.

Butyl  benzyl  phthalate   (67) values were detected  on 4 of the  6
sampling days in this   subcategory.   The  maximum   concentration
found  was  0.55  mg/1.  Some of the concentrations  are above the
treated  effluent   levels  achievable  with  available   specific
treatment  methods.  The presence of this  pollutant  is related to
the  use of binders  and  other chemical additives   in  the   casting
sands.

3,4-benzofluoranthene   (74)  values  were  detected  on 2 of the  6
sampling  days in this   subcategory.   The  maximum   concentration
found  was  0.013 mg/1.  Some of the concentrations  are above the
treated   effluent   levels  achievable  with  available   specific
treatment  methods.    This  pollutant   is  present as a combustion
byproduct of  the binders and other sand  additives.

Benzo(k)fluoranthene  (75)  values were detected  on   2  of   the   6
sampling  days   in   this   subcategory.   The  maximum  concentration
found  was 0.013  mg/1.   Some of  these  concentrations  are above the
optimum   expected   30-day   average    treated    effluent    levels
achievable  with   available   specific   treatment methods.    This
pollutant is  present  as a  combustion  byproduct of  the  binders and
other  sand  additives.
                               389

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 Pyrene (84) values were detected on 5 of the 6 sampling  days  in
 this  subcategory.   The  maximum  concentration  found was 0.034
 mg/1.    Some  of  these  concentrations  are  above  the  optimum
 expected  30-day  average treated effluent levels attainable with
 available  specific  treatment  methods.   This  pollutant  is  a
 combustion byproduct of the binders and other sand additives.

 Copper  (120)  values were detected on all 4 sampling days in this
 subcategory.   The maximum concentration  found  was  147.9  mg/1.
 Some  of  these  concentrations  are  above  the optimum expected
 30-day average treated effluent levels achievable with  available
 treatment methods.  Copper is considered for specific regulation,
 as  it  is the primary metal used in this subcategory.

 Lead (122)  values were detected on all 6 of sampling days in this
 subcategory.    The  maximum  concentration  found  was 32.1  mg/1.
 Some of the concentrations are above the treated effluent -levels
 achievable   with  available  specific  treatment methods.   Lead's
 presence as a  process wastewater pollutant is related to its  use
 as   an  alloying  material,   as  well  as  to  its use in process
 equipment and  facilities.

 Nickel (124) values  were  detected on all 4 sampling days in   this
 subcategory.    The  maximum  concentration  found  was 1.02  mg/1.
 Some of these   concentrations  are  above  the  optimum  expected
 30-day  average treated effluent levels achievable with available
 treatment methods.   The presence of  nickel  in process wastewaters
 is a result of  its use as  an  alloying  material   for   copper,   as
 well   as   its  use  in   process equipment   (molds,   etc.)   and
 facilities.

 Zinc (128)  values  were detected on all  6 sampling  days  in  this
 subcategory.    The  maximum   concentration  found was 144.6  mg/1.
 Some of the concentrations  are  above the treated  effluent  levels
 achievable   with  available  specific   treatment  methods.    The
 presence  of this pollutant  is attributed to its  use as   an   alloy
 for  copper  and  to  its  use  in production  equipment and facilities.

 Total   suspended   solids  were  found on  all 6  sampling  days.   The
 maximum  concentration   found    was    773.9   mg/1.     The    TSS
 concentrations  are  greater  than   the   treated   effluent levels
 achievable  with available treatment  technologies.   In   addition,
 control   of  TSS   in process wastewater  discharges  will  result  in
 the  control, to a  certain extent,  of  several  toxic  pollutants.
 Therefore,  this pollutant is considered  for specific  regulation.

Oil  and  grease   values  were  found on  all 6 sampling days.  The
maximum concentration was 110 mg/1.  As  these concentrations  are
greater  than  the  treated  effluent levels typically achievable
                              390

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with  specific  treatment  technologies,  oil   and   grease   is
considered for specific, regulation in this subcategory.

nH  can  be  controlled  within  the  limits  of 7.5 to 10.0 with
available spec??ic treatment methods and is therefore  considered
for specific regulation in this subcategory.

           values  were  detected  on  all  6 sampling days.  The
        concentration found was "0.97 wg/1.  Js severa 1^ of  these
concentrations  are  greater  than  the  treated  effluent  levels
acSiSSSe 5i!h specific  treatment  technologies   manganese  is
considered for specific regulation in this subcategory.


               ^un
cncnr   ons are  greater   than  the   treated  effluent   levels
acnle^aole   with  specified   treatment   technologies   phenol  is
considered for specific regulation in this subcategory.
Pollutants Not Considered for Specific
Regulation in the Copper Casting Subcateqory

A  total  of  one  hundred  twenty-four  pollutants  which   were
evaluated were eliminated from further consideration for specif ic
regulation   in   the   copper  casting  subcategory.   Fifty one
nollutants were dropped from further consideration because  their
^esence  in  ?aw wastewaters was not detected.  Forty pollutants
lire  eliminated  from   further   consideration,   beca^  £he
concentrations   of   these   pollutants   were   less  than  the
analytically quantifiable limits.

The remaining thirty-three pollutants were found  to  be  present
InlrequenV or  found at levels below those  usually achieved^
specific  treatment  methods.   Discussions  of these   pollutants
follow.

Acenaphthene   (1)   concentrations  appeared  on  4  of  6 Process
csamnling  davs   in    the   copper    subcategory.    The  maximum
?onc"en?ratiof was  0.011 mg/1    Three concentration values  appear
belSS  the level  considered to  be analytically  quantifiable.   The
rtmSining  concentration  value   is  only  slightly above the level
co^slderld  to  be achievable  with  available   specific  treatment
Se?hodl!    Therefore,  acenaphthene  is not considered  for  specific
regulation  in  this  subcategory.

Carbon tetrachloride  (6)   concentrations  appeared
SocSss  sampling  days  in  , the copper  subcategory
?oncSlral?Sn  wa2 0.032 mg/1.
This concentration
                                                      on   1  of   6
                                                     .   The maximum
                                                     is  below  the
                                391

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 level  considered to be achievable by specific treatment methods.
 Therefore, carbon tetrachloride is not  considered  for  specific
 regulation in this subcategory.
                                           i
 1,1,1-trichloroethane  (11)  concentrations  appeared  on  1 of 6
 process sampling days in the  copper  subcategory.   The  maximum
 concentration  was  0.14 mg/1.    Because this toxic pollutant was
 found at only one plant,  1,1,1-trichloroethane is not  considered
 for specific regulation in this subcategory.

 1,1,2-trichloroethane  (14)  concentrations  appeared  on  1 of 6
 process sampling days in  the  copper  subcategory.   The  maximum
 concentration  was  0.013 mg/1.  Because this toxic pollutant was
 found at only one plant,  and the maximum  concentration  is  less
 than  the concentration achievable by specific treatment methods,
 1,1,2-trichloroethane is  not considered for  specific  regulation
 in this subcategory.

 Chloroform (23)  concentrations  appeared on all 6  process sampling
 days  in  the  copper subcategory.   The maximum concentration was
 0.093  mg/1.    Five  concentration   values   are  below  the  level
 considered   to   be   analytically   quantifiable.    The  remaining
 concentration  is  less   than  the  concentration  achievable  by
 specific   treatment   methods.    Therefore,   chloroform  is  not
 considered for specific regulation in this subcategory.

 2,4-dimethylphenol  (34) concentrations  appeared on 3  of  6  process
 sampling  days  in   -the    copper    subcategory.    The    maximum
 concentration   was    0.084 mg/1.    This   concentration   is   only
 slightly  above   the   level   considered  to   be  achievable   with
 available      specific      treatment     methods.      Therefore,
 2,4-dimethylphenol is  not considered  for specific  regulation  in
 this subcategory.

 2,6-dinitrotoluene (36) concentrations appeared on 1 of  6 process
 sampling   days   in the copper subcategory.  The concentration was
 0.012 mg/1.    The  concentration  value  is    below    the    level
 considered  to   be  achievable  by  specific   treatment  methods.
 Therefore, 2,6-dinitrotoluene   is  not  considered for  specific
 regulation in  this subcategory.

 Methylene chloride (44) concentrations appeared on 3 of  6 process
 sampling   days   in   the   copper   subcategory.   The  maximum
 concentration was 0.016 mg/1.  Two concentration  values are below
 the  level  considered  to  be  analytically  quantifiable.   The
remaining concentration value is below the level  considered to be
achievable  by  specific treatment methods.  Therefore, methylene
chloride is  not  considered  for-  specific  regulation  in   this
subcategory.
                              392

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Methyl  chloride  (45)  concentrations appeared on 1  of 6 Process
sampling  days  in   the   copper   subcategory.    The   maximum
concentration  was  0.028 mg/1.   This concentration is below the
level considered to be achievable by specific treatment  methods.
Therefore,   methyl  chloride  is  not  considered  for  specific
regulation in this subcategory.

Isophorone  (54)  concentrations  appeared  on  3  of  6  process
sampling   days   in   the   copper   subcategory.   The  maximum
c5n?en?rationywas 0.015 mg/1.  Two concentration values are below
the level considered to be analytically quantifiable.  The  other
concentration   value   is   below  the  level   considered  to  be
a?hiSvable by specific treatment methods.  Therefore,  isophorone
is not considered for specific regulation in this subcategory.

4-nitrophenol   (58)  concentrations  appeared   on  2 of 6 process
sailing  days  in   the   copper   subcategory    The   maximum
concentration   was  0.019  mg/1.  This concentration is below the
level considered to be achievable by specific  treatment  methods.
Therefore,  4-nitrophenol  not considered for  specific regulation
in this subcategory.

Pentachlorophenol  (64.) concentrations appeared on 4 of 6  process
sapling   days   in   the    copper   subcategory.   The  maximum
concentration was  0.051 mg/1.  Only one  concentration  value  was
detected  above the   level   considered   to  be  achievable  with
available    specific     treatment      methods..     Therefore
pentachlorophenol   is not   considered" for specific  regulation  irt
this  subcategory.

Phenol  (65)  concentrations appeared on  5  of   6  process   sampling
days   in   the   copper subcategory.  The maximum concentration  was
 0 031  ma/1.   Two   concentration  values  are   below -the <  level
 considered   to   be analytically  quantifiable.   This  concentration
 is below  the  level  considered   to   be  achievable   by-specific
 treatment  methods.    Therefore,  phenol  is  not  considered  for
 specific  regulation in this  subcategory.

