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]ett.george@epa.gov
George M.. Jett
Chemical Engineer
US Environmental Protection Agency
Engineering and Analysis Divisionrt303)
1200 Pennsylvania Avenue, Nw
Washington, D.C. 20460
-------
ORGANIZATION OF THIS DOCUMENT
This development document for the nonferrous metals manufacturing
category consists of a general development document which
considers the general and overall aspects of the regulation and
31 subcategory specific supplements. These parts are organized
into 10 volumes as listed below.
The information in the general document and in the supplements is
organi2ed by sections with the same type of information reported
in the same section of each part. Hence to find information on
any specific aspect of the category one would need only look in
the same section of the general document and the specific
supplements of interest.
The ten volumes contain contain the following subjects:
Volume I General Development Document
Bauxite Refining
Primary Aluminum Smelting
Secondary Aluminum Smelting
Primary Copper Smelting
Primary Electrolytic Copper Refining
Secondary Copper Refining
Metallurgical Acid Plants
Primary Zinc
Primary Lead
Secondary Lead
Primary Antimony
Primary Precious Metals and Mercury
Secondary Precious Metals
Secondary Silver
Secondary Mercury
Primary Tungsten
Secondary Tungsten and Cobalt
Primary Molybdenum and Rhenium
Secondary Molybdenum and Vanadium
Primary Beryllium
Primary Nickel and Cobalt
Secondary Nickel
Secondary Tin
Volume VIII Primary Columbium and Tantalum
Secondary Tantalum
Secondary Uranium
Volume II
Volume III
Volume IV
Volume V
Volume VI
Volume VII
Volume IX
Volume X
Primary and Secondary Titanium
Primary Zirconium and Hafnium
Primary and Secondary Germanium and Gallium
Primary Rare Earth Metals
Secondary Indium
-------
DEVELOPMENT DOCUMENT
for
EFFLUENT LIMITATIONS GUIDELINES AND STANDARDS
for the
NONFERROUS METALS MANUFACTURING POINT SOURCE CATEGORY
. VOLUME VII
5
Primary Beryllium
Primary Nickel and Cobalt
Secondary Nickel
Secondary Tin
William K. Reilly
Administrator
Rebecca Hanmer, Acting
Assistant Administrator for Water
Martha Prothro, Director
Office of Water Regulations and Standards
Thomas P. O'Farrell, Director
Industrial Technology Division
Ernst P. Hall, P.E., Chief
Metals Industry Branch
and
Technical Project Officer
May 1989
U.S. Environmental Protection Agency
Office of Water
Office of Water Regulations and Standards
Industrial Technology Division
Washington, D. C. 20460
-------
-------
ORGANIZATION OF THIS DOCUMENT
This development document for the nonferrous metals manufacturing
category consists of a general development document which
considers the general and overall aspects of the regulation and
31 subcategory specific supplements. These parts are organized
into 10 volumes as listed below.
The information in the general document and in the supplements is
organized by sections with the same type of information reported
in the same section of each part. Hence to find information on
any specific aspect of the category one would need only look in
the same section of the general document and the specific
supplements of interest. ;
The ten volumes contain contain the following subjects:
Volume I
Volume II
Volume III
Volume IV
Volume V
Volume VI
Volume VII
General Development Document
Bauxite Refining
Primary Aluminum Smelting
Secondary Aluminum Smelting
Primary Copper Smelting
Primary Electrolytic Copper Refining
Secondary Copper Refining
Metallurgical Acid Plants
Primary Zinc
Primary Lead
Secondary Lead
Primary Antimony
Primary Precious Metals and Mercury
Secondary Precious Metals
Secondary Silver
Secondary Mercury
Primary Tungsten
Secondary Tungsten and Cobalt
Primary Molybdenum and Rhenium
Secondary Molybdenum and Vanadium
Primary Beryllium
Primary Nickel and Cobalt
Secondary Nickel
Secondary Tin
Volume VIII Primary Columbium and Tantalum
Secondary Tantalum
Secondary Uranium
Volume IX
Volume X
Primary and .Secondary Titanium
Primary Zirconium and Hafnium
Primary and Secondary Germanium and Gallium
Primary Rare Earth Metals
Secondary Indium
-------
11
-------
TABLE OF CONTENTS
Supplement
Primary Beryllium
Primary Nickel and Cobalt
Secondary Nickel
Secondary Tin
Paqe
3605
3819
3933
4019
For detailed contents see
individual supplement.
detailed contents list in
111
-------
IV
-------
tfONFERROUS METALS MANUFACTURING POINT SOURCE CATEGORY
DEVELOPMENT DOCUMENT SUPPLEMENT
for the
Primary Beryllium Subcategory
William K. Reilly
Administrator
Rebecca Hanmer
Acting Assistant Administrator for Water
Martha Prothro, Director
Office of Water Regulations and.Standards
"•&
5
Thomas P. O'Farrell, Director
Industrial Technology Division
Ernst P. Hall, P.E., Chief
Metals Industry Branch
and
Technical Project Officer
May 1989
U.S. Environmental Protection Agency
Office of Water
Office of Water Regulations and Standards
Industrial Technology Division
Washington, D. C. 20460
3605
-------
3606
-------
PRIMARY BERYLLIUM SUBCATEGORY
Section
I
II
III
IV
V
TABLE OF CONTENTS
SUMMARY /'I'..
CONCLUSIONS
SUBCATEGORY PROFILE
Description of Primary Beryllium Production
Raw Materials
Production of Beryllium Hydroxide
Beryllium Oxide Production
Beryllium Metal Production
Process Wastewater Sources
Other Wastewater Sources
Age, Production, and Process Profile
SUBCATEGORIZATION
Factors Considered in Subdividing the Primary
Beryllium Subcategory
Other Factors
Production Normalizing Parameters
WATER USE AND WASTEWATER CHARACTERISTICS
Wastewater Flow Rates
Wastewater Characteristics Data
Data Collection Portfolios
Field Sampling Data
Wastewater Characteristics and Flows by
Subdivision
Solvent Extraction Raffinate from Bertrandite
Solvent Extraction Raffinate from Beryl Ore
Beryllium Carbonate Filtrate
Beryllium Hydroxide Filtrate
Beryllium Oxide Calcining Furnace Wet Air
Pollution Control
Beryllium Hydroxide Supernatant
Process Water
Fluoride Furnace Scrubber
Chip Treatment Wastewater
Beryllium Pebble plant Area Vent Wet Air
Pollution Control
Additional Building Blocks
3641
3641
3642
3643
3643
3644
3645
3645
3651
3651
3652
3652
3655
3656
3656
3657
3657
3658
Ore3658
3659
3659
3659
3660
3660
3660
3661
3661
3662
3662
3607
-------
PRIMARY BERYLLIUM SUBCATEGORY
Section
VI
VII
VIII
TABLE OF CONTENTS (Continued)
SELECTION OF POLLUTANT PARAMETERS
Conventional and Nonconventional Pollutant
Parameters
Conventional Pollutant Parameters Selected
Toxic Priority Pollutants
Toxic Pollutants Never Detected
Toxic Pollutants Never Found Above Their
Analytical Quantification Concentration_
Toxic Pollutants Present Below Concentrations
Achievable by Treatment
Toxic Pollutants Detected in a Small Number
of Sources
Toxic Pollutants Selected for Further
Consideration in Limitations and Standards
CONTROL AND TREATMENT TECHNOLOGIES
Current Control and Treatment Practices
Beryllium Hydroxide Production
Beryllium Oxide and Beryllium Metal Production
from Beryllium Hydroxide
Control and Treatment Options
Option A
Option C
COSTS, ENERGY, AND NONWATER QUALITY ASPECTS
Treatment Options for Existing Sources
Option A
Option C
Cost Methodology
Nonwater Quality Aspects
Energy Requirements
Solid Waste
Air Pollution
Page
3729
3729
3729
3730
3731
3731
3731
3731
3737
3745
3745
3745
3746
3746
3746
3746
3749
3749
3749
3749
3749
3749
3750
3750
3651
3608
-------
PRIMARY BERYLLIUM SUBCATEGORY
Section
IX
X
XI
TABLE OF CONTENTS (Continued)
BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY 3753
AVAILABLE
l " " - '
Technical Approach to BPT 3753
Industry Cost and Pollutant Removal Estimates 3755
BPT Option Selection — Proposal 3755
BPT Option Selection Promulgation 3756
Wastewater Discharge Rates 3757
Solvent Extraction Raffinate from Bertrandite Ore3758
Solvent Extraction Raffinate from Beryl Ore 3758
Beryllium Carbonate Filtrate 3758
Beryllium .Hydroxide Filtrate 3758
Beryllium Oxide Calcining Furnace Wet Air 3759
Pollution Control
Beryllium Hydroxide Supernatant 3759
Process Water 3759
Fluoride Furnace Scrubber 3759
Chip Treatment Wastewater • 3760
Beryllium Pebble Plant Area Vent Wet Air 3761
Pollution Control
Additional Building Blocks 3761
Regulated Pollutant Parameters 3761
Effluent Limitations 3762
BEST AVAILABLE TECHNOLOGY ECONOMICALLY 3775
ACHIEVABLE
Technical Approach to BAT 3775
Option A 3776
Option C 3776
Industry Cost and Pollutant Removal Estimates 3776
Pollutant Removal Estimates 3776
Compliance Costs 3777
BAT Option Selection - Proposal 3778
BAT Option Selection - Promulgation 3778
Final Amendments to the Regulation 3778
Wastewater Discharge Rates 3779
Regulated Pollutant Parameters 3779
Effluent Limitations 3780
NEW SOURCE PERFORMANCE STANDARDS 3793
Technical Approach to NSPS 3793
NSPS Option Selection - Proposal 3793
NSPS Option Selection - Promulgation 3794
Regulated Pollutant Parameters 3794
New Source Performance Standards 3794
3609
-------
PRIMARY BERYLLIUM SUBCATEGORY
Section
XII
TABLE OF CONTENTS (Continued)
PRETREATMENT STANDARDS
Technical Approach to Pretreatment
Pretreatment Standards for New Sources
PSNS Option Selection - Proposal
PSNS Option Selection - Promulgation
Regulated Pollutant Parameters
Pretreatment Standards for New Sources
Page
3805
3805
3805
3806
3806
3806
3807
XIII
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY 3817
3610
-------
PRIMARY BERYLLIUM SUBCATEGORY
LIST OF TABLES
Table Title
V-l Water Use and Discharge Rates for Solvent
Extraction Raffinate from Bertrandite Ore
Page
3663
V-2
V-3
V-4
V-5
V-6
V-7
V-8
V-9
V-10
V-ll
V-l 2
V-l 3
V-14
Water Use and Discharge Rates for Solvent 3663
Extraction Raffinate from Beryl Ore
Water Use and Discharge Rates for Beryllium 3663
Carbonate Filtrate
Water Use and Discharge Rates for Beryllium 3664
Hydroxide Filtrate
Water Use and Discharge Rates for Beryllium 3664
Oxide Calcining Furnace Wet Air Pollution Control
Water Use and Discharge Rates for Beryllium 3664
Hydroxide Supernatant
Water Use and Discharge Rates for Process Water 3665
Water Use and Discharge Rates for Fluoride 3665
Furnace Scrubber
Water Use and Discharge Rates for Chip Treatment 3665
Wastewater
Water Use and Discharge Rates for Beryllium 3666
Pebble Plant Area Vent Wet Air Pollution Control
Primary Beryllium Sampling Data Beryllium 3667
Oxide Calcining Furnace Wet Air Pollution
Control Raw Wastewater
Primary Beryllium Sampling Data Beryllium 3672
Hydroxide Supernatant Raw Wastewater
Primary Beryllium Sampling Data Process Water 3676
Raw Wastewater ,
Primary Beryllium Sampling Data Pebble Plant 3691
Area Vent Scrubber Raw Wastewater
3611
-------
PRIMARY BERYLLIUM SUBCATEGORY
LIST OF TABLES (Continued)
Table Title
V-15 Primary Beryllium Sampling Data Chip Treatment
Raw Wastewater
V-16 Primary Beryllium Sampling Data Triangular
Lagoon Effluent
V-17 Primary Beryllium Sampling Data Number 6 Lagoon
Effluent
V-18 Primary Beryllium Sampling Data Lime
Tank Effluent
V-19 Primary Beryllium Sampling Data Stripper
Effluent
V-20 Primary Beryllium Sampling Data Number 5 Lagoon
VI-1 Frequency of Occurrence of Priority Pollutants
Primary Beryllium Subcategory Raw Wastewater
VI-2 Toxic Pollutants Never Protected
VI-3 Toxic Pollutants Never Found Above Their
Analytical Quantification Concentration
VIII-1 Cost of Compliance for the Primary Beryllium
Subcategory Direct Dischargers
IX-1 BPT Wastewater Discharge Rates for the Primary
Beryllium Subcategory
IX-2 ' BPT Mass Limitations for the Primary Beryllium
Subcategory
X-l Pollutant Removal Estimates Primary Beryllium
Subcategory
X-2 Cost of Compliance for the Primary Beryllium
Subcategory Direct Dischargers
X-3 BAT Wastewater Discharge Rates for the Primary
Beryllium Subcategory
X-4 BAT Mass Limitations for the Primary Beryllium
Subcategory
Page
3696
3700
3705
3715
3719
3723
3739
3742
3744
3752
3763
3765
3781
3782
3782
3785
3612
-------
PRIMARY BERYLLIUM SUBCATEGORY
Table
XI-1
XI-2
XII-1
XII-2
LIST OF TABLES (Continued)
Title
Page
NSPS Wastewater Discharge Rates for the Primary 3796
Beryllium Subcategory
NSPS for the Primary Beryllium Subcategory
3798
PSNS Wastewater Discharge Rates for the Primary 3808
Beryllium Subcategory
PSNS for the Primary Beryllium Subcategory
3810
3613
-------
PRIMARY BERYLLIUM SUBCATEGORY
LIST OF FIGURES
Figure No. Title Page
III-l Beryllium Hydroxide Production Process 3646
III-2 Beryllium Oxide Production Process 3647
III-3 Beryllium Metal Production Process 3648
III-4 Geographic Locations of the Primary Beryllium 3649
Subcategory Plants
V-l Sampling Locations at Beryllium Plant A - 3727
Beryllium Oxide Production Area
V-2 Sampling Locations at Beryllium Plant A - 3728
Beryllium Metal Production Area
IX-1 Treatment Scheme 3773
X-l BAT Treatment Scheme for Option A 3791
X-2 BAT Treatment Scheme for Option C 3792
3614
-------
, PRIMARY BERYLLIUM SUBCATEGORY SECT - I
SECTION I
SUMMARY
This document provides the technical basis for promulgating
effluent limitations based on best practicable technology (BPT)
and best available technology economically achievable (BAT) for
existing direct dischargers, pretreatment standards for new
indirect dischargers (PSNS), and standards of performance for new
source direct dischargers (NSPS).
The primary beryllium subcategory consists of three plants. One
discharges directly to a river or stream, and two achieve zero
discharge of process wastewater.
EPA first studied the primary beryllium subcategory to determine
whether differences in raw materials/ final products,
manufacturing processes, equipment, age and size of plants, and
water usage required the development of separate effluent
limitations and standards for different segments of the
subcategory. This involved a detailed analysis of wastewater
discharge and treated effluent characteristics, including the
sources and volumes of water used, the processes used, the
sources of pollutants and wastewaters in the plant, and the
constituents of wastewaters including priority pollutants. As a
result, 16 subdivisions or building blocks have been identified
for this subcategory that warrant separate effluent limitations.
These include: -•!.'•.
a Solvent extraction raffinate from bertrandite ore,
b Solvent extraction raffinate from beryl ore,
c Beryllium carbonate filtrate,
d Beryllium hydroxide filtrate,
f Beryllium oxide calcining furnace wet air pollution
control,
g Beryllium hydroxide supernatant,
h Process water,
i Fluoride furnace scrubber,
j Chip treatment wastewater,
k Beryllium pebble plant area vent wet air pollution
control,
1 Beryl ore gangue dewatering,
m Bertrandite ore gangue dewatering,
n Beryl ore processing,
o AIS area wastewater,
p Bertrandite ore leaching scrubber, and
q Bertrandite ore counter current decantation scrubber.
EPA also identified several distinct control and treatment
technologies (both in-plant and end-of-pipe) applicable to the
primary beryllium subcategory. The Agency analyzed both
historical and newly generated data on the performance of these
technologies, including their nonwater quality environmental
3615
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - I
impacts and air quality, solid waste generation, and energy
requirements. EPA also studied various flow reduction techniques
reported in the data collection portfolios (dcp) and plant
visits.
Engineering, costs were prepared for each plant for each of the
control and treatment options considered for the subcategory.
These costs were then used by the Agency to estimate the impact
of implementing the various options in the subcategory. For each
control and treatment option that the Agency found to be most
effective and technically feasible in controlling the discharge
of pollutants, the number of potential closures, number of
employees affected, and impact on price were estimated. These
results are reported in a separate document entitled "Economic
Impact Analysis of Effluent Limitations and Standards for the
Nonferrous Metals Manufacturing Industry."
After examining treatment technology being operated in the
subcategory, the Agency has identified promulgated BPT as
pollutant removal based on chemical precipitation and
sedimentation technology, and ammonia steam stripping and cyanide
precipitation pretreatment for selected waste streams. To meet
the BPT effluent limitations based on this technology, the
primary beryllium subcategory is estimated to incur a capital
cost of $226,500 and an annual cost of $251,200.
For BAT, the Agency has built upon the BPT technology basis by
adding filtration as an effluent polishing step to the end-of-
pipe treatment scheme. To meet the BAT effluent limitations
based on this technology, the primary beryllium subcategory is
estimated to incur a capital cost of $256,200 and an annual cost
of $265,600.
NSPS and PSNS are equivalent to BAT. In selecting NSPS and PSNS,
EPA recognizes that new plants have the opportunity to implement
the best and most efficient manufacturing processes and treatment
technology. However, no such processes or treatment technology
were considered to meet the NSPS or PSNS criteria. Therefore,
the technology basis of BAT has been determined as the best
demonstrated technology.
The best conventional technology (BCT) replaces BAT for the
control of conventional pollutants. BCT is not being promulgated
because the methodology for BCT has not yet been finalized.
The mass limitations and standards for BPT, BAT, NSPS, and PSNS
are presented in Section II.
3616
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
SECTION II
CONCLUSIONS
EPA has divided the primary beryllium subcategory into 16
subdivisions for the purpose of effluent limitations and
standards. These subdivisions are:
(a) Solvent extraction raffinate from bertrandite ore,
(b) Solvent extraction raffinate from beryl ore,
(c) Beryllium carbonate filtrate,
(d) Beryllium hydroxide filtrate,
(e) Beryllium oxide calcining furnace wet air
pollution control,
(f) Beryllium hydroxide supernatant,
(g) Process water, ,
(h) Fluoride furnace scrubber,
(i) Chip treatment wastewater,
(j) Beryllium pebble plant area vent wet air pollution
control. ..-•'•','
(k) Beryl .ore gangue dewatering,
(1) Bertrandite ore gangue dewatering,
(m) Beryl ore processing,
(n) AIS area wastewater,
(o) Bertrandite ore leaching scrubber, and
(p) Bertrandite ore counter current decantation scrubber.
BPT ^is promulgated based :on the performance achievable by the
application of ammonia steam stripping and cyanide precipitation
pretreatment for selected .waste streams, followed by chemical
precipitation and sedimentation (lime and settle) technology.
The following BPT effluent aimitations are promulgated:
(a) Solvent Extraction Raffinate from Bertrandite Ore
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs). of beryllium carbonate produced
from bertra'ndite ore as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
PH
2,763.000
988.200
4,267.000
651.300
299,400.000
78,610j.OOO
92,090!.000
1,235.000
404.300
2,246.000
269.500
131,600.000
44,700.000
43,800.000
Within the range of 7.5 to 10.0 at all times
3617
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
(b) Solvent Extraction RafEinate from Beryl Ore
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium carbonate produced
from beryl ore as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
270.600
96.800
418.000
63.800
29,330.000
7,700.000
9,020.000
121.000
39.600
220.000
26.400
12,890.000
4,378.000
4,290.000
Within the range of 7.5 to 10.0 at all times
(c) Beryllium Carbonate Filtrate
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium carbonate produced
as beryllium
Beryllium
Chromium (Total)
Copper '
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
263.800
94.380
407.600
62.210
28,590.000
7,508.000
8,795.000
118.000
38.610
214.500
25.740
12,570.000
4,269.000
4,183.000
Within the range of 7.5 to 10.0 at all times
(d) Beryllium Hydroxide Filtrate BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium hydroxide produced
as beryllium
167.280
59.840
258.400
39.440
18,128.800
4,760.000
5,576.000
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
(e) Beryllium Oxide Calcining^ Furnace^ Wet Air_ Pollution
Control BPT
74.800
24.480
136.000
16.320
7,969.600
2,652.000
2,652.000
Within the range of 7.5 to 10.0 at all times
3618
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium oxide produced
Beryllium
Chromium (Total)
Gopper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
324.400
116.000
: 501.000
76.470
35,150.000
9,230.000
10,810.000
145.000
47.470
263.700
31.640
15,450.000
5,248.000
5,142.000
Within the range of 7.5 to 10.0 at all times
(f) Beryllium Hydroxide Supernatant BPT
Pollutant
Pollutant
or
Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million lbs;) of beryllium hydroxide produced
from scrap and residues as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
282.900
101.200
437.000
66.700
30,660.000
160,300.000
9,430.000
126.500
41.400
230.000
27.600
13,480.000
71,200.000
4,485.000
Within theirange of 7.5 to 10.0 at all times
(g) Process Water
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mgAg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
: 215.000
76.91Q
332.100
. 50.690
23,300.000
6,118.000
7,167.000
96.140
31.460
174.800
20.980
10,240.000
3,479.000
3,409.000
Within the,range of 7.5 to 10.0 at all times
3619
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
(h) Fluoride Furnace Scrubber BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
.g/kg (Ib/million Ibs) of beryllium pebbles produced
m<
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
Within the range of 7.5 to 10.0 at all times
(i)
Treatment Wastewater BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium scrap chips treated
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
9.533
3.410
14.730
2.248
1,033.000
271.300
317.800
4.263
1.395
7.750
0.930
454.200
154.200
151.100
Within the range of 7.5 to 10.0 at all times
(j) Beryllium Pebble Plant Area Vent Wet Air Pollution
Control BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
ng/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
Within the range of 7.5 to 10.0 at all times
3620
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
(k) Beryl Ore Gangue Dewatering BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg '.(-pounds per million pounds) of beryl ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
PH
1.283
0.459
" 1.982
0.302
139.032
36.505
42.763
0.57.4
0.188
1.043
0.125
61.120
20.756
20.339
Within the, range of 7.5 to 10.0 at all times
(1) Bertrandite Ore Gangue Dewatering BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (pounds per million pounds) of bertrandite processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
PH
3.279
1.173
5,064
0.773
355,245
93.275
109;265
1.466
0.480
2.665
0.320
156.169
53.034
51.968
Within the range of 7.5 to 10.0 at all times
(m) Beryl Ore Processing
Pollutant or
Pollutant Property
Maximum for
Any ;One Day
Maximum for
Monthly Average
mg/kg (pounds per million pounds) of beryl ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
8.983
3.213
13.876
2.118
973.490
255.-605
299.423
4.017
1.315
7.303
0.876
427.956
145.330
142.409
Within the range of 7.5 to 10.0 at all times
3621
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
(n) Aluminum Iron Sludge (AIS) Area Wastewater BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
nig/kg (pounds per million pounds) of total beryllium
carbonate produced as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
575.640
205.920
889.200
135.720
62,384.400
16,380.000
19,188.000
247.400
84.240
468.000
56.160
27,424.800
9,313.200
9,126.000
Within the range of 7.5 to 10.0 at all times
(o) Bertrandite Ore Leaching Scrubber BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg of bertrandite ore
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
PH
1.859
0.665
2.871
0.438
201.416
52.885
61.951
0.831
0.272
1.511
0.181
88.545
30.069
29.465
Within the range of 7.5 to 10.0 at all times
(p) Bertrandite Ore Countercurrent and Decantation
(CCD) Scrubber BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg of
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
bertrandite
0.124
0.044
0.192
0.029
13.463
3.535
4.141
ore processed
0.056
0.018
0.101
0.012
5.919
2.010
1.970
pH
Within the range of 7.5 to 10.0 at all times
3622
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
BAT ^is promulgated based on the performance achievable by the
application of ammonia steam stripping and cyanide precipitation
pretreatment for selected waste streams, followed by chemical
precipitation, sedimentation, and multimedia filtration (lime,
settle, and filter) technology. The following BAT effluent
limitations are promulgated:
(a) Solvent Extraction Raffinate from Bertrandite Ore BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium carbonate produced
from bertrandite ore as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
1,842.000
831.000
2,875.000
449.200
299,400.000
78,610.000
831.000
336.900
1,370.000
179.700
131,600.000
44,700.000
(b) Solvent Extraction Raffinate from Beryl Ore BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium carbonate produced
from beryl ore as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
180.400
81.400
281.600
44.000
29,330.000
7,700.000
81.400
33.000
134.200
17.600
12,890.000
4,378.000
(c) Beryllium Carbonate Filtrate BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium carbonate produced
as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
;175.900
79.370
274.600
42.900
28,590.000
7,508.000
79.370
32.180
130.800
17.160
12,570.000
4.269.000
3623
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - II
(d) Beryllium Hydroxide Filtrate BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of.beryllium hydroxide
produced as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
111.520
50.320
174.080
27.200
18,128.800
4,760.000
50.320
20.400
82.960
10.880
7,969.600
2,706.400
7~e")Beryllium Oxide Calcining Furnace We_t Air_ Pollution
Control BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium oxide produced
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
216 200
97.570
337.500
52.740
35,150.000
9,230.000
97.570
39.560
160.900
21.100
15,450.000
5,248.000
(f) Beryllium Hydroxide Supernatant BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium hydroxide produced
from scrap and residues as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
188.600
85.100
294.400
46.000
30,660.000
160,300.000
85.100
34.500
140.300
18.400
13,480.000
71,200.000
3624
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - II
(g) Process Water
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
143.300
64.680
223.700
34.960
23,300.000
6,118.000
64.680
26.220
106.600
13.980
10,240.000
3,479.000
(h) Fluoride Furnace Scrubber BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
(i) Chip Treatment Wastewater BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium scrap chips treated
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
6.355
2.868
i 9.920
1.550
1,033.000
271.300
2.868
1.163
4.728
0.620
454.200
154.200
3625
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
(j) Beryllium Pebble Plant Area Vent Wet Air Pollution
Control BAT
Pollutant for
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
(k) Beryl Ore Gangue
0.000
0.000
0.000
0.000
0.000
0.000
Dewatering BAT
0.000
0.000
0.000
0.000
0.000
0.000
Pollutant or
Pollutant Property
Maximum for
Any One Day
Monthly Average
(pounds per million pounds) of beryl ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
0.855
0.386
1.335
0.209
139.032
36.505
0.386
0.156
0.636
0.083
61.120
20.756
(1) Bertrandite Ore Gangue Dewatering BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (pounds per million pounds) of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
2.185
0.986
3.411
0.533
355.245
93.275
0.986
0.400
1.626
0.213
156.169
53.034
3626
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT -II
(m) Beryl Ore Processing BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (pounds per million pounds) of beryl ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
5.988
2.702
9.348
1.461
973.490
255.605
2.702
1.095
4.455
0.584
427.956
145.330
(n) Aluminum Iron Sludge (AIS) Area Wastewater BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
(pounds per million pounds) of total beryllium carbonate
produced as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
383.760
173.160
599.040
93.600
62,384.400
16,380.000
173.160
70.200
285.480
37.440
27,424.800
9,313.200
(o) Bertrandite Ore Leaching Scrubber BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg of bertrandite ore processed
Beryllium
Chromium (Total)
Coppe r
Cyanide (Total)
Ammonia (as N)
Fluoride
1.239
0.559
1.934
0.302
201.416
52.885
0.559
0.227
0.922
0.121
88.545
30.069
3627
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - II
(p) Bertrandite Ore Countercurrent and Decantation
(CCD) Scrubber BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
0.083
0.037
0.129
0.020
13.463
3.535
0.037
0.015
0.062
0.008
5.919
2.010
NSPS is promulgated based on the performance achievable by the
application of ammonia steam stripping and cyanide precipitation
pretreatment for selected waste streams, followed by chemical
precipitation, sedimentation, and multimedia filtration (lime,
settle, and filter) technology. The following effluent standards
are promulgated for new sources:
3628
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
(a) Solvent Extraction Raffinate from Bertrandite Ore NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium carbonate produced
from bertrandite ore as .beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
1,842.000
831.000
2,875.000
449.200
299,400.000
78,610.000
33,690.000
831.000
336.900
1,370.000
179.700
131,600.000
44,700.000
26,950.000
Within the range of 7.5 to 10.0 at all times
3629
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - II
(b) Solvent Extraction Raffinate from Beryl Ore NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium carbonate produced
from beryl ore as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
180.400
81.400
281.600
44.000
29,330.000
7,700.000
3,300.000
81.400
33.000
134.200
17.600
12,890.000
4,378.000
2,640.000
Within the range of 7.5 to 10.0 at all times
(c) Beryllium Carbonate Filtrate NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium carbonate produced
as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
175.900
79.370
274.600
42.900
28,590.000
7,508.000
3,218.000
79.370
32.180
130.800
17.160
12,570.000
4,269.000
2,574.000
Within the range of 7.5 to 10.0 at all times
(d) Beryllium Hydroxide Filtrate NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
ing/kg (Ib/million Ibs) of beryllium hydroxide produced as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
111.520
50.320
174.080
27.200
18,128.800
4,760.000
2,040.000
50.320
20.400
82.960
10.880
7,969.600
2,706.400
1,632.000
Within the range of 7.5 to 10.0 at all times
3630
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
(e) Beryllium Oxide Calcining Furnace Wet Air Pollution
Control NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium oxide produced
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
216.200
97.570
337.500
52.740
35,150.000
9,230.000
3,956.000
97.570
39.560
160.900
21.100
15,450.000
5,248.000
3,164.000
Within the range of 7.5 to 10.0 at all times
(f) Beryllium Hydroxide Supernatant NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
(Ib/million Ibs) of beryllium hydroxide produced
from scrap and residues as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
188.600
85.10Q
294.400
46.000
30,660.000
160,300.000
3,450.000
85.100
34.500
140.300
18.400
13,480.000
71,200.000
2,760.000
Within the range of 7.5 to 10.0 at all times
(g) Process Water NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
143.300
64.68Q
223.700
',• 34.960
23,300.000
6,118.000
2,622.000
64.680
26.220
106.600
13.980
10,240.000
3,479.000
2,098.000
Within the range of 7.5 to 10.0 at all times
3631
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - II
(h) Fluoride Furnace Scrubber NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH Within the
0.000
0.000
0.000
0.000
0.000
0.000
0.000
range of 7.5
0.000
0.000
0.000
0.000
0.000
0.000
0.000
to 10.0 at all times
(i) hip Treatment Wastewater NSPS
___ ;
Pollutant or
Pollutant Property
Any One Day
Monthly Average
mg/kg (Ib/million Ibs) of beryllium scrap chips treated
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
6.355
2.868
9.920
1.550
1,033.000
271.300
116.300
2.868
1.163
4.728
0.620
454.200
154.200
93.000
Within the range of 7.5 to 10.0 at all times
(j) Beryllium Pebble Plant Area Vent Wet Air Pollution
Control NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium (Total
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
(k) Beryl Ore
0.000
) 0.000
0.000
0.000
0.000
0.000
0.000
Within the range of 7.5
Gangue Dewatering NSPS
0.000
0.000
0.000
0.000
0.000
0.000
0.000
to 10.0 at all times
Pollutant or
Pollutant Property
Any One Day
Monthly Average
3632
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
mg/kg (pounds per
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH Within
million pounds)
i. 0.855
0.386
; 1.335
0.209
139.032
36.505
15.645
the range of 7.