 Bis(2-ethvlhexyl)  phthalate  (66) concentrations appeared on all 6
 procesfsampling days in the  copper   subcategory    The  maximum
 Concentration was 0.15 mg/1.  However,  this co^!fratl^e^f^f
 lower    than    the    human    toxicity    level.     Therefore,
 bis(2-ethylhexyl)   phthalate  is  not  considered  for   specific
 regulation in this subcategory.

 Di-n-butyl  phthalate  (68)   concentrations  appeared  on  5 of 6
 process sampling days in the  copper  subcategory.    The  maximum
 Concentration was 0.023 mg/1.  Two concentration values are below
 the  level  considered  to  be  analytically   quantifiable.   The
                                393

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 maximum  concentration   is  below   the   level   considered   to   be
 achievable  by specific  treatment methods.  Therefore, di-n-butyl
 phthalate is not  considered  for   specific  regulation  in  this
 subcategory.

 Diethyl  phthalate  (70)  concentrations appeared on 5 of 6 process
 sampling  days  in   the   copper   subcategory.    The   maximum
 concentration was 0.01 mg/1.  Four  concentration values are below
 the  level  considered   to  be  analytically  quantifiable.   The
 remaining concentration  is  below   the   level  considered  to  be
 achievable  by  specific  treatment  methods.  Therefore, diethyl
 phthalate is not  considered  for   specific  regulation  in  this
 subcategory.

 Dimethyl phthalate  (71) concentrations appeared on 3 of 6 process
 sampling   days   in   the   copper   subcategory.    The  maximum
 concentration was 0.151 mg/1.   One concentration value  is  below
 the  level   considered to be analytically quantifiable.  Only one
 concentration is  above  the  level  considered  achievable  with
 Su?u ? Ze   specific   treatment  methods.    Therefore,  dimethyl
 phthalate is not  considered  for  specific  regulation  in  this
 subcategory.

 Benzo(a)anthracene (72)  concentrations appeared on  1  of 6  process
 «ao?iing,, ays  in  the c°PPer subcategory.  This concentration was
 0.089 mg/1.   Because this toxic  pollutant was  found  on   only  one
 sampling  day,   it  is   not  considered for  specific  regulation  in
 this subcategory.

 Benzo(a)pyrene  (73)  concentrations  appeared on   3  of   6  process
 sampling   days    in   the  copper    subcategory.    The  maximum
 concentration was  0.038  mg/1.  Two  of   the  concentration   values
 are   below   the  level considered  to  be analytically quantifiable.
 Therefore,   benzo(a)pyrene  is  not    considered   for   specific
 regulation in this subcategory.

 Chrysene  (76) concentrations appeared on 4 of  6 process sampling
 nYoo1"      copper subcategory.  The  maximum   concentration  was
 0.108  mg/1.   Two of the  concentration values are below the  level
 considered to be analytically quantifiable.  Therefore,  chrysene
 is not considered for specific regulation in this subcategory.

Acenaphthylene  (77)  concentrations  appeared  on 4 of 6 process
sampling  days  in   the   copper    subcategory.    The   maximum
concentration  was 0.013 mg/1.   Three of  the concentration values
are below the level considered to be  analytically  quantifiable.
Therefore,   acenaphthylene   is   not  considered  for  specific
regulation in this subcategory.
                              394

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Anthracene  (78)  concentrations  appeared  on  3  of  6  process
sampling   days  "in   the   copper   subcategory.   The  maximum
concentration was 0.038 mg/1.   These three  concentration  values
are   either  below  the  level  considered  to  be  analytically
quantifiable  of	inseparable.   Therefore,  anthracene  is   not
considered for specific regulation in this subcategory.
                              i ,-- ..  ... - . -,»sr-,,  ., .  ,- , i j, .. „„
Phenanthrene  (81)  concentrations  appeared  on  3  of 6 process
sampling  days   in   the   copper   subcategory.    The   maximum
concentration  was  0.038 mg/1.  These three concentration^values
are  either  below  the  level  considered  to  be   analytically
quantifiable  or  inseparable.   Therefore,  phenanthrene  is not
considered for specific regulation in this subcategory.

Tetrachloroethylene  (85)  concentrations  appeared  on  3  of  6
process  sampling  days  in   the copper subcategory.   The^aximum
concentration was 0.28 mg/1.   Two of the concentration values are
below the  level  considered   to  be   analytically  quantifiable.
Therefore,  tetrachloroethylene   is  not   considered for specific
regulation in this subcategory.

Trichloroethylene  (87) concentrations  appeared on 1 of 6  process
sampling  days   in the copper subcategory.  The  concentration was
018 mg/1.  Because  this .toxic pollutant was  found on only  one
sampling  day,   is   is  not considered for specific regulation  in
this subcategory.

Arsenic  (115) concentrations  appeared   on   both   of   the   process
sampling   days   in  the    copper    subcategory.    The   maximum
concentration   was   0.016 mg/1.   Arsenic   was    excluded/  from
verification  analysis.   This maximum concentration  is below the
level  considered to  be achievable by specific treatment  methods.
Therefore,   arsenic   is  not  considered for specific  regulation  in
this  subcategory.

Cadmium (11 8)  concentrations  appeared on all  4  process  sampling
days   in  the  copper  subcategory.   The maximum concentration was
 013  mg/1.    All  of  the  concentrations  are  below  the  level
 considered  to   be  achievable  by  specific  treatment  methods.
 Therefore,  cadmium is  not considered for specific  regulation  in
 this  subcategory.

 Cyanide  (121)concentrations appeared on all 6 process sampling
 days  in the copper subcategory.   The  maximum  concentration  was
 0 032 mg/1.    All of the concentration values are below the level
 considered  to  be  achievable  by  specific  treatment  methods.
 Therefore,  cyanide  is not considered for specific regulation in
 this subcategory.
                               395.

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 Mercury  (123)  concentrations appeared on all  4  process   sampling
 days   in   the   copper subcategory.  The maximum concentration was
 0.0005 mg/1.   One of the concentration values is below the   level
 considered  to be  analytically quantifiable.  All of the values
 are below the  level  considered  to  be  achievable  by   specific
 treatment  methods.   Therefore,  mercury  is not considered for
 specific regulation in this subcategory.

 Ammonia concentrations appeared on all 6 process sampling days in
 the copper subcategory.  The maximum concentration was 2.77 mg/1.
 All of the concentration values are below the level considered to
 be toxic in humans.  Therefore,  ammonia is   not  considered  for
 specific regulation in this subcategory.

 Sulfide concentrations appeared on all 6 process sampling days in
 the  copper  subcategory.   The maximum conentration was 1  .-3 mg/1
 Four of the concentration values are below the  level  considered
 to be analytically quantifiable.   The remaining two concentration
 values  are  above  the  levels  considered  to  be achievable by
 specific  treatment  methods  for  their  respective  operations
 However,   sulfide  is  not   considered  for  regulation  in  this
 subcategory.

 Fluoride concentrations  appeared  on all  6  process   sampling  day's
 in   the  copper  subcategory.    The  maximum  concentration   was
 4.2 mg/1.   All  of  the  concentration values  are  below  the  level
 considered  to   be  achievable  by   specific   treatment methods.
 Therefore,  fluoride  is not   considered  for  regulation  in  this
 subcategory.

 Iron  concentrations  appeared  on  all 3 process sampling  days  in
 the copper  casting subcategory.   The   maximum concentration  was
 0.07   mg/1.   All  of the concentration values are below the level
 considered  to   be achievable  by  specific   treatment  methods.
 Therefore,  iron is not considered for  specific regulation  in  this
 subcategory.
                                           j
 Ferrous Casting Subcategory

 Pollutants Considered for Specific
 Regulation in the Ferrous Casting Subcateqorv

 Based  on sampling results and careful examination of the  ferrous
 casting  subcategory  manufacturing  processes  and   raw   waste
materials, thirty-five pollutants were selected for consideration
 for   specific   regulation   through  effluent  limitations  and
standards for this subcategory.   These pollutants were  found  in
raw  wastewaters  from  processes  in  this  subcategory  and are
amenable to control by identified wastewater treatment practices.
                              396

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(eg.,      activated      carbon      adsorption,       chemical
precipitation-sedimentation). - Disucssions  of  these pollutants
follow.                                   .             .._...

Acenaphthene (1) values were detected on 27 of  the  32  sampling
days  in  this  subcategory.  The maximum concentration found was
0 081 mg/1.  Some of the concentrations  are  above  the^ treated
effluent  levels  achievable  with  available  specific treatment
methods.  Acenaphthene may be found in dust collection  and  sand
washing wastewaters and in various casting sand additives.

2-chlorophenol  (24) values were detected on 17 of the  32^sampling
days  in  this  subcategory.  The maximum concentration found was
0.082 mg/1.  Some of these concentrations are above  the  optimum
expected  30-day  average treated effluent levels achievable with
available treatment methods.  This  pollutant  is  present  as   a
result  of  the materials used in Discussions of  these pollutants
follow.  the melting process.                                    _.

2,4-dichlorophenol  (31) values were detected  on  14   of  the   32
sampling  days  in  this  subcategory.  The maximum concentration
found was 0.372 mg/1.  Some  of the concentrations are  above  the
treated   effluent  levels   achievable  with  available   specific
treatment methods.  This pollutant  originates   i«: the-,  products
used in the casting processes  (ie., casting sand  additives).

2,4-dimethylphenol   (34)  values  were  detected  on  22  of^the.32
sampling days  in  this  subcategory.   The  maximum  concentration
found  was   1.2 mg/1.  Some  of these  concentrations are  above the
optimum expected  30-day    average   treated    effluent   levels
achievable  with  available  treatment  methods.   This pollutant may
also originate in the  products used  in  the   casting   and melting
porcesses.

Fluoranthene   (39)   values  were  detected  on  30  of the 32 sampling
days in "this  subcategory.   The maximum   concentration .found was
 1.5 mg/1.    Some   of   the   concentrations  are   above the? treated
 effluent  levels  achievable  with  available  specific  treatment
 methods.    This  contaminant's   presence  is  related  to the  use  of
 coke in the melting process.  As  the  coke   is  combusted,   this
 pollutant  may be  evolved as a by-product.

 2,4-dinitrophenol  (59)   values   were  detected  on  8^. of-the_32.
 sampling  days in  this  subcategory.    The  maximum  concentration
 found  was  0.13  mg/1.   Some of the concentrations are above the
 treated  effluent  levels  achievable  with  available   specific
 treatment methods.  This pollutant's presence can^also_be related
 to  the  raw  materials (coke and oily scrap)  .used in the melting
 processes.                                ,
                                397

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  4,6-dinitro-o-cresol  (60)  values  were  detected  on  1 2   of   the  32
  fon^f   n^  in/1this   subcategory.   The  maximum concentration
  found was  0.137  mg/1 .  Some of  these concentrations are above the
  optimum  expected   30-day   average    treated    effluent    levels
  be found ?„ fhth available treatment methods.   This pollutant may
  be found in this subcategory 's  process wastewaters  as  a result of
  the raw materials used in  the melting process.

  N-nitrosodiphenylamine (62) values were  detected on 1 4 of  the  32
  ?an£;r!!g   cay,S   il]1 this   subcategory.   The  maximum concentration
  found was  5.95 mg/1.  Some of the concentrations are  well  above
  the  treated  effluent  levels  achievable with  available specific
  treatment methods.   This pollutant's presence is related   to   the
  raw materials used  in the melting process.

 Pentachlorophenol   (64)  values  were  detected  on  1 3 of the  32
 Snn£iing dar,vn t/^S  subcategory.    The  maximum  concentration
 found  was 0.47 mg/1.   Some of these concentrations are above  the
 optimum  expected  30-day   average   treated   effluent   levels
                   aailable  treatment  methods.  The presence of
                        aSSOCiated *ith the raw materials used  in
                         det?cted on 27 of the 32 sampling days in
      o   h              maximum concentration found was 7.4 mg/1.
 Some of the concentrations are well above  the  treated  effluent
 Phenof'^nriSlf16-  Wlt?  arilable  sPedfic  treatment methods^
 Phenol s presence is related  to the use of coke and oily scrap in
 the  melting process  and  to the binders and other  additives  used
 in CHStixncj
Butyl  benzyl phthalate  (67) values were detected on  23  of  the  32
Knni1"9   yn ^ thi/S  subcategory.   The  maximum  concentration
found  was  0.32 mg/1.   Some of the concentrations are  above the
treated  effluent  levels  achievable  with  available    specific
treatment  methods.   This pollutant's presence  is related  to the
materials used in the casting and melting processes.

Benzo( a) anthracene (72) values were detected  on  15  of  the   32
fnnSi^L naXS-7 in/-,this,  subcategory.  The maximum concentration
found was 0.047 mg/1.  Some of these concentrations are above the
optimum  expected  30-day   average   treated   effluent    levels
achievable  with available treatment methods.  This pollutant may
be found as a result of the raw materials  used  in  the  melting


          (76)  values were detected on 22 of the 32 sampling days
             Categ°ry;  ,?he  maximum  concentration  found   was
          .    Some  of  the  concentrations are above the treated
Chrysene

S VQ
U.U29
                              398

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effluent levels  achievable  with  available  specific  treatment
methods    This  pollutant's  presence  is  related  to  the  raw
mlte??lis used inPthe melting .process  and  to  the ^ binders  and
other additives used  in the casting sand.  This polluant is also
a combustion by-product of coke and the sand additives.

Arenaohthvlene (77) values were detected on 25 of the 32 sampling
davS  in  thi?  subcategory.  The maximum concentration found was
043 mg/1 .  S me of thele concentrations are  above  the  optimum
exacted  30-day  average treated effluent levels achievable with
Ivatlable  treatment  methods.   This   pollutant's   origin    is
IsSociatSd with the raw materials used  in the melting process.

Fluorene   (80) values were detected on  27 of the 32  sampling days
in   tM.1  subcategory.   The  maximum   concentration found   was
18  mg/1    Some  of  the  concentrations  are  above the treated
effluent levels  achievable  with  available  specific  treatment
methods.   As  with  chrysene,   this  pollutant  is  a  combustion
by-product of  coke and  the sand  additives.

Phenanthrene  (81)  values were detected  on  27 of the   32  sampling
davS  in   this subcategory.  The maximum  concentration found was
OH mg/1 .  Some of  theSe  concentrations  are  above   the  optimum
expected   30-day   average  treated effluent levels  attainable with
available  specific treatment  methods.

Pyrene (84)  values were detected on  29  of  the  32 sampling days  in
this subcategory.   The  maximum  concentration  found was  3.3  mg/1.
SomS  of  thele concentrations are well  above  the optimum  expected
 30-day average treated  effluent levels  achievable  with  available
 treatment methods.   This pollutant  may  ^^              UStl°n
 by-product of the casting sand binders  and other
(85)
values  were  detected on 27 or the 32
 Tetrachloroethylene

      "  ?yf Is

 raw materials used in the melting process.

 Antimony (114) values were detected on all  19  sampling  days  in
 this  subcateqorv.  The maximum concentration found was  1.4 mg/1.
 ISml'of thSs? concentrations , are  above   the  optimum  expected
 30-dav  average treated effluent  levels achievable with  available
 treatment methods.  The presence  of this pollutant is related  to
 its use as  an alloy.
 Arsenic   (115) values were detected on 25  of the  27 sampling days
 tn  this  subcategory.   The  maximum  concentration  found    was
                                399

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     i      i*  -,Some  Of  the
  effluent levels  achievable

  wlstewlters  Sar1i,Utant iS
  meftfnfprocess   ^  1S  *
                               concentrations are above the treated
                               with  available  specific  treatment
                               resfnt.in thi* subcategory ' s p?oc1ss
                               contaminant  - the coke used in the
  Cadmium (118)  values were detected on 25 of the 26 sampling  days
  *n   this  subcategory.    The  maximum  concentration  foCnd  was
             Some of these concentrations  are  above  the  optimum
            30-day  average treated effluent levels achievable with
            treatment methods.   The presence of this  pollutant  is
                    use as  an alloy.   It may also be present as a
                    of plated materials in the

  Chromium
  in  this
  3.1 mg/1,
  effluent
  methods.
  alloying
  sands.
          (I,!2i ^alues were detected on 26 of the 27 sampling days
           subcategory    The  maximum  concentration  found   waS
             borne  of  the  concentrations  are  above the treated
            Th s  non^n^  Wlth  available  specific  trea?men?
            This  pollutant's presence is related to its use as an
          material or as a result of  its  washing  from  chromite
 Copper (120)  values were detected on all 60 sampling davs in
     -                                                  "
                                                   te


Lead  (122)  values  were  detected on  all  63  sampling davs  in
Iom2ao?g?hr    The  maXimUm   ^centration  Sn^w^s 0 mg/
 Ha?f Se^a%eC?rneae^ae^
                  -   This pollutant
Nickel  (124) values were detected on 58 of the 59  sampling  days
0 98 la/1  ^oSfo?0^'   The  maximum  concentration  foSnd  wal
                       SS Concentrations are  above  the  optimum
pollutant is related to its use ,as, an alloy in
pollutant
                     as a contaminant in the scrap charge
                              400

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Total suspended solids values were^found on a*y
The   maximum  concentration  found  was  39,000 mg/1.   The  TSS
concentrations are greater than the typically achievable effluent
levels and are, therefore, considered  for  specific Regulation-
in  addition, the control of TSS will result in the control, to a
certain extent, of several toxic pollutants.

Oil and grease values were detected on all 63 sampling days.  The

 once^r .t^S^tT than° B^fluXt 1=3. t&c.ft
achievable  Si 1 and grease is considered for specific  regulation
in this subcategory.

nH  can  be  controlled  within  the  limits  "of 7.5 to 10.0-with-
available Specific treatment methods and is therefore  considered
for specific regulation  in this subcategory >•

Ammonia , values  were  detected  on  all   78  sampling days.  .The
maxtmum value  detected was  120 mg/1   As many of^these valuesjjre
well  above  the treated effluent levels  achievable  with  available
treatment   methods,   ammonia  is considered f°VTif ^noUutant
subcategory.   Ammonia's presence  as   a   wastewater   P°;^utant
results  from  the   various materials used in casting  and melting
operations.

Sulfide values were   detected on   all   63  sampling^ days.    The
materials  used
casting
 pollutant is related to the various
 and melting operations.

 Fluoride  values "wire" detected  on all 63 sampling days in this
 subcategory.  The maximum level found was 242^mg/l,;  As  many  of
 IhesS  values  are  well  above  the  attainable treated effluent
 levels, fluoride is considered for specific  regulation  in  this
 ^category.   Fluoride's  presence  as a wastewater pollutant is
 associated with the fluxes used in melting operations.      r   -

 Manganese values were detected on all 63 sampling ^days  in ^this
 subcategory.   The  maximum  concentration detected was 392_mg/l.
    many of these values are greater  than  the  treated  effluent
       * attainable  with  available  specific  treatment .methods
 manganese   is  considered  for  specific   regulation   in   this
 sSbcategory.  Its presence is related to its use as an alloy.

 Iron  values  were detected on 48 of the 49 sampl tng _ days _in this
 subcategory.  The maximum dissolved iron   concentration  detected
                                401

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 was   26 mg/1.   Iron  is  considered  for specific  regulation  in  this
 subcategory,  because   it   is   the primary   constituent   of   the
 products of this subcategory.

 Phenols  values  were   detected  on  all 79 sampling days  in  this
 subcategory.  The  maximum  concentration  found  was   16.5 mg/1
 Some  of these concentrations are  substantially above the  optimum
 expected 30-day average treated effluent levels  achievable   with
 available  treatment  methods.   This  pollutant, detected by the
 4-AAP wet chemistry  technique,  encompasses  a  variety  of   the
 individual  phenolic  compounds.   Its presence is related to the
 raw materials used in the melting process and to the binders   and
 additives used in casting sand.

 Pollutants Not Considered for Specific
 Regulation in the Ferrous Casting Subcateqory

 A  total  of  one  hundred and two pollutants that were evaluated
 were  eliminated  from   further   consideration   for   specific
 regulation   in  the  ferrous  casting  subcategory.    Twenty-six
 pollutants were dropped from further consideration,  because their
 presence  in  raw   process   wastewaters   was   not   detected.
 Thirty-seven    pollutants    were    eliminated   from   further
 consideration,  because the  concentrations   of  these  pollutants
 were less  than  the  analytically quantifiable limits.