of beryl ore processed
0.386
0.156
0.636
0.083
61.120
20.756
12.516
5 to 10.0 at all times
(1) Bertrandite Ore Gangue Dewatering NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (pounds per million pounds) of bertrandite ore proces
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH Within
2.185
0.986
3.411
0.533
355.245
93.275
39.975
the range of 7 . 5
0.986
0.400
1.626
0.213
156.169
53.034
31.980
to 10.0 at all
times
(m) Beryl Ore Processing NSPS
Pollutant or
Pollutant Property
Maximum for
Any 'One Day
Maximum for
Monthly Average
mg/kg (pounds per million pounds) of beryl ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
5.988
2.702
; 9.348
1.461
973.490
255.605
109.545
2.702
1.095
4.455
0.584
427.956
145.330
87.636
Within the range of 7.5 to 10.0 at all times
3633
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - II
(n) Aluminum Iron Sludge (AIS) Area Wastewater NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (pounds per million pounds) of total beryllium carbonate
produced as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
383.760
173.160
599.040
93.600
62384.400
16380.000
7020.000
173.160
70.200
285.480
37.440
27424.800
9313.200
5616.000
pH
Within the range of 7.5 to 10.0 at all times
(o) Bertrandite Ore Leaching Scrubber NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg of
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
bertrandite
1.239
0.559
1.934
0.302
201.416
52.885
22.665
ore processed
0.559
0*^ O *"7
. 227
0.922
0.121
88.545
30.069
18.132
pH
Within the range of 7.5 to 10.0 at all times
(p) Bertrandite Ore Countercurrent and Decantation
(CCD) Scrubber NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
TSS
pH
0.083
0.037
0.129
0.020
13.463
3.535
1.515
0.037
0.015
0.062
0.008
5.919
2.010
1.212
Within the range of 7.5 to 10.0 at all times
3634
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
EPA is not promulgating pretreatment standards for
sources (PSES) for the primary beryllium subcategory.
existing
PSNS_ are promulgated based on the performance achievable by the
application of ammonia steam stripping and cyanide precipitation
pretreatment for selected waste streams, followed by chemical
precipitation, sedimentation, and multimedia filtration (lime,
settle, and filter) technology. The following pretreatment
standards are promulgated for new sources:
(a) Solvent Extraction Raffinate from Bertrandite Ore PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium carbonate produced
from bertrandite ore as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
1,842.000
831.OQO
2,875.000
449.200
299,400.000
78,610.000
831.000
336.900
1,370.000
179.700
131,600.000
44,700.000
(b) Solvent Extraction Raffinate from Beryl Ore PSNS
Pollutant or
Pollutant Property
Maximum for
Any:One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium carbonate produced
from beryl ore as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
180.000
81.400
281.600
44.000
29,330.000
7,700.000
81.000
33.000
134.200
17.600
12,890.000
4,378.000
3635
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - II
(c) Beryllium Carbonate Filtrate PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium carbonate produced
as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
175.900
79.370
274.600
42.900
28,590.000
7,508.000
79.370
32.180
130.800
17.160
12,570.000
4,269.000
(d) Beryllium Hydroxide Filtrate PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium hydroxide produced
as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
111.520
50.320
174.080
27.200
18,128.800
4,760.000
50.320
20.400
82.960
10.880
7,969.600
2,706.400
(e) Beryllium Oxide Calcining Furnace Wet Air Pollution
Control PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium oxide produced
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
216.200
97.570
337.500
52.740
35,150.000
9,230.000
97.570
39.560
160.900
21.100
15,450.000
5,248.000
3636
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
(f) Beryllium Hydroxide Supernatant PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
rag/kg (Ib/million Ibs) of beryllium hydroxide produced
from scrap and residues as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
188.600
85.100
: 294.400
46.000
30,660.000
160/300.000
85.100
34.500
140.300
18.400
13,480.000
71,200.000
(g) Process Water PSNS
Pollutant or
Pollutant Property
Maximum for
Any•One Day
Maximum for
Monthly Average
(Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
143.300
64.680
223.700
34.960
23,300.000
6,118.000
64.680
26.220
106.600
13.980
10,240.000
3,479.000
(h) Fluoride Furnace Scrubber PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
rag/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium 0.000 0.000
Chromium (Total) 0.000 0.000
Copper ; 0.000 0.000
Cyanide (Total) 0.000 0.000
Ammonia (asN) 0.000 0.000
Fluoride
3637
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - II
(i) Chip Treatment Wastewater PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million. Ibs) of beryllium scrap chips treated
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
6.355
2.868
9.920
1.550
1,033.000
271.300
2.868
1.163
4.728
0.620
454.200
154.200
(j) Beryllium Pebble Plant Area Vent Wet Air Pollution
Control PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
(k) Beryl Ore Gangue Dewatering PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (pounds per million pounds) of beryl ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
0.855
0.386
1.335
0.209
139.032
36.505
0.386
0.156
0.636
0.083
61.120
20.756
3638
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - II
(1) Bertrandite Ore Gangue Dewatering PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (pounds per million pounds) of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
; 2.185
0.986
; 3.4ii
0.533
355.245
93.275
0.986
0.400
1.626
0.213
156.169
53.034
(m) Beryl Ore Processing PSNS
Pollutant or
Pollutant Property
Maximum for
Any 1 Day
Maximum for
Monthly Average
mg/kg(pounds per million pounds) of beryl ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
5.988
2.702
9.348
1.461
973.490
255.605
2.702
1.095
4.455
0.584
427.956
145.330
(n) Aluminum Iron Sludge (AIS) Area Wastewater PSNS
Pollutant or
Pollutant Property
Maximum for
Any 1 Day
Maximum for
Monthly Average
rag/kg (pounds per million pounds) of total beryllium
carbonate produced as beryllium
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
383.760
173.160
599.040
93.600
62384.400
16380.000
173.160
70.200
285.480
37.440
27424.800
9313.200
3639
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - II
(o) Bertrandite Ore Leaching Scrubber PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
1.239
0.559
1.934
0.302
201.416
52.885
0.559
0.227
0.922
0.121
88.545
30.069
(p) Bertrandite Ore Countercurrent and Decantation
(CCD) Scrubber PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
0.083
0.037
0.129
0.020
13.463
3.535
0.037
0.015
0.062
0.008
5.919
2.010
EPA is not promulgating best conventional pollutant control
technology (BCT) limitations for the primary beryllium
subcategory at this time.
3640
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - III
SECTION III
SUBCATEGORY PROFILE
This section of the primary beryllium supplement describes the
raw materials and processes used in producing primary beryllium
and presents a profile of the primary beryllium plants identified
in this study.
Beryllium, the seventh lightest known metal, is manufactured and
used, in three principal product forms: beryllium copper alloy,
beryllium oxide and beryllium metal. It is estimated that about
80 percent of beryllium consumption is in the form of beryllium
copper or other master alloy, and the remaining 20 percent
represents approximately :egual quantities of beryllium as the
oxide and as the pure metal. Beryllium copper alloy, containing
0.5 to 2.75 percent beryllium is used in various electrical and
mechanical applications including current carrying springs,
welding components, tooling dies, safety tools, bearing sleeves,
and overseas cable housings. Beryllium oxide, in pure or ceramic
form, _is used in a number of electronic applications as a heat
sink in resistor cores, integrated circuit chip carriers,
traveling wave tubes, and laser tubes. Pure beryllium metal is
used primarily in aerospace applications including missile
components, aircraft brakes, nozzles, optics, and nuclear
components.
DESCRIPTION OF PRIMARY BERYLLIUM PRODUCTION
The production of beryllium products can be divided into three
distinct operations - production of beryllium hydroxide from
beryllium ores, production of beryllium oxide from beryllium
hydroxide, and production of beryllium metal from beryllium
hydroxide. The primary beryllium production processes are shown
schematically in Figures III-l through 111-3 (pages 3646-3649)
and described below. Beryllium-copper master alloy is produced
from beryllium hydroxide in a two-step process: calcination of
beryllium hydroxide to beryllium oxide, and production of
beryllium-copper master alloy using a carbon reduction process
No process wastewater is generated by beryllium-copper master
alloy production. ;.. ..
RAW MATERIALS :
Most domestic beryllium is extracted from bertrandite ore
(4Be02SiO2H20). Imported iand domestically produced beryl ore
(3BeOAl2036Si02) is another raw material for the primary
beryllium industry. The only company processing ore maintains
the capability for processing beryl ore, and, in 1985, processed
approximately 2,200 tons of beryl ore, compared with the 95,000
tons of bertrandite ore processed that year.
3641
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - III
PRODUCTION OF BERYLLIUM HYDROXIDE
The production of beryllium hydroxide from beryl and bertrandite
ores is presented schematically in Figure III-l (page 3646).
Bertrandite ore is first wet ground and screened to form a slurry
which is leached with a 10 percent sulfuric acid solution. The
mixture is washed and tailings removed in countercurrent
thickeners. The sludge from the thickeners is pumped to the
tailings pond as a slurry. The thickener supernatant, containing
0.5 to 0.6 grams per liter of beryllium, next enters a solvent
extraction process where beryllium is extracted from solution
with di-2-ethylhexyl phosphoric acid in kerosene. The barren
raffinate solution is discarded as a wastewater stream.
Wastewater streams are generated from both the bertrandite ore
qanque and beryl ore gangue dewatering processes. Further,
wastewater streams are generated in the bertrandite ore leaching
scrubber and bertrandite counter current decantation scrubber
processes.
The beryllium is stripped from the organic phase into an aqueous
solution containing 4 to 5 grams per liter of beryllium.
Aluminum and iron are precipitated from solution and the aluminum
iron sludge is discarded. Beryllium is then precipitated from
solution as beryllium carbonate which is separated from_ the
liquid phase by filtration. The barren filtrate is discarded as
a wastewater stream or further processed for uranium recovery by
solvent extraction prior to discharge. The beryllium carbonate
may be sold as a product or further processed to beryllium
hydroxide.
The beryllium carbonate filter cake is reslurried in deionized
water and hydrolyzed in an autoclave to convert the suspended
solids to beryllium hydroxide. Beryllium hydroxide is then
separated from the liquid phase by filtration and the filtrate
discarded as a waste stream. Beryllium hydroxide may be further
processed to make beryllium copper alloy, beryllium oxide, or
pure beryllium metal.
When beryl ore is processed, the ore is crushed and melted at
about 1625°C. The molten material is quenched with cold
water to produce a glassy material called frit. The frit is
dried, ground and leached with strong -sulfuric acid, forming a
mixture of beryllium sulfate, aluminum sulfate, and silica.
Water is added to the mixture and the silica is separated in_ a
series of countercurrent decantation steps. The resultant silica
sludge is discarded. The beryllium solution, containing
approximately 10 to 11 grams per liter of beryllium is further
processed by solvent extraction, purification and precipitation
in an identical manner as beryllium solution from bertrandite
ore. Beryl ore processing generates wastewater streams from the
quench pit, scrubber and washdown operations.
3642
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - III
BERYLLIUM OXIDE PRODUCTION;
Pure beryllium oxide is produced for use in ceramics production
or sold directly to customers. The . process is shown
schematically in Figure III-2 (page 3647). The oxide is produced
by dissolving beryllium hydroxide in water and sulfuric acid.
The resulting beryllium sulfate solution is then filtered to
remove impurities. The solution flows to an evaporator followed
by two crystallizers in parallel where beryllium sulfate crystals
are formed. The crystals are separated from the mother liquor in
a centrifuge and the mother liquor is recycled to the beryllium
hydroxide dissolver. The beryllium sulfate is calcined in gas-
fired furnaces at about 1100°C to beryllium oxide.
Sulfur dioxide in the exhaust gases from the calcining furnaces
is removed in caustic scrubbers which discharge scrubber water to
treatment.
BERYLLIUM METAL PRODUCTION
The beryllium manufacturing process is shown schematically in
Figure III-3 (page 3649). Beryllium hydroxide, Be(OH)2, is added
to a batch makeup tank along with an ammonium bifluoride
solution, calcium carbonate, and recycled beryllium fluoride
(BeF2). The resultant ammonium beryllium fluoride solution is
filtered to remove insoluble impurities. The filter cake is
filtered a second time and rinsed with ammonium bifluoride
solution to recover any beryllium present in the filter cake.
The rinse water is sent to an evaporator where it is concentrated
prior to being recycled to the batch makeup tank. The washed
filter cake is a fluoride sludge which is sent to treatment. The
condensate from the evaporator flows to the process water pit for
reuse.
The filtered ammonium beryllium fluoride solution is treated with
ammonium sulfide to precipitate dissolved impurities,
particularly iron. The precipitated solids are removed in a
filter and the resultant sulfide sludge is sent to treatment.
The ammonium beryllium fluoride solution flows to a crystallizer
where ammonium beryllium fluoride crystals are formed. Solids are
separated from the liquid phase in a centrifuge, the supernatant
from the centrifuge is recycled back to the crystallizer and the
solids are sent to a drier. The condensate from the crystallizer
is sent to the process water pit for reuse.
The dried ammonium beryllium fluoride, (NH4)2BeF4, is heated in a
graphite induction furnace jto drive off ammonium fluoride (NH4F)
and produce beryllium fluoride (BeF2). The off-gases from the
fluoride furnace pass through- a recirculating wet scrubber where
ammonium fluoride is absorbed from the gas into an aqueous
solution. The resultant ammonium fluoride solution generated in
the scrubber is used, along with hydrofluoric acid, to make
ammonium bifluoride solution. This solution is used in various
steps in the beryllium metal production process, particularly in
3643
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - III
the dissolution of beryllium hydroxide to produce ammonium
beryllium fluoride solution.
Beryllium fluoride is reduced to beryllium metal in a furnace.
Magnesium is added to the furnace and the resulting product is a
matrix of beryllium metal and magnesium fluoride (MgF2). This
matrix is crushed in a hammer mill and ball mill. The beryllium,
referred to as beryllium pebbles, is separated from magnesium
fluoride by washing our during milling. Gravity separation in a
bath of bromochloromethane is used to separate heavy metals from
beryllium pebbles after milling. The magnesium fluoride residue
is washed with ammonium bifluoride solution to recover any
beryllium which may be present as beryllium fluoride. The
beryllium fluoride solution is recycled to the batch makeup tank
where beryllium hydroxide is dissolved to produce ammonium
beryllium fluoride solution. The magnesium fluoride residue is
then slurried to a disposal pond.
Two other additional beryllium recovery operations are present in.
the primary beryllium subcategory. These are recovery of
beryllium as a hydroxide from low-grade sources and treatment of
high-grade beryllium chips. The hydroxide operation recovers
beryllium from various internal and external sources, although
the amount of total plant beryllium production resulting from
secondary material (i.e.. beryllium scrap .recycled from
customers) is very small. Beryllium is recovered by
precipitating it as Be(OH)2 with sodium hydroxide, separating
the precipitate in a clarifier, and dewatering the hydroxide in a
centrifuge. The overflow (or supernatant) from the clarifier is
discarded.
PROCESS WASTEWATER SOURCES
Although a variety of processes are involved in primary beryllium
production, the process wastewater sources can be subdivided into
the 18 building blocks listed below.
(a) Solvent extraction raffinate from bertrandite ore,
(b) Solvent extraction raffinate from beryl ore,
(c) Beryllium carbonate filtrate,
(d) Beryllium hydroxide filtrate,
(e) Beryllium oxide calcining furnace wet air pollution control,
(f) Beryllium hydroxide supernatant,
(g) Process water,
(h) Fluoride furnace scrubber
(i) Chip leaching wastewater,
(j) Beryllium pebble plant area vent wet air pollution control,
(k) Beryl ore gangue dewatering,
(1) Bertrandite ore gangue dewatering,
(m) Beryl ore processing,
(n) AIS area wastewater,
(o) Bertrandite ore leaching scrubber, and
(p) Bertrandite ore counter current decantation scrubber.
3644
-------
PRIMARY BERYLLIUM SUBCATEGORY. SECT - III
OTHER WASTEWATER SOURCES
There may be other wastewater streams associated with the primarv
an7 mi?ni-JUbCateg0^% TheSe Streams include stormwate? runoff
ooL-S ^ an°e and cleanuP water. These waste streams are not
considered as a part of. this rulemaking. EPA believes that ?h^
flows and pollutant loadings associated with these wlste stream!
beItinha?SlfdChnt^relatiVe:t0 the WaSte Streams selectel and ™e
rJ^ h^J? /, Y theuaPPr°Priate permit authority on a case-by-
case basis under authority -of Section 403 of the Clean Water Act.
AGE, PRODUCTION^ AND PROCESS PROFILE
Figure 111-4 (page 3649) shows the location of the three primarv
berylllum plants operating in the United States. The facility
which produces beryllium hydroxide from ore is a zero
Y 3Sd 1S i°Cated ln a net evaporation area
pr?duces beryllium oxide, beryllium-copper
The
master
allov
3645
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - III
Beryl or
Bertrandite-
Ore
Sulfuric
Acid
H2°
Solvent
Deionized
Water
Ore
Preparation
Leaching
and
Countercurrent
Decantation
I
Solvent
Extraction
and
Stripping
Iron
Precipitation
Beryllium
Carbonate
Precipitation
Repulping,
Autoclaving,
and
Filtration
Sludge and 1
"to Disposal
^Raffinate to
Disposal
Iron Sulfide
Sludge to Disposal
Filtrate to
Disposal
^Filtrate to
Disposal
Beryllium Hydroxide
Figure III-1
BERYLLIUM HYDROXIDE PRODUCTION PROCESS
3646
-------
PRIMARY BERYLLIUM SUB;CATEGORY SECT - III
Be(OH),
Mother Liquor to
Beryllium -, Centrate
Hydroxide Production
Periodic Bleed
H20 : H2S04
LI I
Dissolver
Filter
•Waste Solids
Evaporator
Condensates
Crygtallizer
Centrifuge
Vent to
Atmosphere
Beryllium
Sulfate Crystals
Calcining
Furnace
Caustic
Scrubber
Beryllium
Oxide
Wastewater
'Water
Figure III-2
BERYLLIUM OXIDE PRODUCTION PROCESS
3647
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - III
C/3
CO
w
C.3
Q-i
2S
O
Q
O
OS
S-i
=1
00
•J
nJ
><
OS
3648
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - III
w
PQ
M CO
Pi H
I W
M PC
M H
-------
PRIMARY BERYLLIUM SDBCATEGORY SECT - III
THIS PAGE INTENTIONALLY LEFT BLANK
3650
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - IV
SECTION IV
SUBCATEGORIZATION
This section summarizes the factors considered during the
designation of the primary beryllium subcategory and its related
subdivisions. Production normalizing parameters for each
subdivision will also be discussed.
FACTORS CONSIDERED IN SUBDIVIDING THE PRIMARY BERYLLIUM
SUBCATEGORY ~"
The factors listed previously were each evaluated when
considering subdivision of the primary beryllium subcategory. In
the» dicsrMlc-cs-i nn 4-hat- fnl 1 /kr.Tc. 4-1-,.-* P-.,-. 4-~ .. _ ..i-t-i i ji • i
described as
the discussion that follows, the factors"will be
they pertain to this particular subcategory.
The rationale for considering further subdivision of the primary
beryllium subcategory is based primarily on differences in the
production processes and raw materials used. Within this
subcategory. a number of different operations are performed,
which may or may not have a water use or discharge and which may
require the establishment of separate effluent limitations. While
primary beryllium is still considered a single subcategory, an
examination of the production processes has illustrated the need
for limitations and standards based on a specific set of
wastewater streams. Limitations will be based on specific flow
allowances for the following subdivisions:
(a)
(b)
(c)
(d)
(e)
(f)
(9)
(h)
(i)
(i)
(k)
(1)
(m)
(n)
(o)
(P)
Solvent extraction raffinate from bertrandite ore,
Solvent extraction raffinate from beryl ore,
Beryllium carbonate filtrate,
Beryllium hydroxide filtrate,
Beryllium oxide calcining furnace wet air pollution control,
Beryllium hydroxide supernatant,
Process water, |
Fluoride furnace scrubber.
Chip treatment wastewater,
Beryllium pebble plant area vent wet air pollution control,
Beryl ore gangue dewatering,
Bertrandite ore ganguej dewatering,
Beryl ore processing,
AIS area wastewater, ;; •
Bertrandite ore leaching scrubber, and
Bertrandite ore counter current decantation scrubber.
These building blocks follow directly from differences within the
three distinct beryllium1 production operations: beryllium
hydroxide production from bre, beryllium oxide production from
beryllium hydroxide, and beryllium metal production from
beryllium hydroxide. !