 The  remaining   thirty-nine  pollutants   were  found  to be  present
 infrequently, found at  levels  below  those   usually   achieved   bv
 specific   treatment    methods,    or   present  as   a  result   of
 site-specific   conditions.    Discussions  of    these    pollutants
 follow.

 Benzene   (4) concentrations  appeared on 26 of  32 process sampling
 days   in  the    ferrous    casting   subcategory.    The   maximum
 concentration was 0.361  mg/1.  Seventeen  concentrations  are below
 the  level  considered  to be analytically quantifiable.  Only  one
 of  the  remaining  values   is  greater   than  the  concentration
 considered  to  be  achievable  with available specific  treatment
 methods.  Therefore,  benzene  is   not  considered  for  specific
 regulation in this subcategory.

 Carbon  tetrachloride   (6)   concentrations  appeared  on 14 of 32
 process sampling days in the ferrous  casting  subcategory     The
maximum  concentration  was  0.016 mg/1.   Thirteen concentrations
 are below the level considered to be  analytically  quantifiable.
The remaining value is lower than the concentration considered  to
be   achievable   with   available  specific  treatment  methods.
Therefore,  carbon tetrachloride is not  considered  for  specific
regulation in this subcategory.
                              402

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1,2,4-trichlorobenzene  (8)  concentrations  appeared  on 6 of 32
process sampling days in the ferrous  casting  subcategory.   The
Maximum  concentration  was  O..30mg/l.   Five concentrations are
below the level considered to be analytically quantifiable.  Only
one concentration value is greater than the level  considered -to
be   achievable   with   available  specific  treatment  methods.
Therefore., 1,2,4-trichlorobenzene is not considered for  specific
regulation in this subcategory.

1 1 1,-trichloroethane  (11)  concentrations appeared on 18 of 32
process sampling days in the ferrous  casting  subcategory,.   The
maximum  concentration  was  0.075 mg/1.  Fourteen concentrations
are below the level considered to be  analytically  quantifiable.
The  remaining  values  are  all  lower  than  the  concentration
considered to be achievable  with  available  specific  treatment
methods.   Therefore, 1,1,l-trichloroethane is not considered for
specific regulation in  this subcategory.

Bis(2-chloroethyl) ether (18) concentrations appeared on 4 of  32
process  sampling  days in the ferrous casting  subcategory.  The
maxium concentration was 0.014 mg/1.    Three  concentrations  are
below  the level considered to be analytically quantifiable.  The
remaining value is lower than the concentration  considered to  be
achievable with available  specific treatment .methods.   Therefore,
this toxic pollutant is not considered  for specific regulation in
this subcategory.

 2,4,6-trichlorophenol   (21)  concentrations  appeared on  14  of 32
process, sampling days  in the ferrous   casting  subcategory.   The
maximum   concentration  was  0.195 mg/1.   All   but  three of the
 concentrations  are below the level considered to be  analytically
 quantifiable.   Therefore,  2,4,6-trichlorophenol  is not  considered
 for  specific  regulation in this subcategory.

 Parachlorometacresol   (22)  concentrations   appeared  on   8  ofJJ2
 process sampling days  in the ferrous   casting  subcategory.   The
 maximum   conentration   was  0.536 mg/1.    Four concentrations are
 less  than   the analytically  quantifiable   limit.     Only    two
 concentrations  are   above  the  level  considered to  be  achievable
 with   available    specific   treatment   methods.      Therefore,
 parachlorometacresol  is not considered for specific  regulation, in
 this subcategory.              -    -     ( .      ;

 Chloroform    (23)   concentrations   appeared   on   all   32   process
 sampling  days in the ferrous casting   subcategory.    The   maximum
 concentration  was  0.692  mg/1.    Sixteen concentrations  are less
 than the  analytically quantifiable  limit.   Fifteen concentrations
 are lower then that concentration   considered  to  be  achievable
                               403

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 with available specific  treatment methods.  Therefore,  chloroform
 is not considered for specific regulation  in this subcategory.

 1,2,-trans-dichloroethylene   (30) concentrations appeared on  1 of
 32 process sampling days  in  the  ferrous  casting  subcategorv.
 That  concentration  was  0.033 mg/1.  The concentration value is
 lower than the concentration  considered  to  be  achievable  with
 available      specific     treatment     methods,      therefore,
 1,2-trans-dichloroethylene  is  not   considered   for   specific
 regulation in this subcategory.                          »p«i.iiit.

 1,3-dichloropropylene  (33)   concentrations  appeared  on 2 of 32
 process sampling days in the ferrous  casting  subcategory.   The
 maximum  concentration  was  0.24 mg/1.    Only  one concentration
 value is above  that  level   considered  to  be  achievable  with
 available     specific     treatment     methods.       Therefore,
 1,3-dichloropropylene is not considered for  specific  regulation
 in this subcategory.

 Bis(2-chloroethoxy)  'methane (43)  concentrations appeared on 6 of
 32 process sampling  days in  the ferrous  casting subcategorv.   The
 maximum concentration was 0.045 mg/1.   Four  concentrations  are
 below  the level  considered  to be analytically  quantifiable.   All
 conentration  values  are  lower  than the  concentration  considered
 ThPrplnrf  ihT!  JS ."^available   specific   treatment methods.
 Therefore,  this  toxic pollutant is not  considered   for  specific
 regulation in this subcategory.

 Methylene  chloride   (44)  concentrations   appeared   on  26  of 32
 process sampling  days  in  the ferrous   casting   subcategory     The
 maximum   concentration  was  2.05 mg/1.   Twelve  concentrations  are
 below the level considered to  be analytically quantifiable.  Only
 two of the  remaining  concentrations are  greater -than  the   level
 considered  to be  achievable by specific treatment methods.  Both
 of those  concentrations are from one  plant.  Therefore,  methylene
 cnionde  is   not   considered   for  specific  regulation  in  this
 subcategory.

 Methyl  chloride   (45) concentrations appeared  on 1 of  32 process
 sampling  days  in  the   ferrous   casting   subcategory      The
 concentration  was  0.012 mg/1.  Because this toxic pollutant  was
 found at  only one plant, at a  level lower than  the  concentration
 considered  to  be  achievable  with  available  specific  treatment
methods,  methyl  chloride  is  not    considered   for   specific
regulation in this subcategory.
Bromoform  (47)
sampling  days
concentration  was
 concentrations  appeared  on  1   of  32  process
in  the   ferrous   casting   subcategory.    The
    0.018 mg/1.  Because this toxic pollutant was
                              404

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found at ony one plant, at a level lower than  the  concentration
considered  to  be  achievable  with available specific treatment
methods, bromoform is not considered for specific  regulation  in
this subcategory.

Trichlorofluoromethane  (49)  concentrations  appeared on 1 of 32
process sampling days in the ferrous  casting  subcategory.   The
concentration  was  0.12 mg/1.    Because this toxic pollutant was
found at only one plant, at a level lower than the  concentration
considered  to  be  achievable  with available specific treatment
methods, trichlorofluoromethane is not  considered  for  specific
regulation in this subcategory.

Chlorodibromomethane   (51)  concentrations  appeared  on  1 of 32
process sampling days in the ferrous  casting  subcategory.   The
concentration  was  0.019 mg/1.  Because this toxic pollutant was
found at only one plant, at a level lower than the  concentration
considered  to  be  achievable  with available specific treatment
methods, Chlorodibromomethane  is  not  considered  for  specific
regulation in this subcategory.

Isophorone  (54)  concentrations  appeared  on   10  of 32 process
sampling days in the ferrous casting  subcategory.   The  maximum
concentration  was  0.074 mg/1.   Eight  concentration values are
below the level considered to be analytically quantifiable.  Only
one of  the remaining concentration  values  is   above  the  level
considered  to  be  achievable  by  specific  treatment  methods'.
Therefore, this toxic pollutant is not considered for  regulation
in this subcategory.

Naphthalene   (55)  concentrations  appeared  on  29 of 32 process
sampling days in the ferrous casting  subcategory.   The  maximum
concentration  was'0.13 mg/1.  Seventeen concentration values are
below the level considered to be analytically quantifiable.  Some
concentrations are above the level considered  to  be  achievable
with  available  specific treatment methods.  However, all  of the
concentrations  are  below  human  toxicity  levels.   Therefore,
naphthalene   is  not   considered  for specific regulation  in this
subcategory.

Nitrobenzene  (56) concentrations appeared  on  5 of  32  process
sampling  days   in  the ferrous casting subcategory.  The maximum
concentration was 0.86 mg/1.  Three concentrations are less than
the  analytically  quantifiable limit.  Only one of the remaining
two concentration values  is above  the  level  considered   to  be
achievable with available specific treatment methods.  Therefore,
nitrobenzene  is  not   considered for specific regulation  in this
subcategory.
                               405

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 2-nitrophenol (57) concentrations appeared on 15  of  32  process
 sampling  days  in  the ferrous casting subcategory.  The maximum
 concentration was 0.052 mg/1.    Eleven  concentrations  are  less
 than  the  analytically  quantifiable  limit.   Three of the four
 remaining concentration values are less than the level considered
 to be achievable by specific treatment methods.   Only the maximum
 concentration is at the level  considered to  be  achievable  with
 available  specific  treatment methods.  Therefore,  2-nitrophenol
 is not considered for specific regulation in this subcategory.

 4-nitrophenol (58) concentrations appeared on  7  of  32  process
 sampling  days  in  the ferrous casting subcategory.  The maximum
 concentration was 0.16 mg/1.   Three concentrations are less  than
 the analytically quantifiable  limit.   Three of the remaining four
 concentrations   are   less  than  the  level  considered  to  be
 achievable by  specific  treatment  methods.   Only   the  maximum
 concentration is above the level considered to be achievable with
 available  specific  treatment methods.  Therefore,  4-nitrophenol
 is not considered for specific regulation in this subcategory.

 Bis(2-ethylhexyl)  phthalate (66) concentrations  appeared on 31  of
 32 process sampling days in the ferrous casting  subcategory.  The
 maximum concentration was 0.42 mg/1.    Ten  concentration  values
 are  below  the  level considered to be analytically  quantifiable.
 Many of the concentrations are above  the level that  is considered
 achievable with  available specific treatment   methods.    However,
 all  of  the  concentrations   are  below  human   toxicity levels.
 Therefore,  bis(2-ethylhexyl)   phthalate  is  not   considered  for
 specific regulation in this subcategory.

 Di-n-butyl   phthalate  (68)  concentrations  appeared  on 30 of  32
 process sampling days in the ferrous   casting subcategory.   The
 maximum  concentration  was 0.598  mg/1.   Seventeen concentrations
 are less than  the  analytically quantifiable limit.   All   of  the
 concentrations   are   below human   toxicity  levels.    Therefore,
 di-n-butyl  phthalate  is  not considered  for  regulation   in  this
 subcategory.

 Di-n-octyl   phthalate   (69)  concentrations  appeared  on  5 of  32
 process  sampling days  in  the ferrous   casting subcategory.   The
 maximum   concentration   was 0.054  mg/1.   Three concentrations are
 less   than   the  analytically   quantifiable  limit.    Only   two
 concentrations   are   slightly   above   the   level  considered to  be
 achievable   with   specific    treatment    methods.    Therefore,
 di-n-octyl phthalate  is  not considered  for  specific  regulation  in
 this subcategory.

Diethyl  phthatlate   (70)  concentrations   appeared  on  24 of  32
process sampling days  in the ferrous   casting  subcategory.   The
                              406

-------
maximum  concentration  was  0.027 mg/1.  Fourteen concentrations
are less than the analytically  quantifiable  limit.   All  other
concentrations  are  below  human  toxicity  levels.   Therefore,
diethyl phthalate is not considered for  specific  regulation  in
this subcategory.

Dimethyl  phthalate  (71)  concentrations  appeared  on  25 of 32
process sampling days in the ferrous  casting  subcategory.   The
maximum  concentration was 2.9 mg/1.  Ten concentrations are less
than   the   analytically   quantifiable   limit.    All    other
concentrations   are  much  lower  than  human  toxicity  levels.
Therefore, dimethyl phthalate  is  not  considered  for  specific
regulation in.this subcategory.

3,4-benzofluoranthene  (74)  concentrations  appeared  on 2 of 32
process sampling days in the ferrous  casting  subcategory.   The
maximum concentration was 0.019 mg/1.  One concentration value is
below  the  level  considered  to  be  analytically quantifiable.
Because this  toxic  pollutant  was  found  at  only  one  plant,
3,4-benzofluoranthene  is  not considered for specific regulation
in this subcategory.

Benzo(k)fluoranthene (75) concentrations  appeared  on  2  of  32
process  sampling  days  in the ferrous casting subcategory.  The
maximum concentration was 0.018 mg/1.  One concentration value is
below the  level  considered   to  be  analytically  quantifiable.
Because  this  toxic  pollutant  was  found  at  only  one plant,
benzo(k)fluoranthene is not considered for specific regulation in
this subcategpry.

Toluene (86) concentrations appeared on 20 of 32 process sampling
days  in  the    ferrous   casting,  subcategory.    The   maximum
concentration  was  0.015 mg/1.   Fifteen concentrations are less
than the quantifiable limit.   All other concentrations are  below
the  level  that  is  considered  to  be  achievable  by specific
treatment methods.  Therefore,  toluene   is  not  considered  for
specific regulation in this subcategory.

Trichloroethylene   (87)  concentrations   appeared   on   18  of  30
process sampling days in the ferrous  casting  subcategory.   The
maximum  concentration  was 0.77 mg/1.  Eleven concentrations are
less than  the   analytically   quantifiable   limit.   Six  of  the
remaining  concentration values are below.the level considered to
be  achievable   with  available   specific   treatment   methods.
Therefore,  trichloroethylene   is   not  considered  for  specific
regulation in this  subcategory.

Endrin  aldehyde  (99) concentrations appeared on  6 of   21  process
sampling  days   in  the  ferrous casting subcategory.   The maximum
                              • 407

-------
 concentration was 0.019 mg/1.   Four concentrations are below  the
 analytically  quantifiable  limit.    The other two concentrations
 were found at the same plant.   Therefore, endrin aldehyde is  not
 considered for specific regulation  in this subcategory.

 b-BHC-Beta  (103)  concentrations  appeared  on  10 of 21 process
 sampling days in the ferrous casting  subcategory.    The  maximum
 concentration  was  0.019 mg/1.   Eight  concentration values are
 less than the  analytically  quantifiable  limit.    Because  this
 pollutant  was found on only one process sampling  day, b-BHC-Beta
 is not considered for specific regulation in this  subcategory.

 Beryllium (117)  concentrations  appeared  on  46  of  48  process
 sampling  days  in  the ferrous  casting subcategory.   The maximum
 concentration was 0.04 mg/1.   Forty-two concentrations  are  less
 than    the   analytically   quantifiable   limit.     All   other
 concentrations are below the level  considered  to   be  achievable
 with  available  specific treatment  methods.   Therefore,  beryllium
 is not considered for specific regulation in this  subcategory.

 Cyanide  (121)   concentrations  appeared  on  67  of   69  process
 sampling  days  in  the ferrous  casting subcategory.   The maximum
 concentration was 0.35 mg/1.   Only  three concentrations  are above
 the level  considered to be  achievable   with  available   specific
 treatment   methods.    Therefore,  cyanide  is  not  considered for
 specific regulation  in this  subcategory.

 Mercury  (123)   concentrations  appeared  on  56 of   57  process
 sampling  days   in  the ferrous  casting subcategory.   The maximum
 concentration  was 0.015 mg/1.  Eighteen concentrations are  below
 the analytically quantifiable   limit.   All  other  concentrations
 are below  the  level  considered to be  achievable with  available
 specific treatment methods.  Therefore,  mercury  is  not considered
 for specific regulation in this  subcategory.

 Selenium  (125)   concentrations  appeared on  25   of  27  process
 sampling days  in  the  ferrous casting  subcategory.    The  maximum
 concentration  was 2.2  mg/1.   Twenty-two  concentrations  are  below
 the  analytically  quantifiable  limit.    Two   other   concentrations
 are  below  the   level  considered to be achievable  with  available
 specific  treatment  methods.    Therefore,   selenium   is   not
 considered for specific  regulation  in this subcategory.

Silver  (126) concentrations appeared on  14 of 16 process sampling
days    in   the    ferrous   casting   subcategory.    The  maximum
concentration was  0.11 mg/1.   Nine  concentrations are  below  the
analytically quantifiable limit.   All other concentrations are at
or  below  the  level   considered to be achievable with  available
                              408

-------
treatment methods.    Therefore,   silver  is  not  considered  for
specific regulation in this subcategory.

Thallium  (127)  concentrations  appeared  on  14  of. 16 process
sampling days in the ferrous casting  subcategory.   The  maximum
concentration  was 7.0 mg/1.   Twelve concentrations are below the
analytically quantifiable  limit.   Because  this  pollutant  was
found  on  only  two  process  sampling  days,  thallium  is  not
considered for specific regulation in this subcategory.

Xylene (130) concentrations appeared on 7 of 28 process  sampling
days   in   the   ferrous   casting   subcategory.   The  maximum
concentration was 0.023 mg/1.  Six concentration values are below
the analytically quantifiable limit.  Because this pollutant  was
found  on  only  one  sampling  day, xylene is not considered for
specific regulation in this subcategory.

Lead Casting Subcategory

Pollutants Considered for Specific
Regulation .in the Lead Casting Subcateqory

Based on sampling results and careful   examination  of  the  _lead
casting  subcategory  manufacturing  processes and raw materials,
six pollutants  were  selected   for  consideration  for  specific
regulation  through  effluent  limitations and standards for this
subcategory.  These pollutants were found  in raw wastewaters from
processes in this subcategory and  are  amenable  to   control   by
identified wastewater treatment  practices  (e.g., activated carbon
adsorption,  chemical  precipitation-sedimentation).   Discussions
of these pollutants follow.


Copper was detected at a  level   of  0.046  mg/1   in   the  process
wastewaters  sampled  in   this   subcategory.    Copper  is used  for
electrical conductors in  charging operations  and may   be  present
in  process equipment.  While  it is not a  primary raw  material  in
this  subcategory,    copper   may   be    introduced    into   this
subcategory's  process wastewaters by corrosion  of equipment. ,

Lead  was  detected   at   a  level   of   0.85   mg/1   in  the process
wastewaters sampled in this  subcategory.   This  value  is  above  the
level which can be  achieved  by specific treatment methods.

Zinc was detected  at  a   level   of   0.014  mg/1   in   the  process
wastewaters   sampled   in   this   subcategory.    While   it  is  not a
primary  raw material  in  this subcategory,  zinc  may  be  introduced
 into   this  subcategory's process wastewaters as  a  constituent of
the  cast metal.
                               409

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 Oil and grease was detected at a level of <5 mg/1 in the  process
 wastewaters  sampled  in this subcategory.  This pollutant can be
 removed by conventional treatment methods.

 Suspended solids was detected at a level of 5 mg/1 in the process
 wastewaters sampled in this subcategory.  The  TSS  generated  in
 this  subcategory  may  consist  of  large  proportions  of toxic
 pollutants.

 The pH of the process wastewaters sampled in this subcategory was
 7.7.  pH can be controlled within the limits of 7.5 to 10.0  with
 available specific treatment methods.

 Pollutants Not Considered for Specific
 Regulation in the Lead Casting Subcategory

 Analytical  data  for the lead casting subcategory was originally
 collected as part of a study for the Battery Manufacturing  Point
 Source Category.   The screening data for toxic organic pollutants
 in   this  category demonstrated that these pollutants need not be
 considered for specific regulation.   As a  result,   analyses  for
 the  toxic  organic  pollutants were not performed on the sampled
 process  wastewaters  of  this  subcategory.    As  lead   casting
 operations  are  associated  with  the  manufacture  of lead-acid
 batteries,   data  from  the  battery  manufacturing  category  is
 considered to be applicable to the  lead casting subcategory.   The
 toxic  organic  pollutant  dispositions  presented  in Tables VI-I
 through VI-4 for the lead  casting   subcategory  are   based   upon
 battery  manufacturing  category data.    Refer  to  the   Battery
 Manufacturing Point  Source  Category  Development  Document  for
 additional    details   on  the  sampling  carried  out  at  these
 operations.