The production of beryllium;hydroxide from ore gives rise to the
3651
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - IV
subdivisions (a) through (d) and (k) through (p). Solvent
extraction raffinates are a major source of wastewater directly
attributable to leaching bertrandite or beryl ore with sulfuric
acid and extracting beryllium from the leach solution.
Precipitation of beryllium carbonate and beryllium hydroxide each
result in filtrate wastewater streams.
Wastewater is generated from the dewatering of beryl ore and
bertrandite ore gangue. Beryl ore processing generates
wastewater from quenching, scrubber operation and washdown.
Aluminum-iron sludge removal generates wastewater. Wastewater is
also generated by scrubbing operations associated with
bertrandite ore leaching and bertrandite ore counter current
decantation operations.
Wastewater from scrubbers which control emissions from calcining
furnaces are a major source of wastewater associated with the
production of beryllium oxide from beryllium hydroxide.
The operations associated with the production of beryllium metal
from beryllium hydroxide give rise to subdivisions (x) through
(y). In one by-product recovery operation, beryllium is recovered
from internally generated scrap and residues and small amounts of
recycled material from customers, by leaching in sulfuric acid
and precipitating beryllium hydroxide. A supernatant wastewater
stream results. Process condensates result from ammonium
beryllium fluoride crystallization and evaporation of ammonium
bifluoride filtrate. Wet scrubbers are used to control emissions
from fluoride furnaces which convert ammonium beryllium fluoride
to beryllium fluoride, and to recover ammonium fluoride for
reuse. In addition, wet scrubbers are used to control
particulate levels in the air vented from the beryllium pebble
plant. Pure beryllium metal scrap is treated with nitric and
hydrofluoric acid prior to being vacuum cast along with beryllium
pebbles prior to billet manufacturing. The spent acid is
discharged as a wastewater stream.
OTHER FACTORS
The other factors considered in this evaluation were shown to be
inappropriate bases for subdivision. Air pollution control
methods, treatment costs, and total energy requirements are
functions of the selected subcategorization factors — metal
product, raw materials, and production processes. Therefore,
they are not independent factors and do not affect the
subcategorization which has been applied. Certain other factors,
such as plant age, plant size, and the number of employees, were
also evaluated and determined to be inappropriate for use as
bases for further subdivision of the primary beryllium
subcategory.
PRODUCTION NORMALIZING PARAMETERS
As discussed previously, the effluent limitations and standards
developed in this document establish mass limitations on the
3652
-------
PRIMARY BERYLLIUM SUBCATEGORY ; SECT - IV
discharge of specific pollutant parameters. To allow these
regulations to be applied to plants with various production
capacities, the mass of pollutant discharged must be related to a
unit of production.... This factor is known as the production
normalizing parameter (PNP).
In general, for each production process which has a wastewater
associated with it, the; actual mass of beryllium product or
intermediate produced will; be used as the PNP. Thus, the PNPs
for the 16 subdivisions or building blocks are listed below
Building Block
Solvent extraction raffinate
from bertrandite ore;
2v Solvent extraction raffinate
from beryl ore
3. Beryllium carbonate filtrate
4. Beryllium hydroxide filtrate
5.
6. Beryllium hydroxide supernatant
8
9,
10.
11.
12.
Beryllium oxide calcining fur-
nace wet air pollution control
Process water •:
i .
Fluoride furnace scrubber
Chip treatment wastewater
Beryllium pebble plant area
vent wet air pollution control
Beryl ore gangue dewalpering
Bertrandite ore gangue
dewatering
13. Beryl ore processing
PNP
kkg of beryllium carbonate
produced from bertrandite
ore as beryllium
kkg .of beryllium carbonate
produced from beryl ore as
beryllium
kkg of beryllium carbonate
produced as beryllium
kkg of beryllium hydroxide
produced as beryllium
kkg of beryllium oxide
produced
kkg of beryllium hydroxide
produced from scrap and
residues as beryllium
kkg of beryllium pebbles
produced
kkg of beryllium pebbles
produced
kkg of beryllium scrap
chips treated
kkg of beryllium pebbles
produced
kkg of beryl ore processed
kkg of bertrandite ore
processed
kkg of beryl ore processed
3653
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - IV
Building Block
14. AIS area wastewater
15. Bertrandite ore leaching
scrubber
PNP
kkg of total beryllium
carbonate produced as
beryllium
kkg of bertrandite ore
processed
16. Bertrandite ore counter
current decantation
scrubber
kkg of bertrandite ore
processed
Other PNPs were considered. The use of production capacity
instead of actual production was eliminated from consideration
because the mass of the pollutant produced is more a function of:
true production than of installed capacity.
3654
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - V
SECTION V
WATER USE AND WASTEWATER CHARACTERISTICS
This section describes the characteristics of the wastewaters
associated with the primary beryllium subcategory. Water use and
discharge rates are explained and then summarized in tables at
the end of this section. Data used to characterize the
wastewaters are presented, Finally, the specific source, water
use and discharge flows, and wastewater characteristics for each
separate wastewater source are discussed.
Two principal data sources were used in the development of
effluent limitations and standards for this subcategory data
collection portfolios (dcp) and field sampling results. Data
collection portfolios contain information regarding wastewater
flows and production levels.
In order to quantify the pollutant discharge from primary
beryllium plants, a field sampling program was conducted. Samples
were analyzed for 124 of the 126 priority pollutants arid other
pollutants deemed appropriate. (Because the analytical standard
for TCDD was judged to be too hazardous to be made generally
available, samples were never analyzed for this pollutant.
Samples were also never analyzed for asbestos. There is no
reason to expect that TCDD or asbestos would be present in
nonferrous metals manufacturing.) One plant was selected for
sampling in the primary beryllium subcategory. In general, the
samples were analyzed for three classes of pollutants: priority
organic pollutants, priority metal pollutants, and criteria
pollutants (which includes both conventional and nonconventional
pollutants).
i
As described in Section IV of this supplement, the primary
beryllium subcategory has been divided into 16 subdivisions or
wastewater sources, so that the promulgated regulation contains
mass discharge limitations: and standards for 16 building blocks
which may discharge process wastewater. Differences in the
wastewater characteristics associated with these subdivisions are
to be expected. For this reason, wastewater streams
corresponding to each subdivision are addressed separately in the
discussions that follow. These wastewater sources are:
(a) Solvent extraction raffinate from bertrandite ore,
(b) Solvent extraction raffinate from beryl ore,
(c) Beryllium carbonate filtrate,
(d) Beryllium hydroxide filtrate,
(e) Beryllium oxide calcining furnace wet air pollution control,
(f) Beryllium hydroxide supernatant,
(g) Process water, ,
(h) Fluoride furnace scrubber,
(i) .Chip treatment wastewater,
(j) Beryllium pebble plant area vent wet air pollution control,
(k) Beryl ore gangue dewatering,
' i 3655
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - V
(1) Bertrandite ore gangue dewatering,
(m) Beryl ore processing,
(n) AIS area wastewater,
(o) Bertrandite ore leaching scrubber, and
(p) Bertrandite ore counter current decantation scrubber.
WASTEWATER FLOW RATES
Data supplied by dcp responses were evaluated, and two flow-to-
production ratios, water use and wastewater discharge flow, were
calculated for each stream. The two ratios are differentiated by
the flow value used in calculation. Water use is defined as the
volume of water or other fluid required for a given process per
mass of beryllium product and is therefore based on the sum of
recycle and makeup flows to a given process. Wastewater flow
discharged after pretreatment or recycle (if these are present)
is used in calculating the production normalized flow — the
volume of wastewater discharged from a given process to further-
treatment, disposal, or discharge per mass of beryllium produced.
Differences between the water use and wastewater flows associated
with a given stream result from recycle, evaporation, and carry-
over on the product. The production values used in calculation
correspond to the production normalizing parameter, PNP, assigned
to each stream, as outlined in Section IV. As an example,
beryllium oxide calcining furnace wet air pollution control water
flow is related to the production of the beryllium oxide. As
such, the discharge rate is expressed in liters of scrubber water
per metric ton of beryllium oxide produced (gallons of scrubber
water per ton of beryllium oxide as produced).
The production normalized discharge flows were compiled and
statistically analyzed by stream type. These production
normalized water use and discharge flows are presented by
subdivision in Tables V-l through V-10 (pages 3663 - 36666) Where
appropriate, an attempt was made to identify factors that could
account for variations in water use and discharge rates. These
variations are discussed later in this section by subdivision. A
similar analysis of factors affecting the wastewater flows is
presented in Sections IX, X, XI, and XII where representative
BPT, BAT, NSPS, and pretreatment flows are selected for use in
calculating the effluent limitations.
The water use and discharge rates shown do not include nonprocess
wastewater, such as rainfall runoff and noncontact cooling water.
WASTEWATER CHARACTERIZATION DATA
Data used to characterize the various wastewaters associated with
primary beryllium production come .from two sources—data
collection portfolios and analytical data from field sampling
trips.
3656
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - V
DATA COLLECTION PORTFOLIOS
In the data collection portfolios, the beryllium plants that
discharge wastewater were asked to specify the presence or
absence of toxic pollutants in their wastewater. In all cases,
the plants indicated that the priority organic pollutants were
believed to be absent. The responses for the priority metals and
cyanide are summarized below:
Pollutant
Antimony
Arsenic
Beryllium
Cadmium
Chromijum
Copper;
Cyanide
Lead
Mercury
Nickel
Selenium
Silver;
Thallium
Zinc
Known
Present
0
0
1
0
0
1
1
1
0
1
0
0
0
0
Believed
Present
0
0
1
0
0
1
0
1
0
0
0
0
0
0
FIELD SAMPLING DATA ;
In order to quantify the concentrations of pollutants present in
wastewater from primary beryllium plants, wastewater samples were
collected at one of the two primary beryllium plants in the
United States. A diagram indicating the sampling sites and
contributing production processes is shown in Figures V-l and V-2
(page 3727 - 3728).
Raw wastewater data are summarized in Tables V-ll through V-15
(pages 3667 - 3696) Analytical results at various points in the
treatment scheme of plant A are summarized in Tables V-16 through
V-20 (pages 3700 - 3723). ;Note that the stream numbers listed in
the tables correspond to those given in individual plant sampling
site diagrams, Figures V-l ,and V-2. Where no data are listed for
a specific day of sampling, the wastewater samples for the stream
were not collected.
The data tables include some samples measured at concentrations
considered not quantifiable. The base-neutral extractable, acid
extractable, and volatile iorganics generally are considered not
quantifiable at concentrations equal to or less than 0.010 mg/1.
Below this concentration organic analytical results are not
quantitatively accurate; ihowever, the analyses are useful to
indicate the presence of a! particular pollutant. The pesticide
fraction is considered riot quantifiable at concentrations equal
to or less than 0.005 rag/1.;
3657
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - V
The detection limits shown on the data tables for priority metals
and conventional and nonconventional pollutants are not the same
in all cases as the published detection limits for these
pollutants by the same analytical methods. The detection limits
used were reported with the analytical data and hence are the
appropriate limits to apply to the data. Detection limit
variation can occur as a result of a number of laboratory-
specific equipment-specific and daily operator-specific factors.
These factors can include day-to-day differences in machine
calibration, variation in stock solutions, and variation in
operators.
The statistical analysis of data includes some samples measured
at concentrations considered not quantifiable. For data
considered as detected but below quantifiable concentrations. a
value of zero is used for averaging. Priority organic:
nonconventional, and conventional pollutant data reported with a
"less than" sign are considered as detected, but not further-
quantifiable.' 'A value of zero is also used for averaging. If a
pollutant is reported as not detected, it is assigned a value of:
zero in calculating the average. Finally, priority metal values
reported as less than a certain value were considered as not
quantifiable, and consequently were assigned a value of zero in
the calculation of the average.
Finally, appropriate source water concentrations are presented
with the summaries of the sampling data. The method by which
'each sample was collected is indicated by number, as follows:
1. one-time grab
2. manual composite during intermittent process operation
3. 8-hour manual composite
4. 8-hour automatic composite
5. 24-hour manual1 composite
6. 24thour automatic* composite
WASTEWATER 'CHARACTERISTICS AND FLOWS BY SUBDIVISION
Since primary beryllium production involves 16 principal sources
of wastewater and each has potentially different characteristics
and flows, the wastewater characteristics and discharge rates
corresponding to each subdivision will be described separately A
brief description of why the associated production processes
generate a wastewater and explanations for variations of water
use within each subdivision will also be discussed.
SOLVENT EXTRACTION RAFFINATE FROM BERTRANDITE ORE
Beryllium is extracted from bertrandite ore by leaching with
sulfuric acid and extracting beryllium from the acid solution
with an organic solvent, di-2-ethylhexyl phosphoric acid in
kerosene. The barren acid solution, or raffinate stream, is
discarded as a waste stream. Water use and discharge rates for
3658
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - V -
this stream are presented'in Table V-l (page 3663) in liters per
metric ton of beryllium carbonate produced (as beryllium). These
flows were calculated based on process information from the one
facility currently processing bertrandite ore.
Although no sampling data'are available for this waste stream, it
is expected to have an acidic pH, treatable concentrations of
beryllium and other toxic metals which may be leached from the
ore along with beryllium, and treatable concentrations of
suspended solids. It is also possible that low levels of
priority organic pollutants are present in this stream as
residuals from the solvent extraction process.
SOLVENT EXTRACTION RAFPINATE FROM BERYL ORE
Beryllium is extracted from beryl ore in a manner similar to that
used with bertrandite ore. After preliminary processing steps,
the ore is leached with sulfuric acid and beryllium is extracted
from the acid solution with an organic solvent. The barren
raffinate is discharged. Water use and discharge rates for this
wastewater stream are presented in Table V-2 (page 3663) in
liters per metric ton of beryllium carbonate produced (as
beryllium).
No sampling data are available for this waste stream; however, it
is expected to have an acidic pH and treatable concentrations of
beryllium and other priority metals which may be present in the
beryl ore raw material. Treatable concentrations of suspended
solids are also expected to be present. It is also possible that
toxic organic pollutants may be present in this wastewater stream
if they are present in the: organic solvent as impurities.
BERYLLIUM CARBONATE FILTRATE
Beryllium is stripped from the organic phase into an aqueous
solution. Beryllium carbonate is precipitated and separated from
the liquid phase by filtration. The filtrate stream is then
discharged. Water use andidischarge rates for this waste stream
are presented in Table V-3 (page 3663) in liters per metric ton
of beryllium carbonate produced (as beryllium).
Although there are no sampling data available for this waste
stream it is expected to have an alkaline pH and treatable
concentrations of beryllium and possibly other toxic metals.
Since the separation of BeCO4 from the organic phase is virtually
complete, no priority organic pollutants are expected to be
present in this stream. >
BERYLLIUM HYDROXIDE FILTRATE
Beryllium carbonate is teslurried in deionized water, and
hydrolyzed in an autoclave to convert the suspended solids to
beryllium hydroxide. The 'beryllium hydroxide is separated from
the liquid phase by filtration. The filtrate stream is then
; 3659
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - V
discharged. Water use and discharge rates are shown in Table V-4
(page 3664) in liters per metric ton of beryllium hydroxide
produced (as beryllium).
The flow rate shown in Table V-4 was revised based on new
information supplied to Agency after the completion of the
original rulemaking.
No sampling data are available for this wastewater stream;
however, it is expected to have an alkaline pH and may contain
treatable concentrations of beryllium.
BERYLLIUM OXIDE CALCINING FURNACE WET AIR POLLUTION CONTROL
When beryllium oxide is produced from beryllium hydroxide, the
hydroxide is converted to beryllium sulfate and the sulfate is
calcined in a furnace to produce beryllium oxide. Sulfur oxide
emissions from the furnaces are controlled with caustic
scrubbers. The scrubber liquor is discharged as a wastewater
stream. The production normalized water use and discharge rates
for beryllium oxide calcining furnace wet air pollution control
are shown in Table V-5 (page 3664) in liters per metric ton of
beryllium oxide produced and the water use data includes
extensive recycle (i.e., greater than 90 percent recycle).
Table V-ll (page 3667) summarizes the field sampling data for
beryllium oxide calcining wet air pollution control. This waste
stream has a neutral pH and very high concentrations of dissolved
solids (primarily sodium sulfate). Treatable concentrations of
beryllium, fluoride, and suspended solids are present.
BERYLLIUM HYDROXIDE SUPERNATANT
When beryllium is recovered from recycled customer material,
internally generated residues, scrap, and recycled mother liquor
from the beryllium oxide crystallization operations, the raw
material is dissolved in sulfuric acid and beryllium is then
precipitated with caustic as beryllium hydroxide After gravity
separation, the supernatant is discharged as a wastewater stream.
Production normalized water use and discharge data for beryllium
hydroxide supernatant are shown in Table V-6 (page 3664) in
liters per metric ton of beryllium hydroxide produced (as
beryllium).
Table V-12 (page 3672) summarizes the field sampling data for
beryllium hydroxide supernatant. It can be seen that this waste
stream has an alkaline pH and treatable _concentrations of
beryllium, copper, fluoride, and suspended solids.
PROCESS WATER
Process condensates are generated from the ammonium beryllium
fluoride crystallizer and the ammonium fluoride sludge filtrate
evaporator. The condensed water is used as makeup for the
fluoride furnace scrubbing system, for the beryllium pebble plant
3660
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - V
scrubbing system, for sludge washing, and general plant water
usage such as floor washings. Periodic discharge from the
process water pit is necessary to prevent dissolved solids
build-up. Production normalized water use and discharge rates for
process water are presented in Table V-7 in liters per metric ton
of beryllium metal produced.
Field sampling data for process water are summarized in Table V-
13 (page 3676). These data are from samples collected from the
process water pit. The data ,show that process water is
characterized by a neutral pH, and treatable concentrations of
beryllium and fluoride. Ammonia and cyanide are also reported as
present above treatable concentrations.
FLUORIDE FURNACE SCRUBBER ;
Beryllium fluoride (BeF2) intermediate is produced by heating
ammonium beryllium fluoride in a graphite induction furnace and
driving off ammonium flubride (NH4F). Ammonium fluoride is
recovered in a wet scrubbing system. Although the scrubber
liquor is recycled extensively (>99.9 percent), a blowdown stream
is periodically recycled to the ammonium bifluoride makeup tank
to be used in beryllium fluoride intermediate production
Production normalized water use and discharge rates for fluoride
furnace scrubbing liquor are presented in Table V-8 (page 3665)
in liters per metric ton of beryllium pebbles produced.
Although at proposal this stream was believed to have been
sampled, comments from the plant indicated that the scrubber
sampled was the area vent scrubber in the beryllium pebble plant
Fluoride furnace scrubber wastewater is expected to be
contaminated with ammonia and fluoride based on the process
occurring in the furnace. ',
CHIP TREATMENT WASTEWATER ;
Pure beryllium metal scrap in the form of chips is treated with
nitric acid and rinsed prior to being vacuum cast along with
beryllium pebbles into a beryllium metal billet. The spent acid
and rinse water are discharged. This operation combines refining
beryllium from secondary; as well as primary sources. The
quantity of beryllium scra'p treated and subsequently cast with
the beryllium pebbles, however, is small enough to have
negligible impact on the iproduction normalized water use and
discharge rates for this |operation. Water use and discharge
rates are presented in Table V-9 (page 3665) in liters per metric
ton of beryllium scrap chips treated.
Table V-15 (page 3696) summarizes the field sampling data for
chip treatment wastewater. This wastewater is characterized by
an acid pH and very high concentrations of beryllium. Other
priority metals are present at treatable concentrations including
chromium and zinc. Treatable concentrations of fluoride and
suspended solids are also present.
3661
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - V
BERYLLIUM PEBBLE PLANT AREA VENT WET AIR POLLUTION CONTROL
The beryllium pebble plant contains a ventilation system for air
circulation A wet scrubber is employed to clean the used air
prior to venting to the atmosphere. Although the scrubber liquor
is recycled extensively, a blowdown stream is periodically
discharged to the process water pit. Makeup water for the
scrubber is obtained from the process water pit.
Field sampling data for beryllium pebble plant area vent scrubber
are summarized in Table V-14 (page 3691). The data show that
this stream is characterized by a slightly acidic pH, and
treatable concentrations of beryllium and fluoride.
ADDITIONAL BUILDING BLOCKS
In the settlement agreement of April 1987, EPA agreed to propose
to add new building blocks for the following six processes in the
primary beryllium subcategory: beryl ore gangue dewatering,
bertrandite ore gangue dewatering, beryl ore processing
(comprises quench pit, scrubber and washdown), AIS area
wastewater, bertrandite ore leaching scrubber, and bertrandite
ore counter current decantation scrubber. These building blocks
were not included in the promulgated rule because the Agency
lacked adequate information about these processes to promulgate
effluent limits at that time. The Agency anticipated that
effluent limits for these wastestreams would be established on a
best professional judgment ("BPJ") basis by the permit writers
during the permit issuance process. The petitioner has requested
that EPA establish national regulations for these processes and
during the settlement negotiations, the Agency obtained the
necessary additional information about these processes to do so.
The wastewater discharge rates for these six processes are given
below: beryl ore gangue dewatering 1,043 1/kkg of beryl ore
processed, bertrandite ore gangue dewatering 2,665 l/kk9 o£
bertrandite ore processed, beryl ore processing 7,303 1/kkg of
beryl ore processed, aluminum iron sludge (AIS) area wastewater
468,000 1/kkg of total beryllium carbonate produced as beryllium,
bertrandite ore leaching scrubber 1,511 1/kkg of bertrandite ore
processed, bertrandite ore countercurrent decantation (CCD)
scrubber 101 1/kkg of bertrandite ore processed.
3662
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - V
TABLE V-l
WATER USE AND DISCHARGE RATES FOR
SOLVENT EXTRACTION RAFFINATE FROM BERTRANDITE ORE
(103 1/kkg of beryllium carbonate produced
Plant Code
1177
from bertrahdite ore as beryllium)
Percent
Recycle
0 i
Production
Normalized
Water Use
2246
Production
Normalized
Discharge Rate
2246
TABLE V-2
WATER USE AND DISCHARGE RATES FOR
SOLVENT EXTRACTION RAFFINATE FROM BERYL ORE
(103 1/kkg of beryllium carbonate produced
Plant Code
1177
from beryl ore as beryllium)
Percent
Recycle
0
Production
Normalized
Water Use
220
Production
Normalized
Discharge Rate
220
TABLE V-3
WATER USE AND DISCHARGE RATES FOR
BERYLLIUM-CARBONATE FILTRATE
(10 1/kkg of beryllium carbonate produced as beryllium)
Plant Code
1177
Percent
Recycle
0
Production
Normalized
Water Use
214.5
Production
Normalized
Discharge
214.5
3663
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - V
TABLE V-4
WATER USE AND DISCHARGE RATES FOR
BERYLLIUM HYDROXIDE FILTRATE
(103 1/kkg of beryllium carbonate produced as beryllium)
Plant Code
1177
Percent
Recycle
Production
Normalized
Water Use
136.0
Production
Normalized
Discharge Rate
136.0
TABLE V-5
WATER USE AND DISCHARGE RATES FOR
BERYLLIUM OXIDE CALCINING FURNACE WET AIR POLLUTION CONTROL
(103 1/kkg of beryllium oxide produced)
Plant Code
1111
Percent
Recycle
>90
Production
Normalized
Water Use
NR
Production
Normalized
Discharge Rate
263.7
TABLE V-6
WATER USE AND DISCHARGE RATES FOR
BERYLLIUM HYDROXIDE SUPERNATANT
(103 1/kkg of beryllium hydroxide produced
from scrap and residues as beryllium)
Plant Code
1111
Percent
Recycle
0
Production
Normalized
Water Use
230.0
Production
Normalized
Discharge Rate
230.0
3664
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - V
Plant Code
TABLE V-7
WATER USE AND DISCHARGE RATES FOR
PROCESS WATER
1/kkg of beryllium pebbles produced)
Percent
Recycle
NR
Production
Normalized
Water Use
NR
Production
Normalized
Discharge Rate
174.8
, TABLE V-8
WATER USE AND DISCHARGE RATES FOR
SOLVENT EXTRACTION RAFFINATE FROM BERTRANDITE ORE
(103 1/kkg of beryllium carbonate produced
from bertrandite ore as beryllium)
Plant Code
1111
Percent
Recycle
100 ;
Production
Normalized
Water Use
NR
Production
Normalized
Discharge Rate
0
TABLE V-9
WATER USE AND DISCHARGE RATES FOR
CHIP TREATMENT WASTEWATER
(103 1/kkg of beryllium scrap chips treated)
Plant Code
1111
Percent:
Recycle
0 ;
Production
Normalized
Water Use
7.75
Production
Normalized
Discharge Rate
7.75
3665
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - V
TABLE V-10
WATER USE AND DISCHARGE RATES FOR
BERYLLIUM PEBBLE PLANT AREA VENT WET AIR POLLUTION CONTROL
(103 1/kkg of beryllium pebbles produced)
Plant Code
1111
Percent
Recycle
NR
Production
Normalized
Water Use
NR
Production
Normalized
Discharge Rate
3666
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - V
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PRIMARY BERYLLIUM SUBCATEGORY
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PRIMARY BERYLLIUM SUBCATEGORY
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3704
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PRIMARY BERYLLIUM SUBCATEGORY
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PRIMARY BERYLLIUM SUBCATEGORY
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PRIMARY BERYLLIUM SUBCATEGORY SECT - V
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PRIMARY BERYLLIUM SUBCATEGORY SECT - V
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3725
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PRIMARY BERYLLIUM SUBCATEGORY
SECT - V
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PRIMARY BERYLLIUM SUBCATEGORY
SECT - V
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SAMPLING LOCATIONS AT BERYLLIUM PLANT A -
BERYLLIUM OXIDE PRODUCTION AREA
427
3727
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - V
Pebble Plant Area Vent
Scrubber
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473
Process Water Pit
Chip Treatment
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426
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491
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Figure V-2
SAMPLING LOCATIONS AT BERYLLIUM PLANT A -
BERYLLIUM METAL PRODUCTION AREA
3728
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI
; SECTION VI / .
SELECTION !OF POLLUTANT PARAMETERS
Section V of this supplement presented data from primary
beryllium plant sampling visits and subsequent chemical analyses.
This section examines that data and discusses the selection or
exclusion of pollutants for potential limitation./
Eaclv pollutant selected for potential limitation is discussed in
Section VI of - Vol. I. That discussion provides information
concerning the nature of! the pollutant (i.e., whether it is a
naturally occurring substance, processed metal, or a manufactured
compound); general physical properties and the form of the
pollutant; toxic effects: of the pollutant in humans and other
animals; and behavior of the pollutant in POTW at the
concentrations expected in' industrial discharges.
The discussion that follows presents and briefly discusses the
selection of: conventional and nonconventional pollutants for
effluent limitations. Also described is the analysis that was
performed to select or exclude toxic pri9rity pollutants for
further consideration for limitations and standards. Pollutants
will be considered for ! limitation if they are present in
concentrations treatable by the technologies considered in this
analysis. The treatable'concentrations used for the priority
metals were the long-term performance values achievable by
chemical precipitation. Sedimentation, and filtration. The
treatable concentrations used for the priority organics were the
long-term performance values achievable by carbon adsorption.
CONVENTIONAL AND NONCONVENTIONAL POLLUTANT PARAMETERS
This study examined samples from the , primary. beryllium
subcategory for three conventional pollutant parameters (oil and
grease, total suspended slids, .and pH) and two nonconventional
pollutant parameters (ammonia and fluoride).
Other nonconventional pollutants were analyzed for, including
aluminum, barium, boron, cobalt, iron, magnesium, manganese,
molybdenum, tin, titanium, and vanadium. These nonconventional
pollutants were not selected for limitations in this subcategory
because they were generally not found in treatable concentrations
in raw wastewater sampled, and there is no reason to believe
these pollutants should be !present based on an examination of the
raw materials and production processes involved. In addition,
the Agency believes these nonconventional pollutants will be
effectively controlled by the limitations established for the
selected priority metal pollutants. „
CONVENTIONAL AND NONCONVENTIONAL POLLUTANT PARAMETERS SELECTED
The conventional and nonconventional pollutants or pollutant
parameters selected for limitation in this subcategory are:
3729
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI
ammonia
fluoride
total suspended solids (TSS)
PH
Although ammonia was not proposed for limitations, the Agency
stated that it was considering limiting ammonia in the Notice of
Data Availability, based on data received in a comment. Ammonia
is selected for regulation in this subcategory. In samples split
and analyzed by the primary beryllium plant sampled, up to 4,300
mg/1 of NH3 were found in samples of process water. Ammonia
compounds are used throughout the beryllium production process
and are expected to be present in wastewaters generated by the
process. Therefore, the Agency is selecting this pollutant for
regulation.
Fluoride was detected in all 14 raw wastewater samples analyzed.
Eleven of the observed concentrations were above the treatable
concentration of 14.5 mg/1. The treatable concentrations
observed ranged from 35 to 6,650 mg/1. For this reason, fluoride
is selected for limitation in this subcategory.
TSS concentrations ranging from less than 1 to 370 mg/1 were
observed in the 13 raw waste samples analyzed for this study. Ten
of the concentrations are above the 2.6 mg/1 treatable
concentration. Most of the specific methods used to remove toxic
metals do so by converting these metals to precipitates, and
these toxic-metal-containing precipitates should not be
discharged. Meeting a limitation on total suspended solids helps
ensure that removal of these precipitated toxic metals has been
effective. For these reasons, total suspended solids are
selected for limitation in this subcategory.
The 14 pH values observed during this study ranged from 0.97 to
11.5. Effective removal of toxic metals by precipitation
requires careful control of pH. Since pH control within the
desirable limits is readily attainable by available treatment, pH
is selected for limitation in this subcategory.
TOXIC PRIORITY POLLUTANTS
The frequency of occurrence of the priority metal pollutants and
cyanide in the raw wastewater samples taken is presented in Table
VI-1 (page 3739). Table VI-1 is based on the raw wastewater data
from streams 481. 484. 491, 426. 473, and 495 (see Section V).
These data provide the basis for the categorization of specific
pollutants, as discussed below. Treatment plant samples were not
considered in the frequency count.
Some samples were analyzed for toxic organic pollutants, and
although these analytical data were not available in sufficient
time prior to the regulatory proposal to allow for thorough
analysis. these data are presented in Section V and have been
used in the selection of pollutant parameters for limitation for
3730
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI
the promulgated regulation.
TOXIC POLLUTANTS NEVER DETECTED
detected
lisfced in Table VI-2 (page 3742) were not
any raw wastewater samples from this subcateqorv-
H ^ey .are ^Ot selected for consideration in
establishing limitations.
TOXIC POLLUTANTS NEVER FOUND ABOVE THEIR ANALYTICAL
QUANTIFICATION CONCENTRATION
The toxic pollutants listed in Table VI-3 (page 3744) were
found above their analytical quantification c?ncen"it?oS in any
raw wastewater samples from this subcategory; therefore, they are
not selected for consideration in establishing limitations.
m™™ P°LLUTANTS PRESENT BELOW CONCENTRATIONS ACHIEVABLE BY
TREATMENT
selected f°r consideration in
«o« iialons because they were not found in any raw
wastewater samples from this subcategory above concentrations
considered achievable by existing o/ available treatment
list**36 ^llutants are discussed individually
114. arsenic
123. mercury .!.
! .'••"•••
Arsenic was detected above ! its quantifiable concentration of 0.01
*g/1_.^ Kf°Ur °Ut °f 14 r^w wastewater samples analyzed? The
quantifiable concentrations observed ranged from 0.042 to 0.19
*nM,U^ K° W^t°^ are below the concentration considered
achievable by available treatment technology (0.34 mg/1)
regulation3 therefore not selected for further consideration
for
Mercury was detected above the analytical quantification
concentration in six out o;f,14 raw wastewater sampleJ analyzed
The largest concentration observed is 0.0009 mg/1, which is well
below the treatable concentration of 0.036 2g/i. Mercury is
therefore not selected for further consideration for regulation
TOXIC POLLUTANTS DETECTED IN A SMALL NUMBER OF SOURCES
The toxic pollutants listed below were not selected for
limitation because they were detectable in the effluent from only
m and are Unlquely
3. acrylonitrile
4. benzene
6. carbon tetrachloride
3731
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI
10. 1,2-dichloroethane
13. 1,1-dichloroethane
15. 1,1,2,2-tetrachloroethane
19. 2-chloroethyl vinyl ether
22. p-chloro-m-cresol
23. chloroform
29. 1,1-dichloroethylene
30. 1,2-trans-dichloroethylene
32. 1,2-propropane
33. 1,3-dichloropropene
44. methylene chloride
47. bromoform ;
48. dichlorobromomethane
51. chlorodibromomethane
68. di-n-butyl phthalate
70. diethyl phthalate
85. tetrachloroethylene
86. toluene
87. trichloroethylene
118. cadmium
122. lead
124. nickel ;
126. silver
128. zinc .
Acrvlonitrile was detected above the level considered achievable
by identified treatment technology (0.010 mg/1) in three out of
three raw wastewater samples. The treatable concentrations
observed Ire 1.68. 4.59 and 4.56 mg/1. The Agency has no reason
?o believe that treatable concentrations of acrylonitrile should
be plesSnt in primary beryllium wastewaters. The Agency believes
that thlse Sslrved valueJ are not representative and may be due
to analytical error or site specific factors Acrylonitriile is
therefore not selected for further consideration for limitation.
Benzene was detected above the level considered achievable by
identified treatment technology in. three out of three raw
wastewater samples. The treatable concentrations observed are
0"sIT 0^207? and 0.617 mg/1. The Agency has no reason to
believe that treatable concentrations of benzene should be
in primary beryllium wastewaters. The Agency believes
si o6«rveS values are not representative and may be due
to analytical error or site specific factors. ^Benzene is
therefore no? selected for further consideration for limitation.
Carbon tetrachloride was detected above the level considered
achievablf by identified treatment technology (0.010 mg/1) in
?hree out of three raw wastewater samples. The treatable
cSnc!nt?ations observed are 0.069, 0.161 and 0.164 mg/1. The
IgeScy his no reason to believe that treatable concentrations of
clrbon tetrachloride should be present in primary beryllium
wSstewaters The Agency believes that these observed values are
not representative and may be due to analytical error or site
specific labors. Carbon tetrachloride is therefore not selected
for further consideration for limitation.
3732
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI
1,2-Dichloroethane was detected above the level considered
achievable by identified treatment technology (0.010 mg/1) in two
out of three raw wastewater samples. The treatable
concentrations observed ar!e 0.211 and 0.142 mg/1. The Agency has
no reason to believe that treatable concentrations of 1 2-
dichloroethane should ;be present in primary beryllium
wastewaters. The Agency believes that these observed values are
not representative and may be due to analytical error or site
specific factors. l,2-Di;chloroethane is therefore not selected
for further consideration for limitation.
1,1-Dichloroethane was detected above the level considered
achievable by identified treatment technology (0.010 mg/1) in
three out of three raw wastewater samples. The treatable
concentrations observed are 0.019, 0.043, and 0.043 mg/1. The
Agency has no reason to believe that treatable concentrations of
1,1-dichloroethane should be present in primary beryllium
wastewaters. The Agency believes that these observed values are
not _representative and may be due to analytical error or site
specific factors. 1,1-Dichloroethane is therefore not selected
for further consideration for limitation.
1,1,2,2-Tetrachloroethane was detected above the level considered
achievable by identified treatment technology (0.010 mg/1) in one
out of three raw wastewater samples. The treatable concentration
observed is 0.078 mg/1. The Agency has no reason to believe that
treatable concentrations of 1,1,2,2-tetrachloroethane should be
present in primary beryllium wastewaters. The Agency believes
that the observed value is not representative and may be due to
analytical error or site specific factors. 1,1,2,2-
Tetrachloroethane is therefore not selected for further
consideration for limitation.
2-Chlproethyl vinyl ether was detected above the level considered
achievable by identified treatment technology (0.010 mg/1) in
three out of three raw wastewater samples. The treatable
concentrations observed are 0.101, 0.014, and 0.030 mg/1. The
Agency has no reason to believe that treatable concentrations of
2-chloroethyl vinyl ether :should be present in primary beryllium
wastewaters. The Agency believes that these observed values are
not representative and may be due to analytical error or site
specific factors. 2-Chloroethyl vinyl ether is therefore not
selected for further consideration for limitation.
Parachlorometacresol was jdetected above the level considered
achievable by identified treatment technology (0.010 mg/1) in one
out of three raw wastewater samples. The treatable concentration
observed is 0.072 mg/1. The Agency has no reason to believe that
treatable concentrations ; of parachlorometacresol should be
?uefen!L inPrimary beryllium wastewaters. The Agency believes
that the observed value is not representative and may be due to
analyticaVerror or site specific factors. Parachlorometacresol
is therefore not selected for further consideration for
limitation. !
3733
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI
Chloroform was detected above the level considered achievable by
identified treatment technology (0.010 mg/1) in three out of
three raw wastewater samples. The treatable concentrations
observed are 0.044, 0.106, and 0.109 mg/1. The Agency has no
reason to believe that treatable concentrations of chloroform
should be present in primary beryllium wastewaters. The Agency
believes that these observed values are not representative and
may be due to analytical error or site specific factors.
Chloroform is therefore not selected for further consideration
for limitation.
1,1-Dichloroethylene was detected above the level considered
achievable by identified treatment technology (0.010 mg/1) in
three out of three raw wastewater samples. The treatable
concentrations observed are 0.047, 0.111, and 0.115 mg/1. The
Aqency has no reason to believe that treatable concentrations of
1,1-dichloroethylene should be present in primary beryllium
wastewaters. The Agency believes that these observed values are
not representative and may be due to analytical error or site
specific factors. 1,1-Dichloroethylene is therefore not selected
for further consideration for limitation.
1,2-Trans-dichloroethylene was detected above the Jevel
considered achievable by identified treatment technology (0.010
mg/1) in three out of three raw wastewater samples. The
treatable concentrations observed are 0.053, 0.134, and 0.133
mq/1. The Agency has no reason to Believe that treatable
concentrations of 1,2-trans-dichloroethylene should be present in
primary beryllium wastewaters. The Agency believes that these
observed values are not representative and may be due to
analytical error or site specific factors. 1,2-Trans-
dichloroethylene is_ therefore not selected for further
consideration for limitation.
1,2-Dichldropropane was detected above the level considered
achievable by identified treatment technology (0.010 mg/1) in
three out of three raw wastewater samples. The treatable
concentrations observed are 0.043, 0.113, and 0.104 mg/1. The
Aqency has no reason to believe that treatable concentrations _of
1,2-dichloropropane should be present in primary beryllium
wastewaters. The Agency believes that these observed values are
not representative and may be due to analytical error or sire
specific factors. 1,2-Dichlorbpropane is therefore not selected
for further consideration for limitation.
1 3-Dichloropropene was detected above the level considered
achievable by identified treatment technology (0.010 mg/1) in two
out of three raw wastewater samples. The treatable
concentrations observed are 0.036 and 0.023 mg/1. The Agency has
no reason to believe that treatable concentrations of 1,3-
dichloropropene should be : present in primary beryllium
wastewaters. The Agency believes that these observed values are
not representative and may be due to analytical error or site
specific factors. 1,3-Dichloropropene is therefore not selected
3734
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI
i •
for further consideration ;for limitation.
Methylene chloride was detected above the level considered
achievable by identified treatment technology (0.010 mg/1) in
three out of three raw; wastewater samples. The treatable
concentrations observed are.0.114, 0.211, and 0.208 mg/1. The
Agency has no reason to believe that treatable concentrations of
methylene chloride should be present in primary beryllium
wastewaters. The Agency believes that these observed values are
not representative and may be due to analytical error or site
specific factors. Methyjlene chloride is therefore not selected
for further consideration for limitation.
Bromoform was detected above the level considered achievable by
identified treatment technology (0.010 mg/1) in two out of three
raw wastewater samples. The treatable concentrations observed
are 0.130 and 0.077 mg/l.| The Agency has no reason to believe
that treatable concentrations of bromoform should be present in
primary beryllium wastewaters. The Agency believes that these
observed values are not representative and may be due to
analytical error or site specific factors. Bromoform is
therefore not selected for,further consideration for limitation.
Dichlorobromomethane was detected above the level considered
achievable by identified;treatment technology (0.010 mg/1) in
three of three raw wastewater samples. The treatable
concentrations observed are 0.021, 0.041. and 0.041 mg/1. The
Agency has no reason to believe that treatable concentrations of
dichlorobromomethane should be present in primary beryllium
wastewaters. The Agency believes that these observed values are
not ^representative and may be due to analytical error or site
specific factors. Dichlorbbromomethane is therefore not selected
for further consideration for limitation.
Chlorodibromomethane was :detected above the level considered
achievable by identified,treatment technology (0.010 mg/1) in
three of three raw wastewater samples. The treatable
concentrations observed are 0.080, 0.288, and 0.139 mg/1. The
Agency has no reason to believe that treatable concentrations of
Chlorodibromomethane should be present in primary beryllium
wastewaters. The Agency believes that these observed values are
not representative and may be due to analytical error or site
specific factors. Chlorodibromomethane is therefore not selected
for further consideration for limitation.
Di-rt-butyl phthalate was detected above the level considered
achievable by identified treatment technology (0.010 mg/1) in two
out of three raw wastewater samples. The treatable
concentrations observed are 0.034 and 0.134 mg/1. The Agency has
no reason to believe that treatable concentrations of di-n-butyl
phthalate should be present in primary beryllium wastewaters.
The Agency believes that these observed values are not
representative and may be due to analytical error or site
specific factors. Di-n-butyl phthalate is therefore not selected
for further consideration for limitation.
3735
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI
Diethyl phthalate was detected above the level considered
achievable by identified treatment technology (0.010 mg/1) in one
out of three raw wastewater samples. The treatable concentration
observed is 0.270 mg/1. The Agency has no reason to believe that
treatable concentrations of diethyl phthalate should be present
in primary beryllium wastewaters. The Agency believes that the
observed value is not representative and may be due to analytical
error or site specific factors. Diethyl phthalate is therefore
not selected for further consideration for limitation.
Tetrachloroethylene was detected above the level considered
achievable by identified treatment technology (0.010 mg/1) in
three of three raw wastewater samples. The treatable
concentrations observed are 0.184, 0.474, and 0.481 mg/1. The
Agency has no reason to believe that treatable concentrations of
tetrachloroethylene should be present in primary beryllium
wastewaters. The Agency believes that these observed values are
not representative and may be due to analytical error or site
specific factors. Tetrachloroethylene is therefore not selected
for further consideration for limitation.
Toluene was detected above the level considered achievable by
identified treatment technology (0.010 mg/1) in three of three
raw wastewater samples. The treatable concentrations observed
are 0.029, 0.084, and 0.064 mg/1. The Agency has no reason to
believe that treatable concentrations of toluene should be
present in primary beryllium wastewaters. The Agency believes
that these observed values are not representative and may be due
to analytical error or site specific factors. Toluene is
therefore not selected for further consideration for limitation.
Trichloroethylene was detected above the level considered
achievable by identified treatment technology (0.010 mg/1) in
three of three raw wastewater samples. The treatable
concentrations observed are 0.017, 0.014, and 0.086 mg/1. The
Agency has no reason to believe that treatable concentrations of
trichloroethylene should be present in primary beryllium
wastewaters. The Agency believes that these observed values are
not representative and may be due to analytical error or site
specific factors. Trichloroethylene is therefore not selected for
further consideration for limitation.
Although these pollutants were not selected for limitation in
establishing nationwide regulations, it may be appropriate, on a
case-by-case basis, for the local permit issuing authority to
specify effluent limitations.
Cadmium detected above the concentration considered achievable by
identified treatment technology (0.049 mg/1) in one out of 14 raw
wastewater samples. The treatable concentration observed is
0.063 mg/1. The Agency has no reason to believe that treatable
cadmium concentrations should be present in primary beryllium
wastewaters and believes that this one value is not
representative of the subcategory. Cadmium is therefore not
3736
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI '
selected for further consideration for limitation.
Lead was detected above the concentration considered achievable
by identified treatment technology (0.08 mg/1) in one out of 14
raw wastewater samples. The treatable concentration observed is
0.20 mg/1. The Agency has no reason to believe that treatable
lead concentrations should be present in primary beryllium
wastewaters and believes that this one value is not
representative of the subcategory. Lead is therefore not
selected for limitation. ,
Nickel was detected above the concentration considered achievable
by identified treatment technology (0.204 mg/1) in one out of 14
raw. wastewater samples. The treatable concentration observed is
0.78 mg/1. The Agency has no reason to believe that treatable
nickel concentrations should be present in primary beryllium
wastewaters, and does not believe that this one value is
representative of the subcategory. Nickel is therefore not
selected for further consideration for limitation.
Silver was detected above the concentration considered achievable
by identified treatment technology (0.07 mg/1) in three out of 14
raw wastewater samples The treatable concentrations observed
range from 0.10 mg/1 to 0,32 mg/1. The Agency has no reason to
believe that treatable silver concentrations should be present in
primary beryllium wastewaters. Silver is therefore not selected
for further consideration for limitation.
Zinc was detected above the concentration considered achievable
by identified treatment technology (0.23 mg/1) in one out of 14
raw wastewater samples. The treatable concentration observed is
7.2 mg/1. The Agency had no reason to believe that treatable
zinc concentrations should be present in primary beryllium
wastewaters, and does not believe that this one value is
representative. Zinc is i therefore not selected for further
consideration for limitation.
POLLUTANTS SELECTED FOR FURTHER CONSIDERATION IN
ESTABLISHING LIMITATIONS AND STANDARDS - ~" -- ~
The priority pollutants lasted below are selected for further
consideration in establishing limitations and standards for this
subcategory. The toxio pollutants selected for further
consideration for limitation are each discussed following the
list . i
117. beryllium
119. chromium • 1 '.'•.'
120. copper !
121. cyanide i
Beryllium was detected above the concentration considered
achievable by identified treatment technology (0.20 mg/1) in all
14 raw wastewater samples. .The treatable concentrations observed
range from 0.49 mg/1 to 3^300 mg/1. Beryllium is therefore
3737
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI
selected for further consideration for limitation.
Chromium was detected above the concentration considered
achievable by identified treatment technology (0.07 mg/1) in
Sight out of 14 raw wastewater samples. The treatable
concentrations observed range from 0.086 mg/1 to 7.5 mg/1.
Chromium is therefore selected for further consideration for
limitation.
Copper was detected above the concentration considered achievable
by identified treatment technology (0.39 mg/1) in nine out of 14
raw wastewater samples. The treatable concentrations observed
rlnge from 0.50 mg/1 to 1.6 mg/1. Copper is therefore selected
for further consideration for limitation.
Although cyanide was not proposed for limitations, the Agency
stated that it was considering limiting cyanide in the Notice of
nst-a Availability, based on data received in a comment. Cyanide
was deleted above the concentration considered achievable by
identified treatment technology (0.047 mg/1) in the only sample
for which the Agency has reliable cyanide data. This sample was
a split sample from the Agency's sampling visit which was
analyzed by the facility. The observed concentration of 32.6
mg/1 was verified by the plant as being a representative value
?or process water. Cyanide is formed in the carbon lined
induction furnaces which are used to produce BeF4 from
(NHA)2BeF4. The cyanide is picked up in the fluorine
furnace scrubber which discharges an ammonium fluoride solution
to various plant processes.
3738
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - VI
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3739
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - VI
Continued)
OF PRIORITY POLLUTANTS
M SUBCATEGORY
EWATER
Detected Detected
r of Number of Detected Below Below Treat- Above Treat-
ins Samples Quantification able Concen- able Concen-
zed Analyzed ND Concentration tration tration
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48. dichlorbbromonethane
49. trichlorofluororaethane
50. dichlorodif luoromethane
5 1 . chlorodibromoraethane
52. hexachlorobutadiene
53. hexachlorocyclopentadient
54. isophorone
55. naphthalene
56. nitrobenzene
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-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI
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-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI
TABLE VI-2
TOXIC POLLUTANTS NEVER DETECTED
2. acrolein i
5. benzidine
8. 1.2,4-trichlorobenzene
9. hexachlorobenzene
17. bis (chloromerhyl) ether (deleted)
18. bis (2-chloroethyl) ether
20. 2-chloronaphthalene
21. 2,4,6-trichlorophenol
22. 2-chlorophenol
23. 1,2-dichlorobenzene
26. 1,3-dichlorobenzene ,
27. 1,4-dichlorobenzene
28. 3,3'-dichlorobenzidine
31. 2,4-dichlorophenol
33. 1,2-dichloropropylene (1,3-dichloropropene)
34. 2,4-dimethylphenol
35. 2.4-dinitrotoluene
40. 4-chlorophenyl phenyl ether
41. 4-bromophenyl phenyl ether
42. bis(2-chloroisopropyl) ether
49. drichlorofluoromethane (deleted)
50. dichlorodifluoromethane (delered)
60. 4.6-dinicro-o-cresol
63. N-nitrosodi-n-propylamine
64. pentachlorophenol
65. phenol
69. di-n-octyl phthalate
72. benzo (a)anthracene (1,2-benzanthracene)
73. benzo (a)pyrene (3,4-benzopyrene)„
76. chrysene , .
82. dibenzo (a,h)anthracene (1.2.5.6-dibenzanthracene)
83. indeno (i.2.3-cd)pyrene .(w,e,-o-phenylenepyrene)
89. aldrin*
90. dieldrin* .
91. chlordane (technical mixture and metabolites)*
92. 4,4'-DDT*
93. 4,4'-DDE(p,p'DDX)*
94. 4,4'-DDD(p,p'TDE)*
95. Alpha-endosulfan*
96. Beta-endosulfan* 'r
97. endosulfan sulfate*
98. endrin*
99. endrin aldehyde* '
100. heptachlor*
3742
-------
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
116.
129.
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI
TABLE VI-2 (Continued)
TOXIC POLLUTANTS NEVER DETECTED
heptachlor epoxide*
Alpha-BHC*
Beta-BHC* • i
Gamma-BHC (lindane)'*
Delta-BHC*
PCB-1244 (Arochlor
(Arochlor
(Arochlor
(Arochlor
(Arochlor
(Arochlor
(Arochlor
1242)*
1244)*
1221)*
1232)*
1248)*
1260)*
.._ 1016)*
toxaphene* :
asbestos (fibrous)
2,3,7,8-tetra chlorodibenzo-p-dioxin (TCDD)
PCB-1254
PCB-1221
PCB-1232
PCB-1248
PCB.1260
PCB-1016
*The Agency did not analyze for these pollutants in samples of
raw wastewater from this subcategory. These pollutants are not
believed to be present based on the Agency's best engineering
judgment of the manufacturing process operations.
3743
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VI
TABLE VI-3
PRIORITY POLLUTANTS NEVER FOUND ABOVE THEIR
ANALYTICAL QUANTIFICATION CONCENTRATION
1. acenaphthene
7. chlorobenzene
11. l,lfl-trichloroethane
12. hexachloroethane
14. 1,1,2-trichloroethane
16. chloroethane
36. 2,6-dinitrotoluene
37. If2-diphenylhydrazine
38. ethylbenzene
39. fluoranthene
43. bis(2-chloroethoxy)methane
44. methyl chloride :
46. methyl bromide
55. naphthalene
56. nitrobenzene
61. N-nitrosodidimethylamine
62. N-nirrosodiphenylamine
66. bis{2-ethylhexyl)phthalate
67. butyl benzyl phthalare
71. dimethyl phthalate ,
72. 3,4-benzofluoranthene
73. benzo(k)fluoranthene
77. acenaphthylene
78. anthracene
79. benzo(g,h,i)perylene
80. fluorene
81. phenanthrene
84. pyrene
88. vinyl chloride
114. antimony
125. selenium
127. thallium
3744
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VII
i • ' . "
| SECTION VII
CONTROL AND; TREATMENT TECHNOLOGIES
The preceding sections of this supplement discussed the sources,
flows, and characteristics of the wastewaters from primary
beryllium plants. This section summarizes the description of
these wastewaters and indicates the treatment technologies which
are currently practiced in.the primary beryllium subcategory for
each waste stream. Secondly, this section presents the control
and treatment technology! options which were examined by the
Agency for possible application to the primary beryllium
subcategory. J
CURRENT CONTROL AND TREATMENT PRACTICES
This section presents a summary of the control and treatment
technologies that are currently being applied to each of the
sources generating wastewater in this subcategory. As discussed
in Section V, wastewater associated with the primary beryllium
subcategory is characterised by the presence of the toxic metal
pollutants and suspended solids. This analysis is supported by
the raw (untreated) wastewater data presented, for specific
sources as well as combined waste streams in Section V
Generally, these pollutants are present in each of the waste
streams at concentrations above treatability, and these
wastewater streams are i commonly combined for treatment
Construction of one wastewater treatment system for combined
treatment allows plants to take advantage of economies of scale
and in some instances to combine streams of different alkalinity
to reduce treatment chemical requirements. One plant in this
subcategory currently has a; combined wastewater treatment system
consisting of chemical precipitation and sedimentation. None
have chemical precipitation, sedimentation and filtration. As
such, three options have been selected for consideration for BPT,
BAT, NSPS, and pretreatment! based on combined treatment of these
compatible waste streams. i
BERYLLIUM HYDROXIDE PRODUCTION
There is currently only one facility in the United Stated which
produces beryllium hydroxide from bertrandite or beryl ore. This
facility is in a net evaporation area and achieves zero
discharge, through the use of evaporation ponds, of all
wastewater streams associated with beryllium hydroxide production
rrom ore. These ten wastewater streams are listed below:
(a) Solvent extraction raffinate from bertrandite ore,
(b) Solvent extraction raffinate from beryl ore,
(c) Beryllium carbonate filtrate,
(d) Beryllium hydroxide filtrate,
(k) Beryl ore gangue dewatering,
(1) Bertrandite ore gangue dewatering,
3745
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VII
(m) Beryl ore processing,
(n) AIS area wastewater,
(o) Bertrandite ore leaching scrubber, and
(p) Bertrandite ore counter current decantation scrubber.