 A total  of  one hundred thirty-one pollutants were eliminated from
 further  consideration  for specific regulation  in  the  lead  casting
 subcategory.   Eighty-three  pollutants were dropped  from   further
 consideration,   because   their presence in raw  process  wastewater
 was  not  detected.   Thirty-one   pollutants  were  eliminated   from
 further    consideration,  because the   concentrations  of   these
 pollutants  were  less than the  analytically quantifiable limits.
                                           i
 The  remaining  seventeen  pollutants   were  found  to  be  present
 infrequently,  found   at  levels  below  those usually achieved by
 specific  treatment  methods, or  found  only  once.

 The  two  toxic  inorganic pollutants not   considered  for  specific
 regulation  were  detected  at  levels less than 0.003 mg/1 in the
process  wastewaters   sampled    in    this   subcategory.    These
                              410

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concentrations  are
treatment methods.
below  those levels achievable with specific
The five non-conventional pollutants not considered for  specific
regulation   were  detected  at  the  following  levels  in  this
subcategory's sampled process wastewaters:
            Ammonia(N)
            Fluoride
            Manganese
            Iron
            Phenol sUAAP)
                0.05  mg/1
                1.1   mg/1
                0.005 mg/1
                0.32  mg/1
                0.012 mg/1
These concentrations are below  those  levels  considered  to  be
achievable  with  specific  treatment  methods.  Therefore, these
pollutants are not considered for  specific  regulation  in.,  this
subcategory.

Seven of ten toxic organic pollutants not considered for specific
regulation   were   detected   at   levels   considered   to   be
environmentally insignificant.  The other three  pollutants  were
detected  at  levels below those considered to be achievable with
specific treatment methods.  Refer to the  Battery  Manufacturing
Point   Source   Category  Development  Document  for  additional
details.                  j

Magnesium Casting Subcateqory

Pollutants Considered for Specific
Regulation in the Magnesium Casting Subcategory

Based on sampling  results  and  a  careful  examination  of  the
magnesium  casting  subcategory  manufacturing  processes and raw
materials, seven pollutants were Selected for  consideration  for
specific  regulation  through  effluent limitations and standards
for  this  subcategory.   These  pollutants  were  found  in  raw
wastewaters  from  processes  in this subcategory and are amenable
to control by identified wastewater  treatment  practices  (e.g.,
activated      carbon     adsorption,     oxidation,     chemical
precipitation-sedimentation).  Discussions  of  these  pollutants
follow.

Zinc   (128)  values  were detected on all 6 sampling days in this
subcategory.  The maximum concentration found was 1.7 mg/1.  Some
of these concentrations are above  the  optimum  expected  30-day
average   treated   effluent  levels  achievable  with  available
specific treatment methods.   Contamination of process wastewaters
with this pollutant results from contact of process  waters  with
process equipment and facilities.
                               411

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Total  suspended solids were found on all 6 sampling days  in this
subcategory.  The maximum concentration was 63 mg/1.  Several  of
the  TSS  concentrations  are  greater  than the treated effluent
levels  achievable   with   available   treatment   technologies.
Therefore, this pollutant is considered for specific regulation.
                                          j-
Oil  and  grease values were found on all 6 sampling days  in this
subcategory.  The maximum concentration was 17 mg/1.  As some  of
the  concentrations  are greater than the treated effluent levels
typically achievable with available specific  treatment  methods,
oil  and  grease  is  considered  for specific regulation  in this
subcategory.

pH can be controlled within  the  limits  of  7.5  to  10.0  with
available   specific   treatment   methods,   and   is  therefore
considered for specific regulation in this subcategory.

Sulfide values were detected on  all  6  sampling  days  in  this
subcategory.   The  maximum concentration was 21.0 mg/1.  As some
of these values are greater  than  the  treated  effluent  levels
attainable with specific treatment methods, sulfide is considered
for specific regulation in this subcategory.

Manganese  values  were  detected  on all 6 sampling days  in this
subcategory.   The  maximum  concentration  was  0.42 mg/1.    As
several  of  these  values  are greater than the treated effluent
levels achievable with available specific treatment  in  methods,
manganese   is   considered   for  specific  regulation  in  this
subcategory.

Phenols values were detected on  all  6  sampling  days  in  this
subcategory.   The  maximum  concentration  found  was 2.15 mg/1.
Some of these  concentrations  are  above| the  optimum  expected
30-day  average treated effluent levels achievable with available
treatment methods.   This pollutant,   detected  by  wet  chemistry
techniques  (4-AAP),  encompasses  a  variety  of  the individual
phenolic compounds.   Its  presence  is  related  to  the  various
casting sand additives and binders.
                              412

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Pollutants Not Considered for Specific
Regulation i_n the Magnesium Casting Subcateqory

A total of one hundred thirty pollutants that were evaluated were
eliminated  from further consideration for specific regulation in
the magnesium casting subcategory.  Seventy-one  pollutants  were
dropped  from further consideration because their presence in raw
process wastewaters was  not  detected.   Thirty-five  pollutants
were   eliminated   from   further   consideration,  because  the
concentrations  of  these   pollutants   were   less   than   the
analytically quantifiable limits.

The  remaining  twenty-four  pollutants  were found to be present
infrequently, found at levels below  those  usually • achieved  by
specific  treatment methods, or were,present as artifacts related
to sampling procedures.  Discussions of these pollutants follow.

Acenaphthene  (1)  concentrations  appeared  on  2  of  6  process
sampling   days   in  the  magnesium  subcategory.'  The  maximum
concentration was 0.064 mg/1.  One of these two values  is  below
the   quantification   limit.   Therefore,  acenaphthene  is  not
considered for specific regulation in this subcategory.

BenzeneU) concentrations appeared on  1  of  6  process  sampling
days in the magnesium subcategory.  The ,maximum concentration was
0.014  mg/1.   This is lower than the concentration considered to
be  achievable  with  available   specific   treatment   methods.
Therefore,  benzene  is not considered for specific regulation in
this subcategory.

Chloroform  (23) concentrations appeared on all 6 process sampling
days in the magnesium subcategory.  The maximum concentration was
0.016 mg/1.   This  is lower  than  the concentration  considered  to
be   achievable  with  specific   treatment  methods.   Therefore,
chloroform  is not  considered   for specific  regulation   in  this
subcategory.

2,4-dimethylphenol  (34) concentrations appeared on 1 of  6 process
sampling    days    in   the   magnesium   subcategory.   The  maximum
concentration was  0.016   mg/1.   This    is    lower   than   the
concentration considered to be achievable  with available  specific
treatment   methods.    Therefore,    2,4-dimethylphenol    is  not
considered  for specific regulation  in  this subcategory.

Methylene chloride (44) concentrations appeared on 4 of  6 process
sampling  days   in the  magnesium   subcategory.     The   maximum
concentration was 0.15  mg/1.   All  concentrations, except the
maximum  value, were lower than the  concentration  considered  to  be
achievable   with   available  specific  treatment   methods.    The
                               413

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 maximum   concentration   is  only  slightly  above  this  level.
 Therefore,  with only one concentration above the level considered
 to be  achievable  with  available  specific  treatment  methods,
 methylene  chloride  is not considered for specific regulation in
 this subcategory.

 Pentachlorophenol (64)  concentrations appeared on 1 of 6 sampling
 days in the magnesium subcategory.   The concentration  was  0.033
 mg/1.    Since  this  concentration  appeared  on only one process
 sampling day,  pentachlorophenol  is not  considered  for  specific
 regulation  in this subcategory.

 Phenol   (65)   concentrations  appeared on 2 of 6 process sampling
 days in the magnesium subcategory.   The maximum concentration was
 0.350 mg/1.   All  of the concentrations are much  lower  than  the
 human   toxicity  level,   effects in humans.   Therefore,  phenol is
 not considered for specific regulation in this subcategory.

 Bis(2-ethylhexyl)  phthalate (66)  concentrations appeared on  5  of
 6   process   sampling days   in  the  magnesium  subcategory.   The
 maximum concentration was 0.195   mg/1.    All   concentrations  are
 much   lower    than  the   human   toxicity   level.    Therefore,
 bis(2-ethylhexyl)   phthalate  is  not  considered  for   specific
 regulation  in  this subcategory.

 Butyl   benzyl   phthalate  (67)   concentrations appeared  on 4 of  6
 process sampling  days in  the magnesium subcategory.   The  maximum
 concentration  was  0.013 mg/1.  Three  concentrations are  below the
 quantification limit.   The  maximum  concentration is only slightly
 above   the   level   considered  to  be  achievable  with  available
 specific  treatment methods.  However,  this maximum   concentration
 appeared  on   only  one   process  sampling day.   Therefore,  butyl
 benzyl  phthalate  is  not considered  for   specific  regulation  in
 this subcategory.

 Di-n-butyl  phthalate   (68)  concentrations  appeared  on  5  of  6
 process sampling days in  the magnesium subcategory.  The  maximum
 concentration   was   0.051  mg/1.  Only one concentration is  above
 the  level considered  to be   achievable  with   available  specific
 treatment   methods.   Therefore,  di-n-butyl  phthalate  is   not
 considered for  specific regulation  in this subcategory.

Diethyl phthalate  (70) concentrations appeared on 3 of 6  process
sampling   days    in  the  magnesium  subcategory.   The  maximum
concentration was  0.20 mg/1.  Two concentrations  are  below   the
quantification  limit.   All of the concentrations  are lower  than
the human toxicity level.  Therefore, diethyl  phthalate   is   not
considered for specific regulation in this subcategory.
                             414

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Dimethyl phthalate (71) concentrations appeared on 2 of 6 process
sampling   days   in  the  magnesium  subcategory.   The  maximum
concentration'was 1.1 mg/1.  All concentrations  are  lower  than
the  human  toxicity level.  Therefore, dimethyl phthalate is not
considered for specific regulation in this subcategory.

Chrysene (76) concentrations appeared on 3 of 6 process  sampling
days in the magnesium subcategory.  The maximum concentration was
0 016  mg/1.   Two  concentrations  are  below the quantification
limit.  The maximum concentration appeared on  only  one  process
sampling day.  Therefore, chrysene is not considered for specific
regulation in this subcategory.

Acenaphthylene   (77.)  concentrations  appeared  on 5 of 6 process
sampling  days   in  the  magnesium  subcategory.    The   maximum
concentration  was 0.124 mg/1.  Four concentrations are below the
quantification limit.  The maximum concentration  appeared on only
one process  sampling  day.   Therefore,  acenaphthylene  is  not
considered for specific regulation in this subcategory.