BERYLLIUM OXIDE AND BERYLLIUM METAL PRODUCTION FROM BERYLLIUM
HYDROXIDE
There is currently only one facility in the United States which
produces beryllium oxide and beryllium metal from beryllium
hydroxide. This plant is a direct discharger and treats all of
the wastewater streams associated with beryllium oxide and
beryllium metal production with chemical precipitation and
sedimentation technology. These six wastewater streams are
listed below:
(e) Beryllium oxide calcining furnace wet air pollution control,
(f) Beryllium hydroxide supernatant,
(g) Process water,
(h) Fluoride furnace scrubber,
(i) Chip treatment wastewater, and ,,4.. nnt.^^
(j) Beryllium pebble plant area vent wet air pollution control.
The process water stream is used in the beryllium pebble plant
scrubbing system prior to treatment and discharge. Two Plants
produce beryllium copper master alloy from beryllium hydroxide
using a dry process.
CONTROL AND TREATMENT OPTIONS
The Agency examined two control and treatment technology options
that are applicable to the primary beryllium subcategory. The
options selected for evaluation represent a combination of
pretreatment and end-of-pipe treatment technologies.
OPTION A
Option A for the primary beryllium subcategory requires control
and treatment technologies to reduce the discharge of wastewater
pollutant mass.
The Option A treatment scheme consists of
liquors, ammonia steam stripping, and
pretreatment for selected waste streams,
precipitation and sedimentation technology
or some other alkaline compound is used to
as metal hydroxides. The metal hydroxides
settle out and the sludge is collected.
used to dewater sludge.
recycle of scrubber
cyanide precipitation
followed by chemical
Specifically, lime
precipitate metal ions
and suspended solids
Vacuum filtration is
OPTION C
Option C for the primary beryllium subcategory consists of all
3746
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VII
control and treatment requirements of Option A (recycle of
scrubber _liquors, ammonia steam stripping, and cyanide
precipitation pretreatment steps, chemical precipitation and
sedimentation) plus multimedia filtration technology added at the
end of the Option A treatment scheme. Multimedia filtration is
used to remove suspended solids, including precipitates of
metals, beyond the concentration attainable by gravity
sedimentation. The filter suggested is of the gravity, mixed-
media type, although other forms of filters, such as rapid sand
f;^ers or pressure filters would perform satisfactorily. The
addition of filters also provides consistent removal during
periods of time in which there are rapid increases in flows or
loadings of pollutants to the treatment system.
3747
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VII
THIS PAGE INTENTIONALLY LEFT BLANK
3748
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - VIII
'SECTION VIII
COSTS, ENERGY, jAND NONWATER QUALITY ASPECTS
This section presents a summary of compliance costs for the
primary beryllium subcategory and a description of the treatment
options and subcategory-specific assumptions used to develop
these estimates. Together with the estimated pollutant reduction
performance presented in Sections IX, X, XI, and XII of this
supplement, these cost estimates provide a basis for evaluating
each regulatory^ opt ion. These cost estimates are also used in
determining the probable economic impact of regulation on the
subcategory at different pollutant discharge levels. In
addition, this section addresses nonwater quality environmental
impacts of wastewater ^treatment and control alternatives,
including air pollution, solid wastes, and energy requirements,
which are specific to the primary beryllium subcategory.
TREATMENT OPTIONS FOR EXISTING SOURCES
As discussed in Section VII, two treatment options have been
developed for existing primary beryllium sources. The treatment
schemes for each option are summarized below and schematically
presented in Figures X-l and X-2 (pages 3791 and 3792).
OPTION A :
Option A consists of recycle of scrubber liquors, ammonia steam
stripping, and cyanide precipitation pretreatment followed by
chemical precipitation and!sedimentation end-of-pipe technology.
OPTION C
Option C requires recycle of scrubber liquors, ammonia steam
stripping, and cyanide precipitation pretreatment, followed by
end-of-pipe treatment technology consisting of chemical
precipitation, sedimentation, and multimedia filtration.
COST METHODOLOGY
A detailed discussion of ! the methodology used to develop the
compliance costs is preserited in Section VIII of Vol. I. These
compliance costs calculate incremental costs, above treatment
already in place, necessary to comply with the promulgated
effluent limitations and standards. The costs developed for the
final regulation are presented in Table VIII-1 (page 3752). No
subcategory-specific assumptions were used in developing
compliance costs for the primary beryllium subcategory.
NONWATER QUALITY ASPECTS | .
Nonwater quality impacts I specific to the primary beryllium
subcategory,, including energy requirements, solid waste and air
pollution, are discussed below.
3749
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PRIMARY BERYLLIUM SUBCATEGORY SECT - VIII
ENERGY REQUIREMENTS
Energy requirements for Option A are estimated at 1,136,000
kwh/yr. Option C, which includes filtration, is estimated to
increase energy consumption over Option A by approximately one
percent. Further, the total energy requirement for Option C is
approximately two percent of the estimated total plant energy
usage. It is therefore concluded that the energy requirements of
the treatment options considered will have no significant impact
on total plant energy consumption.
SOLID WASTE
Sludge generated in the primary beryllium subcategory is due to
the precipitation of metal hydroxides and carbonates using lime.
Sludges associated with the primary beryllium subcategory will
necessarily contain quantities of toxic metal pollutants. Except
for sludges produced by cyanide precipitation, these sludges are
not subject to regulation as hazardous wastes since -wastes
generated by primary smelters and refiners are currently exempt
from regulation by Act of Congress (Resource Conservation and
Recovery Act (RCRA), Section 3001(b)), as interpreted by EPA. If
a small excess (5-10 %) of lime is added during treatment, the
Agency does not believe these sludges would be identified as
hazardous under RCRA in any case. (Compliance costs include this
amount of lime.) This judgment is based on the results_ of
Extraction Procedure (EP) toxicity tests performed on similar
sludges (toxic metal-bearing sludges) generated by other
industries such as the iron and steel industr>. A small amount
of excess lime was added during treatment, and the sludges
subsequently generated passed the toxicity test. See CFR
8261.24. Thus, the Agency believes that the wastewater sludges
will similarly not be EP toxic if the recommended technology is
applied.
Throughout this study, sludges generated as a result of cyanide
precipitation have been considered as hazardous, and appropriate
costs for disposal have been included in the compliance cost
estimates.
Although it is the Agency's view that solid wastes generated as a
result of these guidelines are not expected to be hazardous,,
generators of these wastes must test the waste to determine if
the wastes meet any of the characteristics of hazardous waste
(see 40 CFR 262.11).
If these wastes should be identified or are listed as hazardous,
they will come within the scope of RCRA's "cradle to grave"
hazardous waste management program, requiring regulation, from
the point of generation to point of final disposition. EPA s
generator standards would require generators of hazardous
nonferrous metals manufacturing wastes to meet containenzation,
labeling, recordkeeping, and reporting requirements; if plants
dispose of hazardous wastes off-site, they would have to prepare
3750
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PRIMARY BERYLLIUM SUBCATEGORY SECT - VIII
a manifest which would track the movement of the wastes from the
generator's premises to a permitted off-site treatment, storage
?nondlSP°Sal facility- See 40 CFR 262. 2O, 45 FR 33142 (May 19
1980), as amended at 45: FR 86973 (December 31, 1980) The
transporter regulations require transporters of hazardous wastes
to comply with the manifest system to assure that the wastes are
de^erfd. to a permitted facility. See 40 CFR 263.20, 45 FR
?Q«n^ ( I- 1?i' 1980)' aS amended at 45 FR 86973 (December 31,
1980). Finally, RCRA regulations establish standards for
hazardous waste treatment, storage, and disposal facilities
allowed to receive such wastes. See 40 CFR Part 464, 46 FR 2802
(January 12, 1981), and 47 FR 32274 (July 26, 1982).
Even if these wastes are not identified as hazardous, they still
must_ be disposed of in compliance with the Subtitle D open
c^?in? standards' implementing Section 4004 of RCRA. See 44 FR
53438 (September 13, 1979). The Agency has calculated as part of
the costs for wastewater treatment the cost of hauling and
disposing of these wastes. ! ^uxing ana
It is estimated that 696 metric tons per year of sludge will be
generated as a result of these promulgated regulations for the
primary beryllium subcategory. Sixty-five metric tons of this
sludge is considered to be 'hazardous.
AIR POLLUTION M
nroho n° -?aS°n t0 bflieve that any substantial air pollution
problems will result !from implementation of chemical
precipitation, sedimentation, and multimedia filtration. These
technologies transfer pollutants to solid waste and are not
likely to transfer pollutants to air.
3751
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PRIMARY BERYLLIUM SUBCATEGORY SECT - VIII
TABLE VIII-1
COST OF COMPLIANCE FOR THE PRIMARY BERYLLIUM SUBCATEGORY
DIRECT DISCHARGERS
(March 1982 Dollars)
Option Capital Cost Annual Cost
A 226500 251200
B 256200 265600
3752
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PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
SECTION IX .
BEST PRACTICABLE CONTROL TECHNOLOGY
CURRENTLY AVAILABLE
This section defines the effluent characteristics attainable
™rr»n?V application of best practicable control technology
currently available (BPT). BPT reflects
the existing performance by plants of various sizes, ages, and
^^tur^processe^ within the primary beryllium subcategory,
QV«I«« ^ the established performance of the recommended BPT
systems. Particular consideration is given to the treatment
already in place,at plants within the data base.
The factors considered in identifying BPT include the total cost
£La??iyinf technology, in relation to the effluent reduction
benefits from such application, the age of equipment and
facilities involved, the manufacturing processes used, nonwater
quality environmental impacts (including energy requirements)
and other factors the Administrator considers appropriate? In
general, the BPT level represents the average of the existing"
performances of plants of various ages, siles. processes? or
other common characteristics. Where existing performance is
uniformly inadequate, BPT may be transferred from a different
subcategory or category. Limitations based on transfer of
technology are supported; by a rationale concluding that the
technology is indeed transferable, and a reasonable prediction
1 i ' caPable of achieving the prescribed effluent
focuses on end-of-pipe treatment rather than process
"uch practices are
TECHNICAL APPROACH TO BPT i
The Agency studied the nonferrous metals category to identify the
processes used, the wastewaters generated and the treatment
processes installed. Information w2s collected from the category
using data collection portfolios, and specific plants werl
sampled and the wastewaters analyzed. In making technical
assessments of data, reviewing manufacturing prolessSS; and
anTSrftrL?aS^Wai;er treatment technology options, both indirect
An ™* <-• SChargefS have b^en considered as a single group.
An examination of plants and processes did not indicate anv
dir?e^So?1ndirrect? baS6d °n ^ ^ °f discha^e' whether^it^
hn KS SectlonIV'!the primary beryllium subcategory has
been subdivided into 16 potential wastewater sources. Since the
water use, discharge rates,;and pollutant characteristics Sf each
Sfi^h^sVastewaters is potentially unique, effluent limi?ati?ns
will be developed for each of the 16 subdivisions. cations
For each of the subdivisions, a specific approach was followed
3753
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PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
for the development of BPT mass limitations The
requirement to calculate these limitations is to account for
production and flow variability from plant to plant. Therefore,
a unit of production or production normalizing parameter (PNP)
was dite?miSed for each waste stream which could then be related
to the flow from the process to determine a production normalized
flowSelection of the PNP for each process element is discussed
In Section IV. Each plant within the Subcategory was then
analyzed to determine (1) which subdivisions were present, 2
the specific flow rates generated for each subdivision, and (3)
the specific production normalized flows for each subdivision.
This analysis is discussed in detail in Section V. Nonprocess
wastewlterlsuch as rainfall runoff and noncontact cooling water
are not considered in the analysis.
Production normalized flows for each subdivision were then
analyzed to determine the flow to be used as part of the basis
f« IS? mass limitations. The selected flow (sometimes referred
to as a BPT regulatory flow or BPT discharge rate) reflects the
water use controls which are common practices within the
category. The BPT regulatory flow is based on the average of all
applicable data. Plants with normalized flows above the average
may have to implement some method of flow reduction to achieve
the BPT limitations.
The second requirements to calculate mass limitations is the set
of concentrations that are achievable by application of the BPP
level Sf treatment technology.' Section VII discusses the various
control and treatment technologies which are currently in place
fS? each wastewater source. In most cases, the current control
and treatment technologies consist of chemical precipitation and
sedimentation (lime and settle technology) and a combination of
reuse and recycle to reduce flow.
Using these regulatory flows and the achievable concentrations,
the next step is to calculate mass loadings for each wastewater
source or subdivision. This calculation was made on a stream
stream-by-stream basis, primarily because plants in this
subcateqory may perform one or more of the operations in various
comMnat?ons. Me mass loadings (milligrams of pollutant per
kilogram of production unit - ^g/kg) are based on multiplying the
BPT regulatory flow (1/kkg) by the concentration achievable by
the BPT level of treatment technology (mg/1) for each pollutant
parameter to be limited under BPT. These mass loadings are
pSllSSl in the Federal Register and in 40 CPR Part 421 as the
effluent limitations guidelines.
The mass loadings which are allowed under BPT for each plant will
be the sum of the individual mass loadings for the various
wastewater sources which are found at particular plants.
IcSordingly, all the wastewater generated within a plant may^ be
combined9 for treatment in a single or common treatment system
but the effluent limitations for these combined wastewaters are
based on the various wastewater sources which actually contribute
to the combined flow. This method accounts for the variety of
3754
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PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
combinations of wastewater sources and production processes which
may be found at primary beryllium plants. .™es wnicn
The Agency usually establishes wastewater limitations in terms of
mass rather than concentration. This approach prevents the use
of dilution as a treatment method (except for controlling PH) .
The production normalized wastewater flow (1/kkg) is a link
between the production operations and the effluent limitations.
The pollutant discharge attributable to each operation can be
£S°« H? xr°?uth! normalized fl°« and effluent concentration
achievable by the treatment technology and summed to derive an
appropriate limitation for each plant.
INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES
In balancing costs in relation to pollutant removal estimates
EPA considers the volume and nature of existing discharges? the
Umand ^ f
h, ?f ^charges expected afte applicaion of
the general environmental effects of the pollutants, and the
?evel anTheeSrH^ 'T^* ^ -the' re<3uired Pollution' contro!
level. The Act does not require or permit consideration of water
attribufcable to particular point sources or
water quality improvements in particular water
™ - Accordf*9ly' water quality considerations were
not the basis for selecting the proposed or promulgated BPT.
The methodology for calculating pollutant removal estimates and
plant compliance costs is discussed in Section x. Pollutant
removal estimates have been revised since proposal to P°llutant
o^o-,^ ^new costs generated for promulgation. Table
3781) shows the estimated pollutant removal estimates
treatment option for direct dischargers. Compliance
each option are presented in Table X-2 (page 3782).
BPT OPTION SELECTION - PROPOSAL
correspond
X-l (page
for each
costs for
nh ba?is for the proposed BPT limitations was Option
, chemical precipitation ;and sedimentation technology to remove
metals and solids from combined wastewaters and to control pH 2nd
fluoride. This technology is already in-place at the one
? ^ th\,sub^tegory. The pollutants • ^eci£ica??y
f°JCoegUl^tl0n at iBPT were beryllium, chromiuS, copper^
nmtaton<, A *"% **' *** A?6nCy W3S als° Considering amSoSIa
limitations based on ammonia steam stripping and cyanide
limitations based on cyanide precipitation. cyanide
Because the one discharging facility in the primary beryllium
subcategory already has the; BPT technology in-place, and our da^
indicated that the technology is achieving ^e proposed BP?
limitations, no pollutant; removal above the current discharge
level and no incremental capital or annual costs were expected 2t
3755
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PRIMARY BERYLLIUM SUBCATEGORY SECT - IX !
BPT OPTION SELECTION ^ PROMULGATION
The technology basis for the promulgated BPT limitations is
Option A, recycle of scrubber liquors, ammonia steam stripping,
and cyanide precipitation pretreatment for selected waste
streams, and chemical precipitation and sedimentation technology
to remove metals and solids from combined wastewaters and to
control pH and fluoride. The Agency decided to promulgate
ammonia and cyanide limitations based on ammonia steam stripping
a^d cyanide precipitation because data submitted in comments
confirmed the presence of ammonia and cyanide in Process waters
Generated in the beryllium industry. The remaining pollutants
Ipecifically promulgated for regulation at BPT are beryllium,
chromium, copper, fluoride, TSS, and pH.
Ammonia steam stripping is demonstrated at ;JxJa££j^J *n
nonferrous metals manufacturing category. These facilities are
treating ammonia bearing wastewaters associated with the
production of primary tungsten, primary columbium and tantalum,
primary molybdenum/ secondary tungsten and cobalt, and primary
Siiconium and hafnium. EPA believes that performance dat a from
the iron and steel manufacturing category provide a valid measure
of this technology's performance on nonferrous metals
Manufacturing category wastewater because raw wastewater
concentrations of ammonia are of the same order of magnitude in
the respective raw wastewater matrices.
Chemical analysis data were collected of raw waste (treatment
iSent) and treated waste (treatment effluent) from one coke
Slant of the iron and steel manufacturing category. A contractor
for EPA, using EPA sampling- and chemical analysis P^tocols,
collected six paired samples in a two-month period. These data
a?e thJ data base for determining the effectiveness of ammonia
steam stripping technology and are contained within the Public
record supporting this document. Ammonia treatment at this coke
plant consisted of two steam stripping columns in series with
Iteam injected countercurrently to the flow of the wastewater. A
!imS reactor for pH adjustment separated the two stripping
columns.
at a
The Agency has verified .-the promulgated stea™ . ^
performance values using steam stripping data collected
zirconium-hafnium plant, which has raw ammonia leve^oa?vhDa
any in the nonferrous metals manufacturing category. _Data
collected by the plant represent almost two years of daily
options, and support thS long-term mean used to establish
treatment effectiveness.
In addition, data submitted by a primary columbium-tantalum
San?, wh?c~h also has significant raw ammonia levels, verifies
the promulgated steam stripping performance values.
Cyanide precipitation technology is required for the _ primary
beryllium subcategory because existing treatment within ^the
subcategory does not effectively remove cyanide. Cyanide
3756
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PRIMARY BERYLLIUM SUBCATEGORY SECT- IX
precipitation is directed at control of free and complexed
cyanides. This subcategory collectively discharges approximately
536 kg/yr of cyanide. The achievable performance is transferred
from three well-operated coil coating plants in the coil coating
category, and are contained within the public record supporting
this document. The Agency believes this technology, and the
achievable concentration limits, are transferable to the primary
beryllium subcategory because raw wastewater cyanide
concentrations (prior to dilution with waste streams without
cyanide) are of the same order of magnitude in both categories.
Further, no pollutants jwere identified in primary
the
™Q«-?f thS P^^ted BPT limitations is estimated to
remove 2,698 kilograms of priority pollutants, 70,000 kilograms
of ammonia and 313 kilograms of TSS from raw wastewater annually?
^ir Snnimatld ^a^tal cost for achieving promulgated BPT Is
5^26,500 and the annual1 cost is estimated at $251,200 (1982
dollars). A schematic ; representation of the selected BPT
treatment option is presented in Figure IX-1 (page 3763).
t0 **! Promul9ated BPT limitations are identical to the
•in Section x° Promulgated BAT limitations which are discussed
WASTEWATER DISCHARGE RATES
A BPT discharge rate is calculated for each subdivision based on
the average of the flows of all representative existing plants
wffch e^mineH- fromanalysis of dcp. The discharge rate is Ssed
*^h the achievable treatment concentrations to determine BPT
?or ™h m ? ?S* Sin°e the discharge rate may be different
IlLhlrS Waftewa^er source, separate production normalized
dtSSSn; K • fSS °r ea°h °f the 16 wastewater sources are
discussed below and summarized in Table IX-1. The discharge
rates are normalized on a production basis by relating the amount
of wastewater generated to the mass of the product which is
produced by the process 'associated with the wast" stream in
parameters, or PNPs, are
-3666)
°f this^ocymen.t! further describes the discharge flow
Pres^ts the water use and discharge flow rates for
subdivision in Tables V-l through V-10 (pages 3663
blockshavphpn ' six new building
blocks have been added to this subcategory, and the production
normalized flow for one additional building block, Pbery?liSm
hydroxide filtrate,, was revised based on more -detailed data
acquired since promulgation; of the original rulemaking
3757
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PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
SOLVENT EXTRACTION RAFFINATE FROM BERTRANDITE ORE
The proposed and promulgated BPT wastewater discharge rate for
solvent extraction raffinate from bertrandite ore is 2,246,000
1/kkg (538,200 gal/ton) of beryllium carbonate precipitated (as
beryllium). This rate is allocated only for those plants which
eSt?act beryllium from an acid solution generated by leaching
bertrandite ore. There is currently only one plant which
practices this operation.
Water use and discharge rates are presented in Table V-l (page
36631. The BPT wastewater discharge rate for solvent extraction
raffinate from bertrandite ore is based on the value reported by
the one facility which currently generates this waste stream.
SOLVENT EXTRACTION RAFFINATE FROM BERYL ORE
The BPT wastewater discharge rate proposed for solvent extraction
raffinate from beryl ore was 200,000 1/kkg (47,900 gal/ton) of
bSryiuS carbonate precipitated (as beryllium) This rate was
allocated only for those plants which extract beryllium from :an
acid solutiongenerated b? leaching beryl ore. After proposal,
EPA received comments from the industry requesting an increase in
the discharge allowance for this waste stream. The Agency
evaluated thS new flow and production data submitted and based on
that it is promulgating a new discharge rate.
The BPT wastewater discharge rate promulgated for solvent
extraction raffinate from beryl ore is 220,000 1/kkg (52,720
qal/ton) of beryllium carbonate precipitated (as beryllium).
This rate is allocated only for those plants which extract
beryllium from an acid solution generated by leaching beryl ore.
Water use and discharge rates are presented in Table V-2 (page
3663). The BPT wastewater discharge rate for solvent extraction
raffinate from beryl ore processing is based on the value
reported by the one facility reporting this waste stream.
BERYLLIUM CARBONATE FILTRATE
The proposed and promulgated BPT wastewater discharge rate for
bervlliSmcarbonate filtrate is 214,500 1/kkg (51,400 gal/ton) of
beryllium carbonate precipitated (as beryllium). This .rate is
allocated only for those plants which precipitate beryllium from
Solution as beryllium carbonate. There is currently only one
plant which practices this operation.
Water use and discharge rates are presented in Table V-3 (Page
3663). The BPT wastewater discharge rate for beryllium carbonate
filtrate is based on the value reported by the one facility which
currently generates this waste stream.
BERYLLIUM HYDROXIDE FILTRATE '•.
The proposed and promulgated BPT wastewater discharge rate for
3758
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PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
beryllium hydroxide filtrate was 52,660 1/kkg (12,620 gal/ton) of
beryllium hydroxide produced (as beryllium). However, based on
more detailed information not available at the time of the
original rulemaking, EPA has revised the BPT wastewater discharge
rate to be 136,000 1/kkg (32,600 gal/ton) of beryllium hydroxide
produced (as beryllium). ;This rate is allocated only for those
plants which produce beryllium hydroxide .from bertrandite or
beryl ore. Water use and discharge rates are presented in Table
V-4 (page 3664).
BERYLLIUM OXIDE CALCINING FURNACE WET AIR POLLUTION CONTROL
The proposed; and promulgated BPT wastewater discharge rate for
beryllium oxide calcining:furnace wet air pollution control is
263,700 1/kkg (63,190 gal/ton) of beryllium oxide produced. Since
proposal, industry comments to EPA have indicated that recycle is
presently practiced for this waste stream at a rate of greater
than 90 percent. This rate is allocated only for those plants
which use wet air pollution control devices to control emissions
from beryllium oxide calcining furnaces. Water use and discharge
rates are presented in Table V-5 (page 3664).
BERYLLIUM HYDROXIDE SUPERNATANT
The BPT wastewater discharge rate proposed for beryllium
hydroxide supernatant was 104,324 1/kkg (25,000 gal/ton) of
beryllium hydroxide produced from scrap and residues (as
beryllium). This rate was allocated only for those plants which
recover beryllium from residues and scrap by dissolution in
sulfuric acid and precipitation of beryllium as beryllium
hydroxide. After proposal, EPA received comments from the
industry requesting an increase in the discharge allowance for
this waste stream. The ; Agency evaluated the new flow and
production data submitted and based on that it is promulgating a
new discharge rate. The BPT, wastewater discharge rate promulgated
for beryllium hydroxide supernatant is 430,000 1/kkg (54,120
gal/ton) of beryl-lium hydrbxide produced from scrap and residues
(as beryllium). This rate1 is allocated only for those plants
which recover beryl-lium from residues and scrap by dissolution
in sulfuric acid and precipitation of beryllium as beryllium
hydroxide. .-• \-
This discharge allowance includes all water generated from the
beryllium hydroxide recovery operation. Because this operation
includes scrap recycled from external sources, it is technically
a secondary as well as primary beryllium operation. The Agency
is, however, considering this as a primary beryllium operation
tor the purposes of this regulation. In establishing the BPT flow
rate, it has given full consideration to the amount of wastewater
generated, due to the secondary nature of this operation. Water
use and discharge rates are^presented ,in Table V-6 (page 3664).
PROCESS WATER ; ".
At proposal, this waste stream was called process condensates. At
3759
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PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
proposal no BPT wastewater discharge allowance for process
condensates was provided. Based on the available data, EPA
believed that this facility reuses all of this water in scrubbing
systems and other plant uses.
Industry comments after proposal clarified the process
condensates collection and reuse system, and indicated ^ that
periodic discharges have to be^made from the process water pit to
prevent dissolved solids build-up. Information was supplied to
the Agency so that a discharge rate for process water could be
calculated.
The BPT wastewater discharge rate promulgated for process water
is 174,800 1/kkg (41,890 gal/ton) of beryllium pebbles produced.
This rate is allocated only for those plants which collect
process condensates generated from the manufacture of beryllium
metal and discharge this process water after extensive recycle in
various plant applications. Water use and discharge rates are
presented in Table V-7 (page 3668).
FLUORIDE FURNACE SCRUBBER
The BPT wastewater discharge rate proposed for fluoride furnace
scrubber water was 2,205 1/kkg (530 gal/ton) of beryllium metal
pebbles produced. This rate was allocated only for those plants
which produce beryllium fluoride (BeF2) intermediate by heating
ammonium beryllium fluoride in a furnace.
Industry comments submitted to the EPA after proposal regarding
the fluoride furnace scrubber indicated that this scrubber does
not generate a discharge. Scrubber liquor is extensively
recycled, makeup water is taken from the process water pit, and a
bleed stream is reused in ammonium bifluoride preparation. For
this reason, EPA is not providing a discharge allowance for the
fluoride furnace scrubber water.
The BPT wastewater discharge rate promulgated for fluoride
furnace scrubber water is zero. The Agency believes that, based
on demonstrated practice, any facility which operates a fluoride
furnace scrubber can achieve zero discharge through recycle and
reuse.
CHIP TREATMENT WASTEWATER
At proposal, this waste stream was called chip leaching. The BPT
wastewater discharge rate for proposed chip leaching wastewater
was 4,742 1/kkg (1,138 gal/ton) of beryllium scrap chips treated.
This rate was allocated only for those plants which treat
beryllium scrap chips with nitric acid prior to vacuum casting.
After proposal, EPA received comments from the industry
requesting an increase in the discharge allowance for this waste
stream. The Agency evaluated the new flow and production data
submitted and based on those, it is promulgating a new discharge
rate.
3760
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PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
The BPT wastewater discharge rate promulgated for chip treatment
wastewater is 7.750 1/kkg (1,860 gal/ton) of beryllium scrap
chips treated. This rate is allocated only for those plants
which treat beryllium scrap chips with nitric acid prior to
vacuum casting. Water use and discharge rates are presented in
Table V-9 (page 3665). ;
BERYLLIUM PEBBLE PLANT AREA VENT WET AIR POLLUTION CONTROL
A BPT pollutant discharge allowance for beryllium pebble plant
area vent scrubber wastewater was not proposed because of
incomplete information about the scrubbers that use water from or
recirculate into the process water pit. Industry comments have
clarified the recycle, reuse, and discharge practices of these
scrubbers. After evaluating the new information, EPA has added a
tenth subdivision.
The BPT wastewater discharge rate used at promulgation for
beryllium pebble plant area vent scrubber wastewater is zero.
Presently, one plant operates a pebble plant scrubber which
obtains makeup water from the process water pit, and discharges a
scrubber liquor bleed stream back to the process water pit.
Because a separate discharge allowance is being promulgated for
process water discharge, the Agency did not believe it necessary
to give an additional discharge allowance for the beryllium
pebble plant scrubber wastewater.
ADDITIONAL BUILDING BLOCKS;
I
The BPT discharge rates for the six new building blocks are
identical to the production normalized wastewater flows presented
for these streams in Section V. These BPT flows would be
applicable to plants processing bertrandite ore and beryl ore
into beryllium hydroxide or beryllium carbonate products.
REGULATED POLLUTANT PARAMETERS
The raw wastewater concentrations from individual operations and
the subcategory as a whole were examined to select certain
pollutant parameters for • limitation. This examination and
evaluation was presented: in Section VI. A total of eight
pollutants or pollutant parameters are selected for limitation
under BPT and are listed below:
117. beryllium - | -
119. chromium |
120. copper : •
121. cyanide .!
ammonia ', •
fluoride • !
TSS
pH ,
3761
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PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
EFFLUENT LIMITATIONS
The treatable concentrations 'achievable by application of the
promulgated BPT are discussed in Section VII of Vol. I and
summarized there in Table VII-21 (page 248), with one exception.
The one exception is the fluoride treatment effectiveness
concentration for the beryllium hydroxide supernatant
subdivision, which has been revised from 14.6 mg/1 to 170 mg/1,
based on the unusually high concentration of total dissolved
solids (TDS) in that wastewater stream. These treatable
concentrations (both one day maximum and monthly average values)
are multiplied by the BPT normalized discharge flows summarized
in Table IX-1 (page 3781) to calculate the mass of pollutants
allowed to be discharged per mass of product. The results of
these calculations in milligrams of pollutant per kilogram of
product represent the BPT effluent limitations and are presented
in Table IX-2 (page 3782) for each individual waste stream.
3762
-------
PRIMARY BERYLLIUJYI SUBCATEGORY SECT - IX
* — i
i
[xj
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UBCATEGORY
YLLIUM S
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Solvent
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Ilium
•H CD >i
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3763
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - IX
•d
Q)
•H
4J
O
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IUM SUBCATEGORY
J^|
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13
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W
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Productin
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Beryllium ore p:
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4-*
rH
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(U
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o
o
5-1
ft
Bertrandite ore
CTl
CO
VD
CD
in
vo
UD
CN
Bertrandite ore gangue
dewatering
•d
o
m
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Beryllium ore p:
in
r-
rH
ro
o
ro
r-
Beryllium ore processing
0
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cd
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tf^ J3
5-1 -H
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Total beryllium
produced as ber
rH
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CN
rH
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0
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AIS area wastewater
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(U
M
02
0)
o
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Bertrandite ore
CM
co
i O
rH
rH
in
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Bertrandite ore leaching
scrubber
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(D
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o
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M
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r\
current decantation scrubl
3764
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
TABLE IX-2
BPT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(a) Solvent Extraction Raffinate from Bertrandite Ore BPT
Pollutant
pollutant
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
pH
or Maximum for
property any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium carbonate
produced from bertrandite ore (as Be)
i
2,763.000 1,235.000
988.200 404.300
4,267.000 2,246.000
;651.300 269.500
299,400.000 131,600.000
78,610.000 44,700.000
92,;090.000 43,800.000
Within the range of 7.5 to 10.0 at all times
(b) Solvent Extraction Raffinate from Beryl Ore BPT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium carbonate
produced from beryl ore (as Be)
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
pH
270.600
i96.800
418.000
63.800
29,330.000
7,700.000
9,020.000
121.000
39.600
220.000
26.400
12,890.000
4,378.000
4,290.000
Within the .range of 7.5 to 10.0 at all times
3765
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(c) Beryllium Carbonate Filtrate BPT
Pollutant or
pollutant property
Maximum for
any one dciy
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium carbonate produced (as Be)
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
pH
28
7
8
Within the
94.
407.
62,
,590,
,508,
,795,
,800
.380
.600
. 210
.000
.000
.000
range of 7.5
12
4
4
to 10.
118.
38.
214.
25.
,570.
,269.
,183.
0 at
000
610
500
740
000
000
000
all
times
(d) BerylliumlHydroxide Filtrate BPT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium hydroxide
produced (as Be)
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
pH
167.300
59.840
258.400
39.440
18,130.000
4,760.000
5,576.000
74.800
24.480
136.000
16.320
7,970.000
2,706.000
2,652.000
Within the range of 7.5 to 10.0 at all times
3766
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(e) Beryllium Oxide Calcining Furnace Wet APC BPT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium oxide produced
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
pH
324.400
116.000
;soi.ooo
i 76.470
35,150.000
9,230.000
10,810.000
Within the: range of 7.5
145.000
47.470
^ / • *c i \j
263.700
31.640
15,450.000
5,248.000
5,142.000
to 10.0 at all
times
(f) Beryllium Hydroxide Supernatant BPT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium hydroxide
produced from scrap and residues (as Be)
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
pH
282.900
101.200
437.000
66.700
30,660.000
160,300.000
9,430.000
126.500
41.400
230.000
27.600
13,480.000
71,200.000
4,485.000
Within the range of 7.5 to 10.0 at all times
3767
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(g) Process Water BPT • ;
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
JL kJ »J
pH
23,
6,
7,
Within the
215.
76.
332.
50.
300,
118,
167,
,000
,910
. 100
.690
.000
.000
.000
range of 7.5
10
3
3
to 10.
96
31
174
20
,240
,479
,409
0 at
.140
.460
.800
.980
.000
.000
.000
all
times
(h) Fluoride Furnace Scrubber BPT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
pH
0.000
0.000
0.000
0.000
0.000
0.000
b.ooo
0.000
0.000
0.000
0.000
0.000
0.000
0.000
Within the range of 7.5 to 10.0 at all times
3768
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(i) Chip Treatment Wastewater BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
PH
(Ib/million Ibs) of beryllium scrap
9.533
3.410
1 14.730
2.248
1,033.000
271.300
317.800
.Within the range of 7.5 to 10.0
chips treated
A 'JK'*
^ • £• \J «J
1.395
•L e *j ^ +j
7 7 SO
i * i ~j\j
Qin
• y j \j
454.200
154.200
151.100
at all times
(j) Beryllium Pebble Plant;Area Vent Wet APC BPT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium pebbles produced
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
PH
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
v»WWW \J 9 \J \J \J
Within the !range of 7.5 to 10.0 at all times
3769
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(M Beryl Ore Gangue Dewatering BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (pounds per million pounds) of beryl ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
Total Suspended Solids
pH Within the
1.283
0.459
1.982
6.302
139.032
36.505
42.763
range of
0.574
0.188
1.043
0.125
61.120
20.756
20.339
7.5 to 10.0 at all times.
(1) Bertrandite Ore Gangue Dewatering BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (pounds per million pounds) of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
Total Suspended Solids
pH —<--
3.279
1.173
5.064
0.773
355.245
93.275
109.265
1.466
0.480
2.665
0.320
156.169
53.034
51.968
[ OOJ.J.UEJ J.UJ./6.UJ — — - —
Within the range of 7.5 to 10.0 at all times.
3770
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(m) Beryl Ore Processing BPT
•Fonutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
(pounds per million pounds) of beryl ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as .N)
Fluoride
Total Suspended Solids
pH
8.983
3.213
13.876
, 2.118
973.490
255.605
299.423
4.017
1.315
7.303
0.876
427.956
145.330
142.409
Within the range of 7.5 to 10.0 at all times.
BPT
(n) Aluminum Iron
Pollutant or
Pollutant Property
Sludge (AIS) Area Wastewater BPT
Maximum for
Any i One Day
Maximum for
Monthly Average
ig/kg (pounds per million pounds) of total beryllium
carbonate produced (as Be)
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
575.640
205.920
889.200
135.720
62384.400
16380.
257.400
84.240
468.000
56.160
27424.800
-i-u j»u . uuu 9313 200
Total Suspended Solids 19188.000 9126.000
pH Within the range of 7.5 to 10.0 at all times,
*Regulated Pollutant
3771
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(o) Bertrandite Ore Leaching Scrubber BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
Total Suspended Solids
pH
1.859
0.665
2.871
0.438
201.416
52.885
61.951
0.831
0.272
1.511
0.181
88.545
30.069
29.465
LOwXXUo u J- « -/ ~* -*-
Within the range of 7.5 to 10.0 at all times
(P)
Bertrandite Ore Countercurrent and Decantation
Scrubber BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg or
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
Total Suspended Solids
« T»7 4 *- Vi -i TI +• 1
bertrandite
0.124
0.044
0.192
0.029
13.463
3.535
4:141
ho T-anrrp> of
ore processed
0.056
0.018
0.101
0.012
5.919
2.010
1.970
7.5 to 10.0 at all times.
pH
3772
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
0)
;j
DO
•r-t
Cil
H
S5
W-
w
33
3773
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - IX
THIS PAGE INTENTIONALLY LEFT BLANK
3774
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - X
; SECTION X
BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
llmitafcions are based on the best control and
i technology used by a specific point source within the
al category or subcategory, or by another industry where
tr re?dliy, transferable. Emphasis is placed on additional
treatment techniques applied at the end of the treatment systems
currently used, as well as, reduction of the amount of wate?Y used
ProcesS c-trol, and treatment technology
The factors considered in assessing best available technoloav
11 (BAT) Delude the -age-of equipment and
P__JT •, •_ . . - ». ' ——— v-"-- t*^t wj. cuuj.ijutt;iic and
facilities involved, the process used, process changes, nonwater
quality environmental impacts (including energy requirements)
and the costs of application of such technology!'BAT represents
the best available technology economically achievable at plantS
£LVa£10?S ag?S' Si2es' Processes, or other characteristics. BAT
may be transferred from a Different subcategory or category and
ShL in^dS feasible process changes or internal controls"7 even
when, not in common industry practice.
The required assessment of BAT considers costs, but does not
require a balancing of costs against pollutant removals. However
in assessing BAT the Agency has given substantial weight to the
economic achievability of the technology.
TECHNICAL APPROACH TO BAT
The Agency reviewed a wide range of technology options and
evaluated the available possibilities to ensure that the most
nlv J6 and beneficial technologies were used as the basis of
BAT. TO accomplish this> the Agency elected to examine two
technology options which could be applied to the primary
bervllmm anh^o™,, as , alternatives for the basis of BAT
ro
were
th* de^el0Pment of BAT! effluent limitations, mass loadings
calculated for each wastewater source or subdivision in the
in
in
the same technical approach as described
for BPT limitations development. The differences n
the mass loadings for BPT and BAT are due to increased treatment
tr^1VrefS -H a?hievable with the more sophisticated BAT
treatment technology and .reductions in the effluent flows
allocated to various waste streams.
below^reatment technologies considered for BAT are summarized
Option A (Figure X-l, page 3791) is based on:
o Recycle of scrubber liquors
3775
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - X
Ammonia steam stripping and cyanide precipitation pre-
treatment for selected waste streams
Chemical precipitation and sedimentation
Option C (Figure X-2, page 3792) is based on:
o
o
o
o
steSmrstrippingUand cyanide precipitation pre-
treatment for selected waste streams
Chemical precipitation and sedimentation
Multimedia filtration
above and beyond the progress achievable by
OPTION A
OPTION C
Option C for the primary beryllium subcategory consists of all
control and treatment requirements of Option A 6
the end of the Option A treatment scheme (see Figure X 2).
filtration is used to remove suspended solids,
satisfactorily.
INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES
hn
with each option. The methodologies are described
below.
POLLUTANT REMOVAL ESTIMATES
A complete description of the methodology used to calculate : the
3776
-------
PRIMARY BERYLDIUM SUBCATEGORY
SECT - X
of the
Vol. I.
proposal
several
removals
are the
estimated pollutant removal achieved by the application
various treatment options is presented in Section X of
The pollutant removal estimates have been revised from
because of new production normalized flows for
subdivisions. The methodology for calculating pollutant
has not changed, and the data used to estimate removals
same as those used to revise compliance costs.
Sampling data collected during the field sampling program were
used to characterize the major waste streams considered for
regulation. At each sampled facility, the sampling data was
production normalized for each unit operation (i.e., mass of
pollutant generated per mass of product manufactured). This
value, referred to as the raw waste, was used to estimate the
mass of toxic pollutants generated within the primary beryllium
subcategory. The pollutant removal estimates were calculated for
each plant by first estimating the total mass of each pollutant
in the untreated wastewater. This was calculated by first
multiplying the raw" waste values by the corresponding production
value for that stream and then summing these values for each
pollutant for every stream generated by the plant.
Next, the volume of wastewater discharged after the application
of each treatment option was estimated for each operation at each
plant by comparing the actual discharge to the regulatory flow.
The smaller of the two values was selected and summed with the
other plant flows. The!mass of pollutant discharged was then
estimated by multiplying the achievable concentration values
attainable with the option (mg/1) by the estimated volume of
process wastewater discharged by the subcategory. The mass of
pollutant removed is the difference between the estimated mass of
pollutant generated by each plant in the subcategory and the mass
of ^pollutant discharged after application of the treatment
option. The pollutant removal estimates for direct dischargers
in the primary beryllium subcategory are presented in Table X-l
(page 3981). !
COMPLIANCE COSTS
I
In estimating subcategory-wide compliance costs, the first step
was to develop a cost estimation model, relating the total costs
associated with installation and operation of wastewater
treatment technologies to, plant process wastewater discharge
EPA applied the model to each plant. The plant's investment and
operating costs are determined by what treatment it has in place
and by its individual process wastewater discharge flow As
discussed above, this flow is either the actual or the BAT
regulatory flow, whichever is lesser. The final step was to
annualize the capital costs, and to sum the annualized capital
costs, and the operating and maintenance costs for each plant
yielding the cost of compliance for the subcategory. A
comparison of the costs developed for proposal and the revised
costs for promulgation are presented in Table X-2 (page 3782) for
direct dischargers in the primary beryllium subcategory. These
costs were used in assessing economic achievability.
3777
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - X
BAT OPTION SELECTION - PROPOSAL
Our proposed BAT limitations for this subcategory were based on
chemical precipitation and sedimentation (BPT technology), with
the addition of in-process wastewater reduction, and filtration.
Plow reduction was based on 90 percent recycle of beryllium oxide
calcining furnace wet air pollution control. The pollutants
specifically limited under BAT were beryllium, chromium, copper,
and fluoride. '•
implementation of the proposed BAT limitations would remove
annually an estimated 257 kg of priority pollutants, which is 8
kg of priority metals over the estimated BPT discharge.
BAT OPTION SELECTION - PROMULGATION
EPA promulgated BAT limitations for the primary beryllium
subcategory based on recycle of scrubber liquors, ammonia steam
stripping, and cyanide precipitation pretreatment for selected
waste streams, followed by chemical precipitation, sedimentation,
and multimedia filtration technology. Flow reduction beyond
what is currently practiced was not promulgated because industry
comments to the Agency indicated that this scrubber is presently
opened with recycle. The Agency decided that further recycle
for this scrubber is not feasible.
The pollutants specifically limited under_promulgated BAT are
beryllium, chromium, copper, cyanide, ammonia, and fluoride. The
Aqency decided to promulgate ammonia and cyanide limitations
blsed on ammonia steam stripping and cyanide precipitation
because data submitted in comments confirmed the presence of
ammonia and cyanide in process waters generated in the beryllium
industry.
implementation of the promulgated BAT limitations would remove
annually an estimated 2,705 kilograms of priority pollutants and
524 kilograms of TSS, which is 7 kilograms of priority metals and
211 kilograms of TSS over the estimated BPT removals. The
estimated capital cost of promulgated BAT is $256,200 and the
estimated annual cost is $265,600 (1982 dollars). The end-of-
pipe treatment configuration for Option C is presented in Figure
X-2.
FINAL AMENDMENTS TO THE REGULATION
For the Primary Beryllium Subcategory, EPA prepared a settlement
agreement in April 1987 which would amend the regulation
promulgated on September 20, 1985, (50 FR 38276), concerning four
topics, which are briefly described here.
EPA agreed to revise the treatment effectiveness concentration
for fluoride in the beryllium I hydroxide supernatant subdivision,
based on the unusually high concentration of total dissolved
solids in this waste stream.
3778
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - X
EPA agreed to revise the regulatory flow for the beryllium
hydroxide filtrate building block based upon more detailed
information not available to EPA at the time of the oriqinal
rulemaking* j-yj-netx
EPA agreed to add new building blocks for the following six
processes in this subcategorys beryl ore gangue dewatering,
bertrandite ore gangue dewatering, beryl ore processing
(comprises quench pit, scrubber and washdown) , AIS area
wastewater, bertrandite ore leaching scrubber, and bertrandite
ore countercurrent decantation scrubber.
EPA agreed to allow modification of the monitoring requirements
", . cyanide at any beryllium manufacturing facility which
certifies that it does not use or generate cyanide at the
facility. This modification would allow yearly cvanide
monitoring. ' J jr «"••."«=
, t
WASTEWATER DISCHARGE RATES
A BAT discharge rate was calculated for each subdivision based
upon the flows of the existing plants, as determined from
analysis of the data collection portfolios. The discharge rate
-*^?**1016 treatment concentrations to determine
r limitations;. Since the discharge rate may be
different for each wastewater source, separate production
normalized discharge rates for each of the 10 wastewate? sources
were determined and are summarized in Table 10-3. The discharge
rates are normalized on a production basis by relating the amount
of wastewater generated to the mass of the intermediate product
which is produced by the process associated with the waste stream
in question. These production normalizing parameters, or PNPs,
are also listed in Table X-4 (page 3785). ' ^±-s,
At proposal, the BAT discharge rates reflected the flow reduction
requirements of the selected BAT option. For this reason, the
one scrubber water which was targeted for flow reduction through
recycle for BAT had a lower flow rate than the corresponding BPT
flow. Since several plants in other subcategories have
demonstrated sufficient ability to achieve substantial recycle of
similar wastewaters, lower flow allowances for this steam were
represent the best Bailable technology economically
The proposed BAT discharge rate for beryllium oxide calcininq
furnace wet air pollution control water was based on 90 percent
recycle of the scrubber effluent (refer to Section VII of the
General Development Document). Consequently, the proposed BAT
production normalized discharge flow for beryllium oxide
?!r?oning-, /?UrnaCe Wet air Pollution control was 26,373 1/kkg
(6,320 gal/ton) of beryllium oxide produced.
I
Since proposal, industry : comments to EPA have indicated that
recycle is presently practiced for the beryllium oxide calcining
3779
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - X
furnace scrubber, and to require additional recycle at BAT would
be unachievable. Upon evaluation of the data, the Agency decided
not to require an? recycle beyond what is presently practiced
Thus, the p?omulgated BAT discharge allowance for beryllium oxide
calcininq furnace wet air pollution control is 263,700 1/Kkg
?63?190 gal/ton) of beryllium oxide produced. This discharge
rate is equivalent to that promulgated at BPT.
REGULATED POLLUTANT PARAMETERS i
The Agency placed particular emphasis on the toxic pollutants.
?h1 raw waJtewater concentrations from individual operations and
the subcateqory as a whole w,ere examined to select certain
pollutant 9anl pollutant parameters for limitation. This
examination and evaluation was presented in Section VI. The
pollutants selected for specific limitation are listed below:
117. beryllium
119. chromium
120. copper
121. cyanide
ammonia
fluoride
EFFLUENT LIMITATIONS
The concentrations achievable by application of BAT are discussed
in Section VII The treatable concentrations both one day maximum
and monthly average values are multiplied by the BAT normalized
lischa?ge flows summarized in Table X-3 (page 3783) to calculate
the mals of pollutants allowed to be discharged per mass of
nroduct The results of these calculations in milligrams of
pollutant per kilogram of product represent the BAT effluent
l?mita??onsP and are presented; in Table X-4 (page 3785) for each
waste stream.
3780
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - X
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PRIMARY BERYLLIUM:SUBCATEGORY SECT - x
TABLE X-2
COST OF COMPLIANCE FOR THE PRIMARY BERYLLIUM SUBCATEGORY
DIRECT DISCHARGERS
(March 1982 Dollars)
Option Capital Cost
A 226500
B 256200
Annual Cost
251200
265600
3782
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - X
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3783
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - X
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-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - X
••• ', TABLE X-4
BAT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(a) Solvent Extraction Ragfinate from Bertrandite Ore BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
rag/kg (Ib/millioh Ibs) of beryllium carbonate
produced from bertrandite ore (as Be)
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
1,842.000
831.000
2,875.000
449.200
299,400.000
76,610.000
831.000
336.900
1,370.000
179.700
131,600.000
44,700.000
(b) Solvent Extraction Raffinate from Beryl Ore
BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium carbonate
produced from beryl ore (as Be)
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
180.400
81.400
>281.600
1 44.000
29,;330.000
7,700.000
81.400
33.000
134.200
17.600
12,890.000
4,378.000
(c) Beryllium Carbonate Filtrate BAT
Pollutant or
pollutant property
^laximum for
any one day
Maximum for
monthly average
mg/k9 (Ib/million Ibs) of beryllium carbonate produced (as Be)
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
175.900
i 79.370
274.600
i 42.900
28,590.000
7,508.000
79.370
32.180
130.800
17.160
12,570.000
4,269.000
3785
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - X
TABLE X-4 (Continued)
BAT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(d) Beryllium Hydroxide Filtrate BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of bery±J.ium nydroxide produced (as Be)
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
(e) Beryllium Oxide
111.520
50.320
174.080
27.200
18,128.800
4,760.000
Calcining Furnace Wet
7,
2,
APC
w
50.320
20.400
82.960
10.880
969.600
706.400
BAT
lav i mum for
pollutant property
any one day
monthly average
mg/kg (Ib/million Ibs) of beryllium oxide produce
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
216.200
97.570
337.500
52.740
35,150.000
9,230.000
97.570
39.560
160.900
21.100
15,450.000
5,248.000
(f) Beryllium Hydroxide Supernatant BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
mg/kg (Ib/million Ibs) or beryllium hydroxide
produced,from scrap and residues (as Be)
188.600 85.100
85.100 34.500
294.400 140.300
46.000 18.400
30,660.000 13,480.000
160,300.000 71,200.000
3786
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - X
.TABLE X-4 (Continued)
BAT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(g) Process Water BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
(lb/million Ibs)
23
6
143
64
223
34
,300
,118
of beryllium
.300
.680
.700
.960
.000
.000
pebbles
64.
26.
106.
13.
10,240.