Anthracene   (78)  concentrations  appeared  on  5  of  6  process
sampling  days   in  the  magnesium  subcategory.    The   maximum
concentration  was  0.10 mg/1.  Four concentrations are below the
quantification limit.  The maximum concentration  appeared on only
one  process  sampling  day.    Therefore,   anthracene    is   not
considered for specific regulation in this subcategory.

Phenanthrene   (81)   concentrations  appeared  on   5  of 6 process
sampling  days   in   the  magnesium  subcategory.    The   maximum
concentration  was   0.10 mg/1.  Four concentrations are below the
quantification limit.  The maximum concentration  appeared on only
one  process   sampling  day.    Therefore,  phenanthrene   is   not
considered  for specific regulation in  this subcategory.

Pyrene  (84)   concentrations   appeared  on  4 of  6  process  sampling
days  in the  magnesium subcategory.  The maximum concentration was
0  019  mg/1.   Three  concentrations are   below  the  quantification
limit.   The  maximum  concentration appeared on  only  one process
sampling  day.  Therefore,  pyrene  is not considered  for   specific
regulation  in this  subcategory.

Toluene  (86)   concentrations appeared on  3 of  6  process  sampling
days  in the magnesium subcategory.  The maximum concentration  was
 0  030  mg/1.   This is lower than the  concentration  considered   to
be   achievable    with   available specific   treatment   methods.
Therefore,  toluene is not considered  for specific  regulation   in
 this  subcategory.
                              .'-'415

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 Copper  (120)   concentrations  appeared on all 4 process sampling
 days in the magnesium subcategory.   The maximum concentration was
 0.08 mg/1.   All concentrations are below the level considered  to
 be   achievable   with   available  specific  treatment  methods.
 Therefore,  copper is not considered for  specific  regulation  in
 this subcategory.
                                           i
 Cyanide  (121)   concentrations appeared on all 6 process sampling
 days in the magnesium subcategory.   The maximum concentration was
 0.01  mg/1.   All concentrations are below the level considered  to
 be   achievable   with   available  specific  treatment  methods.
 Therefore,  cyanide is not considered for specific  regulation  in
 this subcategory.

 Lead (122)  concentrations appeared on all 6  process sampling days
 in the magnesium subcategory.   The maximum concentration was 0.13
 mg/1.    All concentrations   are  below the level considered  to be
 achievable  with available treatment methods.   Therefore,  lead  is
 not considered  for specific  regulation in this subcategory.

 Ammonia concentrations appeared on  all 6 process sampling days in
 the  magnesium   subcategory.    The   maximum  concentration was 2.1
 mg/1.   This concentration is  lower  than the  human toxicity level.
 Therefore,  ammonia is not considered for specific  regulation  in
 this  subcategory.

 Fluoride concentrations   appeared  on all  6  process sampling days
 in  the magnesium subcategory.   The  maximum concentration  was  2.5
 mg/1.    All  concentrations  are  below the level  considered  to be
 achievable  with available treatment methods.   Therefore,  fluoride
 is  not considered for specific  regulation  in  this subcategory.

 Iron  concentrations  appeared on all  5 process   sampling   days  in
 the magnesium casting subcategory.   The maximum concentration was
 0.06   mg/1.   Two of  the  concentration values  are below  the  level
 considered   to   be  analytically  quantifiable.     All    of    the
 concentration   values  are  below   that  level   considered  to be
 achievable  by specific  treatment methods.  Therefore, iron is not
 considered  for  specific regulation  in this subcategory.

 Zinc Casting Subcateqory

 Pollutants Considered for Specific
Regulation  in the  Zinc Casting  Subcategory

Based  upon sampling results and a careful examination of  the  zinc
 casting subcategory manufacturing processes  and   raw  materials,
seventeen pollutants  were selected  for  consideration for  specific
regulation  through   effluent   limitations and  standards  for  this
                               416

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subcategory.  These pollutants "were found in the^raw^ wastewaters
from processes in this subcategory and are amenable to control by
wastewater    treatment   practices   (e.g.,   activated   carbon
adsorption, chemical  precipitation-sedimentation).   Discussions
of these pollutants follow.

2,4,6-trichlorophenol  (21)  values  were detected on 7 of the 11
sampling days in this  subcategory.   The  maximum  concentration
found  was 2.65 mg/1.  Some of these concentrations are^above the
optimum  expected  30-day   average   treated   effluent   levels
achievabl!  with  available  treatment methods.  This pollutant's
presence can be related  to  its  use  as  an  agent  to  control
biological  growth in various process solutions and to the use of
"dirty scrap" in the furnace change.

Parachlorometacresol  ( 22 )  values were detected on  6  of  the_ 1 1
sampling  days  in  this   subcategory.   The maximum concentration
found was 0.40  mg/1.   Some  of  concentrations   are  above  the
treated   effluent  levels achievable   with  available   specific
treatment methods.  This pollutant's presence can  be  related  to
the process solutions used in this subcategory.

2,4-dichlorophenol   (~31 )   values  were   detected   on  7 of the _ 11
sampling days in this  subcategory.   The   maximum concentration
found  was  1.95  mg/1.  Some of  the concentrations are above the
treated  effluent   levels   achievable  with  available    specific
treatment   methods.   This pollutant's presence  can be related to
the use, of  "dirty"  scrap in the  furnace  charge.
 2, 4-dimethylphenol  (34)  values were detected  on  10  of  the^ _ l l
 sampling  days  in   this  subcategory.   The maximum concentration
 found was 9.3  mg/1.   Some of these concentrations are well  above
 the  optimum  expected  30-day  average  treated  effluent levels
 achievable with available treatment  methods.    The  presence  of
 this  pollutant  can  be  related  to  its use as a solvent and a
 biological growth control agent  in  this  subcategory 's  process
 solutions, and to the use of "dirty scrap" in the furnace charge.

 Naphthalene  (55)  values  were  detected on 7 of the 11 sampling
 days in this subcategory.  The maximum  concentration  found  was
 4 0  ma/1.   Some  of  the  concentrations  are above the treated
 effluent levels  achievable  with  available  specific  treatment
 methods.   The  presence  of this pollutant can be related to the
 use of "dirty" scrap in the furnace charge.

 Phenol (65) values were detected on 1 0 of the 11 sampling days in
 this subcategory.  The maximum concentration found was  19.0 mg/l.
 Some of these concentrations, are substantially above the ^optimum
 expected  30-day  average treated effluent levels achievable with
                               417

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 available treatment methods.  This pollutant's  presence  can  be
 related  to  various process solutions and to contaminants in the
 scrap charge to the melting process.

 Butyl benzyl phthalate (67) values were detected on 5 of  the  11
 sampling  days  in  this  subcategory.  The maximum concentration
 found was 0.12 mg/1.   Some of the concentrations  are  above  the
 treated   effluent  levels  achievable  with  available  specific
 treatment methods.  This pollutant's presence can be  related  to
 the use of contaminated scrap in the furnace charge.

 Pyrene  (84) values were detected on 8 of the 11  sampling days in
 this subcategory.   The  maximum  concentration  found  was  0.018
 mg/1.    Some of the concentrations are above the treated effluent
 levels achievable   with  available  specific  treatment  methods.
 This   pollutant   can  be  found  in  process  solutions  (e.g.,
 diecasting and casting quench solutions).

 Tetrachloroethylene (85)  values were detected  on  7  of  the  11
 sampling  days  in  this   subcategory.   The maximum concentration
 found  was 0.142 mg/1.   Some of these concentrations are above the
 optimum  expected   30-day   average   treated   effluent   levels
 achievable  with  available  treatment methods.   This pollutant's
 presence can be related to solutions used  in  this   subcategory's
 processes.

 Lead  (122)   values were  detected on all  11  sampling days in  this
 subcategory.   The  maximum  concentration   found   was  0.42  mg/1.
 Some  of  these concentrations  are  above  the  optimum expected
 30-day average treated effluent levels  achievable with  available
 treatment methods.  The  presence of this  pollutant is related to
 its  use in process equipment  and  facilities and  to   its  presence
 in the cast  metal.

 Zinc  (128)   values were  detected on all  11  sampling days in  this
 subcategory.   The  maximum concentration found was 350  mg/1.   Some
 of the concentrations   are  above  the  treated   effluent  levels
 achievable   with   available   specific  treatment methods.   Zinc is
 considered for  specific regulation  in  this  subcategory as  it  is
 the  major metal  cast.

 Total  suspended  solids were found on  all 11  sampling days  in  this
 subcategory.    The  maximum   concentration   found was  3,800 mg/1.
 The  TSS  concentrations are  greater   than   the  treated   effluent
 levels   achievable  with available specific  treatment methods.  In
 addition, control of TSS  in process  wastewater   discharges  will
 result   in   the  control,  to   a  certain extent,  of several toxic
pollutants.
                              418

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Oil and grease values were found on all 11 sampling days in  this
subcategory.   The  maximum  concentration found was 17,100 mg/1.
These  oils  and  greases   originate   as   process   wastewater
pollutants,  in  the  solutions, products, and scrap used in this
subcategory's processes.   As  many  of  the  concentrations  are
greater  than  the  treated effluent levels typically achievable,
oil and grease is considered  for  specific  regulation  in  this
subcategory.

pH  can  be  controlled  within  the  limits  of 7.5 to 10.0 with
available specific treatment methods and is therefore  considered
for specific regulation in this subcategory.

Sulfide  values  were  detected  on  all 11 sampling days in this
subcategory.  The maximum concentration found was 1.0  mg/1.   As
several  of  the  concentrations  are  greater  than  the treated
effluent levels  attainable  with  available  specific  treatment
technologies,  sulfide  is  considered for specific regulation in
this subcategory.

Manganese values were detected on all  11 sampling  days  in  this
subcategory.   The maximum concentration found was 0.29 mg/1.  As
several of  these values are greater  than  the  treated  effluent
levels  achievable  with  available  specific  treatment methods,
manganese   is  considered  for  specific   regulation   in   this
subcategory.

Phenols  values  were   detected  on  all  11 sampling days  in this
subcategory.  The maximum concentration found was  123 mg/1.  Some
of  these   concentrations  are   substantially  above  the   optimum
expected   30-day  average treated effluent  levels achievable with
available  treatment methods.  This   pollutant,  detected   by   wet
chemistry    techniques   (4AAP),  encompasses  a  variety   of   the
individual  phenolic compounds.  This pollutant results  from   the
process  solutions used in this subcategory and from contaminants
in  the furnace scrap  charge.