3,479.
produced
680
220
600
980
000
000
(h) Fluoride Furnace Scrubber BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
(lb/million Ibs) of beryllium
0.000
1 0.000
0.000
0.000
i 0.000
: 0.000
pebbles produced
o oon
\J • \J \J \J
0 . 000
0 000
\J • \J \J \J
0 000
\J • \J \J \J
0 000
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0.000
(i) Chip Treatment Wastewater
BAT
Pollutant or
pollutant property
; Maximum for
; any one day
Maximum for
monthly average
mg/kg (lb/million Ibs) of beryllium scrap chips treated
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
: 6.355
! 2.868
1 9.920
i 1.550
1>033.000
i 271.300
2.868
1.163
4.728
.620
454.200
154.200
3787
-------
PRIMARY BERYLLIUM' SUBCATEGORY SECT - X
TABLE X-4 (Continued)
BAT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(J) Beryllium Pebble Plant Area Vent Wet APC BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
0.000
0.000
0.000
'o.ooo
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0 . 000
(k) Beryl Ore Gangue Dewatering BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (pounds per
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
million pounds)
0.855
0.386
1.335
0.209
139.032
36.505
of beryl ore
0.386
0.156
0 . 636
0.083
61.120
20.756
processed
(1) Bertrandite Ore Gangue Dewatering
BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (pounds per million pounds) of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
2.185
0.986
3.411
0.533
355.245
93.275
0.986
0.400
1.626
0.213
156.169
53.034
3788
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT — X
TABLE X-4 (Continued)
BAT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(m) Beryl Ore Processing BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
(pounds per million pounds) of beryl ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
5.988
2.702
19.348
1.461
973.490
255.605
2.702
1.095
4.455
0.584
427.956
145.330
(n) Aluminum Iron Sludge (AIS) Area Wastewater BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
ig/kg (pounds per million pounds) of total beryllium carbonate
produced (as Be)
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
383.760
173.160
599.040
•'. 93.600
62,384.400
16,380.000
173.160
70.200
285.480
37.440
27,424.800
9,313.200
(o) Bertrandite Ore Leaching Scrubber BAT
Pollutant or
pollutant property
Maximum for
;any one day
Maximum for
monthly average
mg/kg of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride,
1.239
0.559
i.934
0.302
201,416
52.885
0. 559
0.227
0.922
0.121
88.545
30.069
3789
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - X
TABLE X-4 (Continued)
BAT MASS LIMITATIONS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(p) Bertrandite Ore Countercurrent and Decantation
(CCD) Scrubber BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
0.083
0.037
0>129
0'.020
13.463
3.535
0.037
0.015
0.062
0.008
5.919
2.010
3790
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - X
2:
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PRIMARY BERYLLIUM SUBCATEGORY
SECT - X
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3792
-------
This
PRIMARY BERYLLIUM SUBCATEGORY SECT - XI
; SECTION XI
NEW SOURCE PERFORMANCE STANDARDS
section describes the technologies for treatment of
ssrs;
si
technologi
*
and wastewater treatment
f added costs and restrictions encountered in
process ^^r,^1^^ pjant- Therefore, the best demonstrated
process changes, in-plant controls, and end-of-pipe treatment
gies which reduce pollution to the maximum pvf«ant-
are considered as! a basis for BDT. maximum extent
TECHNICAL APPROACH TO NSPj/
New source performance standards are equivalent to the b^f
available technology (BAT) selected for cu??entl? eSistina
primary beryllium plants, This result is a SonsequSncJ Sf
careful review by the Agency of a wide range of technical Sptionf
for new source treatment systems which is liscussed in Sec??on XI
or voi. i. Additionally, there was nothing found to indicate that
tne wastewater flows and characteristics of new plants would not
J^,~ 6 from.existing plants, since the processes
sources are not expected to differ from those used at
-e
sour s-
Treatment technologies considered for the NSPS
technoi°9ies
OPTION A
o
o
Recycle of scrubber liquors
Ammonia steam stripping and cyanide precipitation
for selected waste streams
Chemical precipitation and sedimentation
OPTION C
o
o
o
o
Recycle of scrubber liquors
Ammonia steam stripping and cyanide precipitation pre-
treatment for selected waste streams
Chemical precipitation and sedimentation
Multimedia filtration
NSPS OPTION SELECTION - PROPOSAL
EPA proposed that the best Available demonstrated technology for
3793
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XI
the primary beryllium subcategory be equivalent to Option C. At
proposal, Option C included in-process flow reduction, chemical
precipitation, sedimentation, and multimedia filtration
technology. The Agency was also considering regulation of
amSonia based on 9aimnonia steam stripping technology, and
regulation of cyanide based on cyanide precipitation.
The wastewater flow rates for NSPS were the same as the proposed
BAT flow rates. Flow reduction measures beyond those proposed at
BAT were not considered feasible because no new demonstrated
technologies existed within the subcategory that improved on
discharge practices. The pollutants proposed for regulation at
NSPS were the same as those proposed for regulation at BAT, with
the addition of TSS and pH.
NSPS OPTION SELECTION - PROMULGATION
EPA is promulgating best available demonstrated technology for
the primary beryllium subcategory equivalent to Option C. in
contrast to Option C at proposal, Option C at promulgation
includes ammonia steam stripping and cyanide precipitation
pretreatment for selected waste streams, followed _by chemical
precipitation, sedimentation, and multimedia filtration.
Our review of the subcategory indicates that no new demonstrated
technologies that improve on BAT technology exist. We do not
believe that new plants could,achieve any further flow reduction
beyond that already promulgated for BAT. Because NSPS is equal
to BAT we believe that the promulgated NSPS will not have a
detrimental impact on the entry of new plants into this
subcategory.
REGULATED POLLUTANT PARAMETERS
The Agency has no reason to believe that the pollutants that will
be found in treatable concentrations in processes within new
sources will be any different than with existing sources.
Accordingly, pollutants and pollutant parameters selected for
limitation under promulgated NSPS, in accordance with the
rationale of Sections VI and X, are identical to those selected
for promulgated BAT. The conventional pollutant parameters TSS
and pH are also selected for limitation.
NEW SOURCE PERFORMANCE STANDARDS :
The NSPS discharge flows for each wastewater source are the same
as the discharge rates for BAT and are shown in Table XI-1 (page
3786) The mass of pollutant allowed to be discharged per mass
of product (mg/kg) is based'on the product of the appropriate
treatable concentration (mg/1) and the production normalized
wastewater discharge flows (1/kkg). The treatment effectiveness
concentrations are listed in Table VII-21 (page 248) of Vol. I
with the exception of fluoride for beryllium hydroxide
supernatant, as discussed in.Section IX. The results of these
3794
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XI
andd
standards.
Th Pr°duction based new source performance
These standards are presented in Table XI-2.
3795
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XI
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wet air
3796
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - XI
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3797
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XI
TABLE XI-2
NSPS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(a) Solvent Extraction Raffinate from Bertrandite Ore
NSPS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mq/kg (Ib/million Ibs) of beryllium carbonate
produced from bertrandite ore (as Be)
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
pH
1,842.000
831.000
2,875.000
449.200
299,400.000
78,610.000
33,690-000
Within the range of 7.5
831.000
336.900
1,370.000
179.700
131,600.000
44,700.000
26,950.000
to 10.0 at all
times
(b) Solvent Extraction Raffinate from Beryl Ore
NSPS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium carbonate
produced from beryl ore (as Be)
*Beryllium
*Chromium
*Copper
*Cyanide
*Ammonia
*Fluoride
*TSS
*pH
(c) Beryllium Carbonate Filtrate"
180.400
81.400
281.600
44.000
29,330.000
7,700.000
3,300.000
81.400
33.000
134.200
17.600
12,890.000
4,378.000
2,640.000
Within the'range of 7.5 to 10.0 at all times
NSPS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
'mg/kg (Ib/million Ibs) of beryllium carbonate produced (as Be)
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
PH
175.900
79.370
274.600
42.900
28,590.000
7,508.000
3,218.000
79.370
32.180
130.800
17.160
12,570.000
4,269.000
2,574.000
Within the range of 7.5 to 10.0 at all times
3798
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(d) Beryllium Hydroxide Filtrate NSPS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/Kg ( ID/million Ibs) of beryllium hydroxide produced (as
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
mo o
-Lob
PH
111.520
50.320
174.080
:27.200
18,128.800
4,760.000
2,040.000
Within the 'range of 7.5
i
50.320
20.400
82.960
10.880
7,969.600
2,706.400
1,632.000
to 10.0 at all
times
(e) Beryllium Oxide Calcining Furnace Wet APC
Pollutant or
pollutant property
NSPS
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium oxide produced
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
pH
216.200
97.570
1337.500
> 52.740
35,150.000
9,230.000
3,956.000
97.570
39.560
160.900
21.100
15,450.000
5,248.000
3,164.000
TT • . .. ---_ -«,-i.ui.
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(g) process Water NSPS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
pH
143.300
64.680
223.700
34.960
23,300.000
6/118.000
2,622.000
64.680
26.220
106.600
13.980
10,240.000
3,479.000
2,098.000
Within the range of 7.5 to 10.0 at all times
(h) Fluoride Furnace Scrubber NSPS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium pebbles produced
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
pH
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
0.000
Within the range of 7.5 to 10.0 at all times
Treatment Wastewater NSPS
Pollutant or
Maximum for
any one day
Maximum for
monthly average
pollutant property
mg/kg (Ib/million Ibs) of beryllium scrap chips treated
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
pH
6.355
2.868
9.920
1.550
1,033.000
271.300
116.300
2.868
1.163
4.728
.620
454.200
154.200
93.000
Within the range of 7.5 to 10.0 at all times
3800
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(j) Beryllium Pebble Plant Area Vent Wet APC NSPS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
TSS
PH
(Ib/million Ibs) of beryllium
0.000
0.000
0.000
0.000
0.000
0.000
0.000
Within the range of 7.5 to
pebbles produced
0.000
0.000
0.000
0.000
0.000
0.000
0.00,0
,10.0 at all times
(k) Beryl Ore Gangue Dewatering NSPS
Pollutant or
pollutant property
.Maximum for
any one day
Maximum for
monthly average
mg/
'kg (pounds per million pounds) of beryl ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
Total Suspended Solids
pH Within the
0.855
0.386
1.335
0.209
139.032
;' 36.505
.'- 15.645
range of 7.5
0.386
0.156
0.636
0.083
61.120
20.756
12.516
to 10.0 at all
times
(1) Bertrandite Ore Gangue Dewatering NSPS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
g (pounds per million pounds) of bertrandite ore processed
Beryllium 2.185
Chromium (Total) . ' ', 0.986
Copper : 3.411
Cyanide (Total) , 0.533
Ammonia (as N) 355.245
Fluoride 93.275
Total Suspended Solids 39.975
pH
0.986
0.400
1.626
0.213
156.169
53.034
31.980
Within the ;range of 7.5 to 10.0 at all times
3801
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XI
TABLE IX-2 (Continued)
NSPS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(m) Beryl Ore Processing
NSPS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (pounds per million pounds) of beryl ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
Total Suspended Solids
pH '
5.988
2.702
9.348
1.461
973.490
255.605
109.545
2.702
1.095
4.455
0.584
427.956
145.330
87.636
Within the range of 7.5 to 10.0 at all times
(n) Aluminum Iron Sludge (AIS) Area Wastewater NSPS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (pounds per million pounds) of total beryllium carbonate
produced (as Be)
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
Total Suspended Solids
pH
383.760
173.160
599.040
93.600
62,384.400
16,380.000
7,020.000
173.160
70.200
285.480
37.440
27,424.800
9,313.200
5,616.000
Within the range of 7.5 to 10.0 at all times
(o) Bertrandite Ore Leaching Scrubber
NSPS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
Total Suspended Solids
1.239
0.559
1.934
0.302
201.416
52.885
22.665
0.559
0.227
0.922
0.121
88.545
30.069
18.132
Within the range of 7.5 to 10.0 at all times
3802
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(p) Bertrandite Ore Countercurrent and Decantation
(CCD) Scrubber NSPS'
Pollutant orMaximum forMaximum for"
pollutant property any one day monthly average
~ ~~ mg/kg of bertrandite ore processed ~
Beryllium 10.083 0.037
Chromium (Total) 0.037 0 015
Copper 0.129 O.*062
Cyanide (Total) 0.020 0.008
Ammonia (as N) 13.463 5 919
Fluoride 3.535 2.'010
Total Suspended Solids 1.515 1.212
pH Within the range of 7.5 to 10.0 at all times
3803
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XI
THIS PAGE INTENTIONALLY LEFT BLANK
3804
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XII
SECTION XII
PRETREATMENT STANDARDS
This section describes the control and treatment technologies for
pretreatment of process: wastewaters from new sources in the
primary beryllium subcategory. Pretreatment standards for
regulated pollutants are presented based on the selected control
and treatment technology. Pretreatment standards are to be
technology based, analogous to the best available technology for
removal of toxic pollutants.
EPA is not promulgating pretreatment standards for
sources at this time because there are currently no
discharging facilities in this subcategory.
TECHNICAL APPROACH TO PRETREATMENT
existing
indirect
Before proposing and promulgating pretreatment standards, the
Agency examines whether the pollutants discharged by the industry
pass through the POTW or interfere with the POTW operation or its
chosen sludge disposal practices. In determining whether
pollutants pass through a well-operated POTW achieving secondary
treatment, the Agency compares the percentage of a pollutant
removed by POTW with the percentage removed by direct dischargers
applying the best available technology economically achievable.
A pollutant is deemed to pass through the POTW when the average
percentage removed nationwide by well-operated POTW meeting
secondary treatment requirements, is less than the percentage
removed by direct dischargers complying with BAT effluent
limitations guidelines for' that pollutant.
This definition of pabs-through satisfies two competing
objectives set by Congress: (1) that standards for indirect
dischargers be equivalent to standards for direct dischargers
while , at the same time, (2) that the treatment capability and
performance of the POTW be recognized and taken into account in
regulating the discharge of pollutants from indirect dischargers.
The Agency compares percentage removal rather than the mass or
concentration of pollutants discharged because the latter would
not take into account th^ mass of pollutants discharged to the
POTW from non-industrial sources or the dilution of the
pollutants in the POTW effluent to lower concentrations due to
the addition of large amounts of non-industrial wastewater.
PRETREATMENT STANDARDS FOR;NEW SOURCES
I
Options for pretreatment; of wastewaters from new sources are
based on increasing the effectiveness of end-of-pipe treatment
technologies. All in-plant changes and applicable end-of-pipe
treatment processes have been discussed previously in Sections X
and XI. The options for PSNS, therefore, are the same as the BAT
3805
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XII ;
options discussed in Section X.
Treatment technologies considered for the PSNS options are:
OPTION A
o Recycle of scrubber liquors
o Ammonia steam stripping and cyanide precipitation
for selected waste streams
o Chemical precipitationland sedimentation
OPTION C
o Recycle of scrubber liquors
o Ammonia steam stripping and cyanide precipitation
pretreatment for selected waste streams
o Chemical precipitation and sedimentation
PSNS OPTION SELECTION - PROPOSAL
EPA proposed that the pretreatment standards technology base for
the primary beryllium subcategory be equivalent to Option C,
inprocess flow reduction, chemical precipitation, sedimentation,
and multimedia filtration. EPA was considering addition of
ammonia steam stripping and cyanide precipitation for control of
ammonia and cyanide. ,
The wastewater discharge rates proposed for PSNS were equivalent
to the proposed BAT discharged races. No flow reduction was
considered feasible beyond the recycle proposed for BAT. The
pollutants proposed for regulation at PSNS were the same as those
proposed for regulation at BAT.
PSNS OPTION SELECTION - PROMULGATION ]
The technology basis for promulgated PSNS is identical to NSPS
and BAT. It includes ammonia steam stripping and cyanide
precipitation pretreatment for selected waste streams, followed
by chemical precipitation, sedimentation, and multimedia
filtration technology. It is necessary to promulgate PSNS to
prevent passthrough of beryllium, chromium, copper, cyanide,
ammonia, and fluoride. We know of no economically feasible,
demonstrated technology that is better than BAT technology. No
additional flow reduction for new sources is feasible. Because
PSNS does not include any additional costs compared to NSPS and
BAT, we do not believe it will prevent entry of new plants. The
PSNS discharge rates are shown in Table XII-1 (page 3808).
REGULATED POLLUTANT PARAMETERS
Pollutants selected for limitation, in accordance with the
rationale of Sections VI and X, are identical to those selected
for limitation for BAT. ]
3806
-------
PRIMARY BERYLLIUM SUBCATEGORY
SECT - XII
PRETREATMENT STANDARDS FOR NEW SOURCES
Pretreatment standards for new sources are based on the treatable
concentrations from the selected treatment technology, (Option
C), and the discharge rates determined in Section X for BAT A
mass of pollutant per mass of product (mg/kg) allocation is given
tor each subdivision within the subcategory. This pollutant
allocation is based on the, product of the treatment effectiveness
concentration from the model treatment (mg/1) and the production
normalized wastewater discharge rate (1/kkg). The achievable
treatment effectiveness concentrations for BAT are identical to
those for PSNS. PSNS are presented in Table XII-2
3807
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XII
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PRIMARY BERYLLIUM SUBCATEGORY SECT - XII
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!3809
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XII
TABLE XI1-2
PSNS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(a) Solvent Extraction Raffinate from Bertrandite Ore PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium carbonate
produced from bertrandite ore (as Be)
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
1,842.000
831.000
2,875.000
449.200
299,400.000
78,610.000
831.000
336.900
1,370.000
179.700
131,600.000
44,700.000
(b) Solvent Extraction Raffinate from Beryl Ore
PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium carbonati
produced from beryl ore (as Be)
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
180.400
81.400
281.600
44.000
29,330.000
7,700.000
81.400
33.000
134.200
17.600
12,890.000
4,378.000
(c) Beryllium Carbonate Filtrate PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
Ibs) of beryllium
175.900
79.370
274.600
42.900
28,590.000
7,508.000
carbonate produced (as 1
79.370
32.180
130.800
17.160
12,570.000
4,269.000
3810
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XII
TABLE XI1-2 (Continued)
PSNS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(d) Beryllium Hydroxide Filtrate PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
rag/kg (lb/million
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
Ibs) of beryllium
18
4
illl.520
; 50.320
174.080
; 27.200
,128.800
,760.000
hydroxide produced
7
2
50 390
•J \J • J £+ \J
20 400
£* \J 9 ~X \J \J
82 .960
10 .880
,969 . 600
,706.400
(as Be)
(e) Beryllium Oxide Calcining Furnace Wet APC PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
(ib/mniion Ibs) of beryllium oxide produced
216.200 97.570
97.570 39.560
337.500 160.900
52.740 21 100
35,150.000 15,450.000
9,230.000 5,248.000
(f) Beryllium Hydroxide Supernatant PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
Ag (lb/million Ibs) of beryllium hydroxide
produced from scrap and residues (as Be)
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
188.600
85.100
2:94.400
46.000
30,660.000
160,300.000
85.100
34.500
140.300
18.400
13,480.000
71,200.000
3811
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XII
TABLE XI1-2 (Continued)
PSNS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(g) Process Water PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) or beryllium pebbles pro<
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
143.300
64.680
223.700
34.960
23,300.000
6,118.000
64.680
26.220
106.600
13.980
10,240.000
3,479.000
(h) Fluoride Furnace Scrubber PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
(Ib/million IDS)
of beryllium
0.000
0.000
0.000
0.000
0.000
0.000
pebbles produced
0.000
0.000
0.000
0.000
0.000
0.000
(i) Treatment Wastewater PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of beryllium scrap chips treat<
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
6.355
2.868
9.920
1.550
1,033.000
: 271.300
2.868
1.163
4.728
.620
454.200
154.200
3812
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XII
TABLE XII-2 (Continued)
PSNS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(j) Beryllium Pebble Plant Area Vent Wet APC PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg
Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride,
(Ib/million Ibs) of beryllium
0.000
; 0.000
0.000
0.000
0.000
0.000
pebbles produced
o nnn
0 000
0.000
o non
Oonn
0.000
(k) Ore Gangue Dewatering PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (pounds per million pounds) of beryl ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
0.855
0.386
1.335
0.209
139.032
36.505
0.386
0.156
0.636
0.083
61.120
20.756
(1) Bertrandite Ore Gangue' Dewatering PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (pounds per million pounds)
of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
2.185
0.986
i 3.411
! 0.533
355.245
=93.275
0.986
0.400
1.626
0.213
156.169
53.034
3813
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XII
TABLE Xli-2 (Continued)
PSNS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(m) Beryl Ore Processing PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (pounds per million pounds) of beryl ore proce
SSGCL
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
5.988
2.702
9.348
1.461
973.490
255.605
2.702
1.095
4.455
0.584
427.956
145.330
(n) Aluminum Iron Sludge (AIS) Area Wastewater PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mq/kq (pounds per million pounds) of total beryllium carbonate
y/ y produced (as Be)
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
383.760
173.160
599.040
93.600
62,384.400
16,380.000
173.160
70.200
285.480
37.440
27,424.800
9,313.200
(o) Bertrandite Ore Leaching Scrubber PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg of bertrandite ore processed
Beryllium
Chromium (Total)
Copper
Cyanide (Total)
Ammonia (as N)
Fluoride
1.239
0.559
1.934
0.302
201.416
52.885
0.559
0.227
0.922
0.121
88.545
30.069
3814
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XII
TABLE XII-2 (Continued)
PSNS FOR THE PRIMARY BERYLLIUM SUBCATEGORY
(P) Bertrandite Ore Countercurrent and Decantation
(CCD) Scrubber PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
of bertrandite ore processed
Beryllium
Chromium (Total)
c°PPer
Cyanide (Total)
Ammonia (as N)
Fluoride
0.083
0.037
0.129
0.020
13.463
3.535
0.037
0.015
0.062
0.008
5 919
2.010
3815
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XII
THIS PAGE INTENTIONALLY LEFT BLANK
3816
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XIII
SECTION XIII
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY
EPA is not promulgating best conventional pollutant control
Uations f °r ths ""
3817
-------
PRIMARY BERYLLIUM SUBCATEGORY SECT - XIII
THIS PAGE INTENTIONALLY LEFT BLANK
3818
-------
NONFERROUS METALS MANUFACTURING POINT SOURCE CATEGORY
DEVELOPMENT DOCUMENT SUPPLEMENT
for the
Primary Nickel and Cobalt Subcategory
William K. Reilly
Administrator
Rebecca Hanmer
Acting Assistant Administrator for Water
Martha Prothro, Director
Office of Water Regulations and Standards
Thomas P. O'Farrell, Director
Industrial Technology Division
Ernst P. Hall, P.E., Chief
Metals Industry Branch
and
Technical Project Officer
May 1989
U.S. Environmental Protection Agency
Office of Water
Office of Water;Regulations and Standards
Industrial Technology Division
Washington, D. C. 20460
3819
-------
3820
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
Section
I
II
III
IV
V
TABLE OF CONTENTS
. SUMMARY
CONCLUSIONS .
SUBCATEGORY PROFILE
Description of Primary Nickel and Cobalt
Production
Raw Materials
Leaching .
Cobalt Precipitation and Reduction
Nickel Reduction
Process Wastewater Sources
Other Wastewater Sources
Age, Production,: and Process Profile
SUBCATEGORIZATION
Factors Considered in Subdividing the Primary
Nickel and Cobalt Subcategory
Other Factors
Production Normalizing Parameters
WATER USE AND WASTEWATER CHARACTERISTICS
Wastewater Flow Rates
Wastewater Characteristics Data
Data Collection Portfolios
Field Sampling Data
Wastewater Characteristics and Flows by
Subdivision
Raw Material Dust Control
Cobalt Reduction Decant
Nickel Reduction Decant
Nickel Wash Water
Paqe
3829
3831
3837
3837
3837
3837
3838
3838
3838
3838
3839
3841
3841
3842
3842
3843
3844
3844
3844
3845
3846
3846
3846
3847
3847
3821
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
Section
VI
VII
VIII
TABLE OF CONTENTS (Continued)
SELECTION OF POLLUTANTS
Conventional and Nonconventional Pollutant
Parameters Selected
Toxic Priority Pollutants
Toxic Pollutants Never Detected
Toxic Pollutants Never Found Above Their
Analytical Quantification Concentration
Toxic Pollutants Present Below Concentrations
Achievable by Treatment
Priority Pollutants Selected for Further
Consideration in Establishing Limitations
and Standards
CONTROL AND TREATMENT TECHNOLOGIES ;
Current Control and Treatment Practices
Raw Material Dust Control
Cobalt Reduction Decant
Nickel Reduction Decant
Nickel Wash Water
Control and Treatment Options
Option A
Option C
COSTS, ENERGY, AND NONWATER QUALITY ASPECTS
Treatment Options for Existing Sources
Option A
Option C
Cost Methodology ;
Nonwater Quality Aspects
Energy Requirements
Solid Waste
Air Pollution
3874
3874
3874
3875
3875
3885
3885
3885
3885
3886
3886
3886
3886
3886
3889
3889
3889
3889
3889
3890
3891
3891
3892
3822
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
Section
IX
XI
TABLE OF CONTENTS (Continued)
BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
AVAILABLE
Technical Approach to BPT
Industry Cost and Pollutant Removal Estimates
BPT Option Selection
Wastewater Discharge Rates
Raw Material Dust Control
Cobalt Reduction Decant
Nickel Reduction Decant
Nickel Wash Water
Regulated Pollutant Parameters
Effluent Limitations
BEST AVAILABLE TECHNOLOGY ECONOMICALLY
ACHIEVABLE
Technical Approach to BAT
Option A
Option C
Industry Cost and Pollutant Removal Estimates
Pollutant Removal Estimates
Compliance Costs
BAT Option Selection - Proposal
BAT Option Selection - Promulgation
Wastewater Discharge Rates
Regulated Pollutant Parameters
Effluent Limitations
NEW SOURCE PERFORMANCE STANDARDS
Technical Approach to NSPS
NSPS Option Selection - Proposal
NSPS Option Selection - Promulgation
Regulated Pollutant Parameters
New Source Performance Standards
3895
3897
3897
3898
3899
3899
3899
3899
3899
3900
3905
3905
3906
3906
3906
3906
3907
3907
3908
3908
3909
3910
3919
3919
3920
3920
3920
3920
3823
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
TABLE OF CONTENTS (Continued)
Section
XII
XIII
PRETREATMENT STANDARDS
Technical Approach to Pretreatment
Pretreatment Standards for New Sources
PSNS Option Selection - Proposal
PSNS Option Selection - Promulgation
Regulated Pollutant Parameters
Pretreatment Standards for New Sources
BEST CONVENTIONAL POLLUTANT CONTROL
TECHNOLOGY
3925
3925
3926
3926
3926
3927
3927
3931
3824
-------
PRIMARY NICKflL AND COBALT SUBCATEGORY
LIST OF TABLES
Table
Title
Page
V-l
V-2
V-3
V-4
V-5
V-6
VI-1
VI-2
VIII-1
IX-1
IX-2
X-l
X-2
X-3
X-4
Water Use and Discharge Rates for Raw Material 3848
Dust Control
Water Use and Discharge Rates for Cobalt 3849
Reduction Decant
Water Use and Discharge Rates for Nickel 3850
Reduction'Decant
Water Use and Discharge Rates for Nickel Wash 3851
W3 tG IT ,
Primary Nickel and Cobalt Subcategory Combined 3852
Wastewater - Influent to Treatment Raw Wastewater
Sampling Data
Primary Nickel and. Cobalt Subcategory Treated 3862
Plant Effluent ;
Frequency of Occurrence of Priority Pollutants 3877
Primary Nickel and Cobalt Subcategory Raw
Wastewater '
Toxic Pollutants ;Never Detected 3881
Cost of Compliance for the Primary Nickel and 3893
Cobalt Subcategory Direct Dischargers
BPT Wastewater Discharge Rates for the Primary 3901
Nickel and Cobalt; Subcategory
BPT Mass Limitations for the Primary Nickel and 3902
Cobalt Subcategory
Pollutant Removal: Estimates for Direct 3911
Dischargers Primary Nickel and Cobalt Subcategory
Cost of Compliance for the Primary Nickel and 3912
Cobalt Subcategory Direct Dischargers
BAT Wastewater Discharge Rates for the Primary 3913
Nickel and Cobalt:Subcategory
BAT Mass Limitations for the Primary Nickel and 3914
Cobalt Subcategory
3825
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
LIST OF TABLES
Table
XI-1
XI-2
XII-1
XII-2
Title
Page
NSPS Wastewater Discharge Rates for the Primary 3921
Nickel and Cobalt Subcategory
NSPS for the Primary Nickel and Cobalt 3922
Subcategory
PSNS Wastewater Discharge Rates for the Primary 3928
Nickel and Cobalt Subcategory
PSNS for the Primary Nickel and Cobalt
Subcategory
3929
3826
-------
Figure
III-l
V-l
IX-1
X-l
X-2
PRIMARY NICKEL AND COBALT SUBCATEGORY
LIST OP FIGURES
Title
Paqe
Primary Nickel and Cobalt Manufacturing Process 3840
3872
Sampling Sites at Primary Nickel and Cobalt
Plant A ; .