Pollutants  Not Considered for Specific
Regulation  in  the Zinc  Casting  Subcategory

A total of  one hundred  twenty pollutants  that were evaluated were
eliminated from  further consideration  for specific regulation   in
the zinc  casting  subcategory.   Fifty pollutants were dropped from
further   consideration,   because   their   presence   in  raw  process
wastewaters was  not  detected.    Thirty-five  pollutants  were
eliminated from  further consideration,  because  the concentrations
of   these  pollutants  were less  than the  analytically quantifiable
 limits.                              ;   '": ;    ,
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 The remaining thirty-five pollutants  were  found   to  be  present
 infrequently or found at levels  below those typically  achieved by
 specific  treatment  methods.    Discussions  of   these pollutants
 follow.

 Acenaphthene (1)  concentrations   appeared  on 4   of  11   process
 sampling  days   in   the  zinc  casting  subcategory.   The maximum
 concentration was 2.5 mg/1.  Two concentrations are  less than  the
 analytically quantifiable limit.   The  maximum  concentration   is
 the only value  above the level achievable with available specific
 treatment methods.    Because  this   concentration level  is  found
 only on  1  of  11  process sampling   days,   acenaphthene  is  not
 considered for  specific regulation in this subcategory.

 Benzene   concentrations appeared on 5 of  11  process  sampling days
 in  the zinc  casting subcategory.   The maximum concentration  was
 0.15 mg/1.    Four  of  these  concentrations are  less   then  the
 analytically quantifiable limit.   As  a quantifiable  concentration
 was found on only one sampling day, benzene is not considered  for
 specific regulation in this subcategory.

 Carbon tetrachloride (6)  concentrations   appeared  on   4  of   11
 process   sampling  days  in  the  zinc casting subcategory.   The
 maximum  concentration was 0.029  mg/1,   which is   less   than  the
 concentration  achievable by  specific treatment  methods.   Three
 concentrations are  below the  analytically  quantifiable  limit.
 Therefore,   this  toxic  pollutant is not  considered for specific
 regulation in this  subcategory.

 1,2,4-trichlorobenzene (8) concentrations  appeared  on   1  of   11
 process   sampling   days  in  the   zinc  casting subcategory.   The
 concentration was 3.15  mg/1.  Because  this   toxic  pollutant   is
 found  at  only   one   plant,  it   is   not  considered for specific
 regulation in this  subcategory.

 1r 1,1-trichloroethane  (11) concentrations appeared  on  3  of   11
process  sampling  days   in  the  zinc  casting subcategory.   The
maximum  concentration   was  0.044 mg/1.   This  concentration   is
 lower  than  the  concentration  considered  to be achievable with
available specific treatment  methods.   Two  concentrations   are
below  the  analytically  quantifiable  limit.   Therefore,  this
pollutant is not  considered  for  specific  regulation  in  this
subcategory.
                                          i
Chloroform    (23)  concentrations  appeared  on  all   11  process
sampling days in  the   zinc  casting  subcategory.   The  maximum
concentration  was  0.067 mg/1.   This concentration is lower than
the concentration considered  to  be  achievable  with  available
specific  treatment  methods.    Ten  concentrations are below the
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analytically quantificable limit.  Therefore, this  pollutant: is
not considered for specific regulation in-this subcategory.

2-chlorophenol(24)  concentrations  appeared  on 3 of 11 sampling
days in the zinc casting subcategory.  The maximum  concentration
was  0.21 mg/1.   One  concentration  is  below  the analytically
quantifiable limit.  Another concentration   is  below  the  level
considered  to  be  achievable  with available specific treatment
methods.   Therefore,  2-chlorophenol  is  not   considered   for
specific regulation in this subcategory.

1,2-trans-dichloroethylene  (30)  concentrations appeared on  1 of
11 process sampling days in the zinc  casting  subcategory.   The
concentration  was  0.043 mg/11.   Because this toxic pollutant is
found at only one plant, and the concentration is lower than  the
concentration considered to be achievable with available specific
treatment  methods, this pollutant is not considered for specific
regulation in this subcategory.

2,4-dinitrotoluene   (35)  concentrations  appeared  on  1  of  11
process  sampling  days  in  the  zinc  casting subcategory.  The
concentration was  0.11 mg/1.  Because this pollutant   is  present
at  only  one plant,  it  is not considered for specific regulation
in this subcategory.

2,6-dinitrotoluene   (36)  concentrations  appeared  on  1  of 11.
process  sampling  days  in  the  zinc  casting subcategory.  The
maximum concentration was 0.11 mg/1.  Because this  pollutant is
present  at  only  one   plant,   it is not considered for specific
regulation  in  this subcategory.

Ethylbenzene  (38)  concentrations  appeared on  2  of   11   process,
sampling  days   in  the  zinc  casting  subcategory.   The  maximum
concentration  was  0.018  mg/1.  This  concentration is   lower   than
the   concentration  considered   to   be  achievable  with available
specific treatment  methods.   One   concentration   is   below  the
analytically   quantifiable   limit.    Therefore,  this pollutant  is
not  considered for specific  regulation  in this subcategory.

 Fluoranthene  (39)  concentrations appeared on   6  of   11   process
 sampling  days  in  the   zinc   casting  subcategory.   The  maximum
 concentration  was 0.029  mg/1.   Two  concentrations are   below  the
 analytically   quantifiable  limit.   Four of  the  concentrations are
 slightly greater than the  level  considered  to   be   achievable  by
 specific treatment methods.   However,  all of these  concentrations
 are   much   lower  than  the   human   toxicity  level.    Therefore,
 fluoranthene  is not considered for  specific   regulation  in   this
 subcategory.
                               421

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 Methylene  chloride  (44)   concentrations  appeared  on  7  of 11
 process  sampling days  in   the  zinc  casting  subcategory.    The
 maximum   concentration  was  0.30 mg/1.    Four concentrations are
 below the analytically quantifiable limit.   Another concentration
 is  lower than the concentration considered to  be  achieved   with
 available  specific  treatment  technology.   Therefore,  methylene
 chloride is  not  considered  for  specific  regulation  in   this
 subcategory.

 Nitrobenzene   (56)   concentrations  appeared  on  1  of  11  process
 sampling days in the zinc  casting subcategory.   The concentration
 was  0.21  mg/1.   Becaus.e this toxic pollutant is present  at   only
 one  plant,  nitrobenzene is not considered for specific  regulation
 in this  subcategory.

 4-nitrophenol  (58)   concentrations  appeared  on 1  of  11  process
 sampling days in the zinc  casting subcategory.   The concentration
 was  1.6  mg/1.   Because this toxic pollutant  is   present   at   only
 one   plant,    4-nitrophenol   is  not  considered  for   specific
 regulation  in this  subcategory.
                                          I
                                          i
 2,4-dinitrophenol  (59)  concentrations appeared  on 2  of  11  process
 sampling days in the  zinc  casting  subcategory.    The   maximum
 concentration  was   0.09 mg/1.    One  concentration   is below the
 analytically  quantifiable  limit.   Therefore,  2,4-dinitrophenol  is
 not  considered  for  specific regulation in this  subcategory.

 Bis(2-ethylhexyl) phthalate (66)  concentrations  appeared   on   all
 11   process   sampling  days in the  zinc  casting  subcategory.   The
 maximum  concentration was  4.3  mg/1.   Many of  the  concentrations
 are  greater than those  considered to be  achievable with available
 specific  treatment   methods.   However,  all of  the  concentrations
 are  much  lower  than  the human  toxicity  level.    to   cause toxic
 effects  in humans.   Therefore,  bis(2-ethylhexyl)  phthalate is  not
 considered for  specific regulation  in  this subcategory.

 Di-n-butyl  phthalate   (68)   concentrations   appeared on  all  11
process sampling days   in   the zinc  casting   subcategory.    The
maximum   concentration v/as  0.30 mg/1.  Many of  the  concentrations
 are  greater than those  considered to be  achievable with available
specific  treatment methods.  However,  all of  the  concentrations
 are  much  lower  than  the  human   toxicity  level.   Therefore,
di-n-butyl phthalate  is not  considered for specific  regulation  in
 this subcategory.

Di-n-octyl phthalate  (69) concentrations  appeared   on  1  of   11
process  sampling  days  in  the  zinc   casting  subcategory.  The
concentration was 2.8 mg/1.    Because  this  toxic   pollutant   is
                              422

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present  at  only one plant, di-octyl phthalate is not considered
for specific regulation in this subcategory.

Diethvl phthalate (70) concentrations appeared on 6 of 11 process
sampling days in  the  zinc  casting  subcategory.   The  maximum
c1ncen?ra??on  was  13.0 mg/1.   Many  of  the concentrations ape
greater than those considered to  be  achievable  with  available
specific  treatment  methods.   Two  concentrations are below the
analytically   quantifiable   limit.    However,   all  ^of   the
concentrations  are  much   lower  than  the human toxicity level,
TherJfore, diSthyl  phthalate  is  not  considered  for  specific
regulation in this subcategory.

Dimethyl pthalate (71) concentrations appeared on 3 ofjl process
sampling  days   in  the  zinc  casting  subcategory.  The maximum
concentration was 0.13 mg/1.   One   concentration  is  below  the
analytically  quantifiable   limit.   All of  the concentrations are
Slower than  the human toxicity   level     Therefore   dimethyl
phthalate  is  not  considered  for  specific regulation  in this
subcategory.,

Benzo(a)anthracene   (72)  concentrations   appeared^ on   2  of   11
process   sampling  days   in  the  zinc  casting  subcategory.  The
m^imum concentration was 0.075 mg/1   One Concentration  is  below
the  analytically  quantifiable   limit.     Because    this    toxic
pollutant  is present  at  only one  plant, benzo
-------
  achievable  with  available specific  treatment  methods,  fluorene  is
  not  considered for  specific  regulation  in  this  subcategory.

  Toluene   (86) concentrations appeared on 4 of 11  process  sampling
  days  in the zinc casting  subcategory.   The maximum   concentration
  was   0.027 mg/1.    All   concentrations   are  lower  than  the
  concentrations   considered   to  be  achievable    with   available
  specific  treatment  methods.   Two  concentrations  are below the
  analytically quantifiable   limit.   Therefore,   toluene   is  not
  considered  for specific regulation in this subcategory.

  Trichloroeth
-------
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