BPT Treatment Scheme for the Primary Nickel and 3904
Cobalt Subcategory
BAT Treatment Scheme for Option A
BAT Treatment Scheme for Option C
3916
3917
3827
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
THIS PAGE INTENTIONALLY LEFT BLANK
3828
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - I
SECTION I
SUMMARY AND CONCLUSIONS
This document provides the technical basis for promulgating
effluent limitations based on best practicable technology (BPT)
and best available technology (BAT) for existing direct
dischargers, pretreatment standards for new indirect dischargers
(PSNS), and standards of performance for new source direct
dischargers (NSPS) for plants in the primary nickel and cobalt
subcategory.
The primary nickel and cobalt subcategory consists of one plant
which discharges directly to a surface water. There are no
indirect dischargers presently operating.
EPA first studied the primary nickel and cobalt subcategory to
determine whether differences in raw materials, final products
manufacturing processes, equipment, age and size of plants, or
water usage required the development of separate effluent
limitations and standards for different segments of the
subcategory. This involved a detailed analysis of wastewater
discharge and treated effluent characteristics including the
sources and volume of water used, the processes used, the sources
of pollutants and wastewaters in the plant, and the constituents
^^stewaters, including toxic pollutants. Asa result, four
subdivisions have been identified for this subcategory that
warrant separate effluent limitations. These include:
o Raw material dust ;control,
o Cobalt reduction decant,
o Nickel reduction decant, and
o Nickel wash water.
Several distinct control ;and treatment technologies (both in-
plant and end-of-pipe) applicable to the primary nickel and
cobalt subcategory were identified. The Agency analyzed both
historical and newly generated data on the performance of these
technologies, including their nonwater quality environmental
air quality, solid waste generation, and energy
EPA also studied various flow reduction techniques
the data collection portfolios (dcp) and plant
impacts and
requirements
reported in
visits.
Engineering costs were prepared for each of the control and
treatment options considered for the subcategory. These costs
were then used by the Agency .to estimate the impact of
implementing the various options on the subcategory. For each
control and treatment option that the Agency found to be most
effective and technically feasible in controlling the discharge
°;L P°llutants, the number of potential closures, number of
employees affected, and impact on price were estimated. These
3829
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
SECT - I
results are reported in a separate document entitled The Economic
Impact Analysis of Effluent Limitations and Standards for_ the
Nonferrous Metals Manufacturing:Industry.
After examining the various treatment technologies, the Agency
has identified BPT to represent the average of the best existing
technoloqy. Metals removal based on chemical precipitation and
sedimentation technology is the basis for the BPT limitations.
Steam stripping was selected as the technology basis for ammonia
limitations. To meet the BPT effluent limitations based on this
technology, the primary nickel and cobalt subcategory is
to incur a capital cost of $71,362 and an annual cost of
For BAT, the Agency has built upon the BPT technology basis by
adding filtration as an effluent polishing step to the end--of-
pipe treatment scheme. To meet the BAT effluent limitations
based on this technology, the primary nickel and cobalt
subcategory is estimated to incur a capital cost of $86,500 and
an annual cost of $31,800.
NSPS is equivalent to BAT. In selecting NSPS, EPA recognizes
that new plants have the opportunity to implement the best and
most efficient manufacturing processes and treatment_technology.
As such, the technology basis of BAT has been determined as the
best demonstrated technology.
The Agency is not promulgating PSES for this subcategory because
there are no indirect dischargers. For PSNS, the Agency selected
end-of-pipe treatment and in-process flow reduction control
techniques equivalent to NSPS.
The best conventional technology (BCT) replaces BAT for the
control of conventional pollutants. BCT is not being promulgated
because the methodology for BCT has not yet been finalized.
The mass limitations and standards for BPT,
are presented in Section II.
BAT, NSPS, and PSNS
3830
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
SECT - II
SECTION II
CONCLUSIONS
EPA has divided the primary nickel and cobalt subcategory into
four subdivisions or building blocks for the purpose of effluent
limitations and standards. These subdivisions are: "Client
(a) Raw material dust control,
(b) Cobalt reduction decant,
(c) Nickel reduction 'decant, and
(d) Nickel wash water.
BPT, .^.Promulgated based on the performance achievable by the
J£?MCf ?n £ Chemical precipitation and sedimentation.(lime and
settle) technology, along with preliminary treatment consisting
of ammonia steam stripping for selected waste streams. The
following BPT effluent limitations are promulgated:
(a) Raw Material Dust Control BPT
Pollutant or
Pollutant property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of copper, nickel, and cobalt in
the crushed raw material
Copper
Nickel
Ammonia (as N)
Cobalt
TSS
PH
0.146
0.148
10.260
0.016
3.157
0.077
0.098
4.512
0.007
1.502
Within the range of 7.5 to 10.0 at all times
(b) Cobalt Reduction Decant BPT
Pollutant or
Pollutant property
Maximum for
Any One Day
Maximum for
Monthly Average
rag/kg (Ib/million Ibs) of cobalt produced
Copper
Nickel
Ammonia (as N)
Cobalt
TSS
pH
;40.660
41.080
2,852.000
;>4.494
877.300
21.400
27.180
1,254.000
1.926
417.300
Within the range: of 7.5 to 10.0 at all times
3831
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
SECT - II
(c) • Nickel Reduction Decant BPT
Pollutant or
Pollutant property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of nickel produced
Copper
Nickel
Ammonia (as N)
Cobalt
TSS
pH
24.120
24.370
1,692.000
2.666
520:500
12.700
16.120
743.90.0
1.143
247.600
Within the range of 7.5 to 10.0 at all times
(d) Nickel Wash Water BPT
Pollutant or
Pollutant property
Maximum;for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of nickel powder washed
Copper
Nickel
Ammonia (as N)
Cobalt
TSS
pH
0.064
0.065
4!.515
0.007
1.389
0.034
0.043
1.985
0.003
0.660
Within the range of 7.5 to 10.0 at all times
BAT is promulgated based on the performance achievable by
T "
the
limitations are promulgated:
(a) Raw Material Dust Control BAT
Pollutant or
Pollutant property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of copper, nickel, and cobalt in
the crushed raw material
Copper
Nickel
Ammonia (as N)
Cobalt
0:099
0.042
10.260
0.011
0.047
0.028
4.512
0.005
3832
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
SECT - II
(b) Cobalt Reduction Decant BAT
Pollutant or
Pollutant property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/k:g (Ib/million Ibs) of cobalt produced
Copper
Nickel
Ammonia (as N)
Cobalt
! 27.390
11.770
2/852.000
2.996
13.050
7.917
1,254.000
1.498
(c) Nickel Reduction Decant BAT
Pollutant or
Pollutant property
.Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of nickel produced
Copper
Nickel
Ammonia (as N)
Cobalt
16.250
6.982
1,692.000
1.777
7.744
4.697
743.900
0.889
(d) Nickel Wash Water BAT
Pollutant or
Pollutant property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of nickel powder washed
Copper
Nickel
Ammonia (as N)
Cobalt
0.043
0.019
4.515
0.005
0.021
0.013
1.985
0.002
NSPS are promulgated based on the performance achievable by the
application of chemical precipitation, sedimentation, and
multimedia filtration (ilime, settle, and filter) technology,
along _with preliminary treatment consisting of ammonia steam
stripping for selected waste streams. The following NSPS are
promulgated for new sources:
3833
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
SECT -II
(a) Raw Material Dust Control NSPS
Pollutant or
Pollutant property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of copper, nickel, and cobalt in
the crushed raw material
Copper
Nickel
Ammonia (as N)
Cobalt
TSS
pH
0.099
0.042
10.260
0.011
1.155
0.047
0.028
4.512
0.005
0.924
Within the range of 7.5 to 10.0 at all times
(b) Cobalt Reduction Decant NSPS
Pollutant or
Pollutant property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of cobalt produced
Copper
Nickel
Ammonia (as N)
Cobalt
TSS
pH
27.390
11.770
2,852.000
2.996
321.000
13.050
7.917
1,254.000
1.498
256.800
Within the range of 7.5 to 10.0 at all times
(c) Nickel Reduction Decant NSPS
Pollutant or
Pollutant property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of nickel produced
Copper
Nickel
Ammonia (as N)
Cobalt
TSS
pH
16.250
6.982
1,692.000
1.777
190.400
7.744
4.697
743.900
0.889
152.300
Within the range of 7.5 to 10.0 at all times
3834
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
SECT - II
(d) Nickel Wash Water NSPS
Pollutant or
Pollutant property
Maximum for
Any One Day
Maximum for
Monthly Average
nig/kg (Ib/million Ibs) of nickel powder washed
Copper
Nickel
Ammonia (as N)
Cobalt
TSS
pH
0.043
0.019
4.515
0.005
0.508
0.02.1
0.013
1.985
0.002
0.406
\J • *i \J O
Within the range of 7.5 to 10.0 at all times
ISlrSS
£°r
since there are
no
(a) Raw Material Dust Control
streams- The
PSNS
Pollutant or
Pollutant property
Maximum for
Any;One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of copper, nickel, and cobalt in
the crushed raw material
Copper
Nickel
Ammonia (as N)
Cobalt
0.099
O.O42
10.260
0.011
0.047
0.028
4.512
0.005
(b) Cobalt Reduction Decant PSNS
Pollutant or
Pollutant property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of cobalt produced
Copper
Nickel
Ammonia (as N)
Cobalt
27.390
11.770
2,852.000
2.996
13.050
7.917
1,254.000
1.498
3835
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - II
(c) Nickel Reduction Decant PSNS
Pollutant or
Pollutant property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of nickel produced
Copper
Nickel
Ammonia (as N)
Cobalt
16.250
6.982
1,692.000
1.777
7.744
4.697
743.900
0.889
(d) Nickel Wash Water PSNS
Pollutant or
Pollutant property
Maximum for
Any One Day
Maximum tor
Monthly Average
mg/kg (Ib/million Ibs) of nickel powder washed
Copper
Nickel
Ammonia (as N)
Cobalt
0.043
0.019
4.515
0.005
0.021
0.013
1.985
0.002
EPA is not promulgating BCT for this subcategory at this time,
3836
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - III
: SECTION III
i - -
INDUSTRY PROFILE
This section of the primary nickel and cobalt supplement
describes the raw materials and processes used in smelting and
refining primary nickel and cobalt and presents a profile of the
primary nickel and cobalt plants identified in this study.
and ^f^ can ^ produced from primary and secondary
, Producti°n °f these metals is regulated under three
subcategories: production of nickel from secondary
materials, production of cobalt from secondary materials? aSd
production of nickel and cobalt from primary materials. This
subcategory consists of one plant which manufactures primar?
SiSS cok>alt. Secondary nickel is regulated as a separatl
r*aul»?g*ry'^ 3S -1? sec0ndary cobalt (secondary cobalt il
regulated with secondary tungsten) .
The -principle
f?r^iarly,i
strength and
use for
thS ^r°
corrosion
; nickel is as an alloying aaent
and Steel Products. Nickel imparts
resistance over a wide ranqe of
Cobalt's value is also 'as an alloying elemen and
o™ tools,, jet engine parts, electrical devices
permanent magnets, catalysts, and pigments and dyes. Cobalt
res1stLrqUali^eS SU?h aS heat ^^tlnce, high s?«ngth; wJar
resistance, and magnetic properties.
DESCRIPTION OF PRIMARY NICKEL AND COBALT PRODUCTION '
The production of primary nickel and cobalt can be divided into
three principal processing steps: leaching, cobalt precipitation
and reduction and nickel reduction. The primary nickel and
cobalt production process is presented schematically in Figure
III-l (page 3840), and described below. ^J-gure
RAW MATERIALS
Domestic primary nickel and cobalt production begins
imported copper-nickel-cobalt ore concentrate or matte.
LEACHING '
with an
vPm
system.
grinding
called matte, is crushed and then ground in a
prior to being fed to a sulfuric acid leachina
Dust and particulate matter from the crushing and
area_are controlled by a baghouse. The dust and fines
ha^h^, c, Le° with water to facilitate .transporting them from the
baghouse. Slurrying results in a process wastewater stream,
co er6 leachi"g Process' the ground matte is reacted
copper as .Vsolid f rom^Se'nicSf aSd'cobalt^'whicS^e^in '"in
3837
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - III
solution. The solids, containing most of the copper, iron, and
some nickel and cobalt, are sent to the copper recovery circuit.
Prom this circuit, a recycle stream containing nickel and cobalt
is returned to the acid leaching process. The liquids produced
in ?he acid leaching process are sent to the nickel and cobalt
recovery system.
COBALT PRECIPITATION AND REDUCTION
persulfate. The nickel-containing solution is routed to nickel
reduction.
The solids from the cobalt precipitation step are routed to a
cobalt purification system. Among other impurities, the solids
contain a large nickel concentration. The solids are dissolved
and thSn treated by the "pentammine process" in which ammonia is
added to the solution to form cobalt pentammine and nickel
diammine. After oxidizing the cobalt with air, acid is added to
?he" solution which causes the nickel and un-°x^zedhec°^lt^
crystallize. These crystals are removed, and the cobaltic
pentammine solution is passed through an ion-exchange column to
?lmovTany remaining traces of nickel The nick jl^ recycled to
the nickel reduction process. The nickel-free cobalt solution is
convened to cobalt powder by reduction in a hydrogen autoclave
fuJnace? The liquid effluent from the cobalt reduction furnace
is ?oS?ed to the ammonium sulfate by-product recovery system.
NICKEL REDUCTION
The nickel solution contains few impurities at this stage.
Reduction of nickel in solution to nickel powder is effected in
an aStocLvl The liquid effluent from the ^t0?'aVLS? J^aS
larae concentration of ammonium sulfate and is sent to an
ammonium sS??ate by-product recovery process. . The nickel powder
produced in the reduction furnace is washed with water which is
discharged to wastewater treatment.
PROCESS WASTEWATER SOURCES
Although a variety of processes are involved in primary nickel
and cobalt production, the significant wastewater sources that
are associated with the primary nickel and cobalt aubcategory can
be subdivided as follows:
1. Raw material dust control,
2. Cobalt reduction decant,
3. Nickel reduction decant, and
4. Nickel wash water.
OTHER WASTEWATER SOURCES
There may be other wastewater streams associated with the primary
nickel and cobalt subcategory. These streams may include
3838
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - III
oolinadh- main^nance and cleanup water, and noncontact
cooling and heating water (such as steam condensates from heat
exchangers). These wastewaters are not considered as part of this
bieves that the flows and pollutant loldingl
AGE, PRODUCTION/ AND PROCESS PROFILE
lo
located
o -^ and cobalt plant in the United States is
Southern Louisiana in order to take advantage of
? f ?^?^.be?an operations in 1959, and came
'-- - Nickel production is
is
3839
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - III
To Atmosphere
t
H2°
Wet
Dust
Control
Cu-Ni-Co Ore
Concentrate
Raw
Material
Crushing
and
Grinding
Acid
Leaching
Nickel and Cobalt Recycled
From Copper Recovery System —^—'
Solids to Copper Recovery
Persulfate
Liquids to
Nickel and Cobalt
Recovery
Cobalt
Precipitation
Solids
Liquids
Cobalt
Purification
by
Pentanmine
Process
Mixed Salt Crystals
Reduction
in
Autoclave
©
Reduction
in
Autoclave
I
Nickel,
Powder
Washing
Nickel
Product
Cobalt
Product
To
Ammonium
Sulfate
Recovery
Process
Figure III-T
PRIMARY NICKEL AND COBALT MANUFACTURING PROCESS
3840
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - IV
SECTION IV
SUBCATEGORIZATION
This
section
° °
summarizes the factors considered durinq the
related subdivisions of the primary nlckll and
|§|§g||GggfIDERED ™ SUBDIVIDING THE PRIMARY NICKEL AND COBALT
were
nh fact°rs l^St6d ir^ Vol.. I for general subcategorization
each evaluated when considering subdivision of the
nickel and cobalt subcategory. in the discussion that
subcf?egor?.Wi11 ^ described as thev Pertain to this
*nrf Shi??alexf°f considering segmentation of the primary nickel
S™H ?b fc subcate9°ry ^ based primarily on differences in the
production processes and raw materials used. Within thiS
subcategory, a number of different operations are per?ormed
which may or may not have a water use or discharge? and which mav
require the establishment of separate effluent limitations^ Whi?e
primary nickel and cobalt is considered a single subcategory a
thorough examination of the production processes has illustrated
the need for limitations and standards based on a specific set of
waste streams. Limitations will be based on specific flow
allowances for the. following subdivisions: speciric tlow
1. Raw material dust control,
2. Cobalt reduction decant,
3. Nickel reduction decant, and
4. Nickel wash water.
These subdivisions follow directly from differences between the
processing steps of primary nickel and cobalt production
Leaching, cobalt precipitation and reduction, and nickel
reduction each have various; steps which may generate wastewaterS.
— fc®rial Crushin9 and grinding creates a need for the first
subdivision - raw material dust control. Although a dry baghoule
ifnS ?h ? cont£01 dust and Particulate matter generated by thl
mills that crush and grind the raw material, water is used to
slurry the solids collected by the baghouse to the tre^men?
Washing the nickel powder : produced in the hydrogen reduction
furnace creates a need for the fourth subdivision Nickel wash
water This water is used to remove traces of acid and
impurities from the nickel iproduct . Excess solution c?ntain?ng
nt?^f1Cant^C°^Centrati°ns °f ammoni^ sulfate decanted from tSe
nickel reduction autoclave creates a need for the third
3841
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - IV
subdivision - nickel reduction decant. Excess solut ion f rom the
cobalt reduction autoclave creates a need for the second
subdivision -cobalt reduction decant.
OTHER FACTORS
category.
PRODUCTION NORMALIZING PARAMETERS
AC. discussed previously, the effluent limitations and standards
nSrmau'ing parame?er (PNP). The PNPs for the four subdivision
are as follows:
Subdivision
1. Raw material dust control
2. Cobalt reduction decant
3. Nickel reduction decant
4. Nickel wash water
PNP
copper, nickel, and cobalt in
the crushed raw material
cobalt produced
nickel produced
nickel powder washed
true production than of installed capacity.
The PNP selected for raw material dust
copper, nickel, and cobalt in the crushed raw
£h?« nlant recovers copper as well as nickel and cobalt trom ^tne
crilhed raw ml?erialf the appropriate PNP to select .JJ^tnc
?ons of copper, nickel, and cobalt in the crushed raw material.
3842
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - V
' SECTION V
WATER USE AND ;WASTEWATER CHARACTERISTICS
This -section describes the characteristics of the wast
"sociated.with the primary nickel and cobalt subcatego"? a
tJ^/ Vd*SCha59Vates are explained and then summarized in
tables at the end of this ;section. Data used to characterize the
wastewaters are presented., Finally, the specific source water
use and discharge flows, and wastewater characteristics for each
separate wastewater source are discussed. ^eristics tor each
tW? n?r^ci]Pal dafca sources used in the development of
= L°rde£ ?? 3ufntify the pollutant discharge from primary nickel
and cobalt plants, a field sampling program was conducted A
complete list of the pollutants considered and a suZary ol* the
in Sec??on To? Vo^T^S? a?d laboratory analyses are included
in section V of Vol. I. Samples were analyzed for 124 of t-he. 1 9C
priority pollutants and other pollutants deeded
to
t
data for this subcategory were obtained
*nH r*™™,,! 4.' - e£5°rts or industrY comments between proposal
and promulgation. Characterization of primary nickel and cobalt
subcategory wastewaters (Section V), and selection of
parameters for limitation /Qaff-i <~>r« TTT \ i~ i_ j 7,
•ii ' - j-»iij. i-av- j-vjti VPCUI.J.IJH vii is Dased unon t-ho
data used at proposal. upuu cne
sme
- . — — -— ^^ * * 1^^ Q J7 Q \^ Q Q g
, ,. . ; -—if . wastewater streams correspondina to
follow Th1S1°n a^ addressed separately in the discLsions that
tollow. These wastewater sources are:
1. Raw material dust control,
2. Cobalt reduction decant.
3843
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - V
3. Nickel reduction decant , and
4. Nickel wash water.
WASTEWATER FLOW RATES
.
limitations and standards.
WASTEWATER CHARACTERISTICS DATA I
trips.
DATA COLLECTION PORTFOLIOS
3844
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - V
FIELD SAMPLING DATA
In order to quantify the concentrations of pollutants present in
wastewater from primary;nickel and cobalt plants, wastewater
samples were collected at the one plant. A diagram indicating
the sampling sites and contributing production processes is shown
in Figure V-l (page 3872).
The sampling data for the primary nickel and cobalt subcategory
are presented in Tables V-5 and V-6 (pages 3852 and 3862). The
stream codes displayed in Tables V-5 and V-6 may be used to
identify the location of each of the samples on the process flow
diagram in Figure V-l. Where no data are listed for a specific
day of sampling, the wastewater samples for the stream were not
collected.
Several points regarding these tables should be noted. First,
the data tables include some samples measured at concentrations
considered not quantifiable. The base-neutral extractable, acid
extractable, and volatile organics generally are considered not
quantifiable at concentrations equal to or less than 0.010 mg/1.
Below this concentration, organic analytical results are not
quantitatively accurate; however, the analyses are useful to
indicate the presence of a particular pollutant. The pesticide
.fraction is considered not quantifiable at concentrations equal
to or less than 0.005 mg/1. Nonquantifiable results are
designated in the tables with an asterisk (double asterisk for
pesticides). .
Second, the detection limits shown on the data tables for metals
and conventional and noncpnventional pollutants are not the same
in all cases as the published detection limits for these
pollutants by the same analytical methods. The detection limits
used were reported with the analytical data and hence are the
appropriate limits to apply to the data. Detection limit
variation can occur as a result of a number of laboratory-
specific, equipment-specific, and daily operator-specific
factors. These factors can include day-to-day differences in
machine calibration, variation in stock solutions, and variation
in operators.
Third, the statistical analysis of data includes some samples
measured at.concentrations considered not quantifiable. For data
considered as detected but: below quantifiable concentrations, a
value of zero is used, for averaging. Priority organic,
nonconventional, and conventional pollutant data reported with a
"less_ than" sign are considered as detected, but not further
quantifiable. A value of zero is also used for averaging. If a
pollutant is reported as not detected, it is assigned a value of
zero in calculating the average. Finally, priority metal values
reported as less than a certain value were considered as not
quantifiable, and consequently were assigned a value of zero in
the calculation of the average.
Finally, appropriate source water concentrations are presented
3845
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - V
with the summaries of the sampling data. The method by which
each sample was collected is indicated by number, as follows:
1 one-time grab
2 manual composite during intermittent process operation
3 8-hour manual composite
4 8-hour automatic composite
5 24-hour manual composite
6 24-hour automatic composite
WASTEWATER CHARACTERISTICS AND FLOWS BY SUBDIVISION
Since primary nickel and cobalt production involves four
principal sources of wastewater and each has potentially
different characteristics and flows, the wastewater
characteristics and discharge rates corresponding to each
subdivision will be described separately. A brief description of
why the associated production processes generate a wastewater and
explanations for variations of water use within each subdivision
will also be discussed.
RAW MATERIAL DUST CONTROL
Primary nickel and cobalt raw material, called matte, is crushed
and ground prior to undergoing copper separation via a leaching
process. Dust and particulates generated by the crushing and
grinding operations may be controlled by a baghouse. Water is
used to slurry the collected material in the baghouse and
transport it to treatment. One plant reported generating this
waste stream, as shown in Table V-l (page 3848). This table
shows water use and discharge rates for this waste stream.
Sampling data were collected on a combined process waste stream
which included raw material dust control water. The sampling
data are presented in Table V-5 (page 3852). The data presented
show copper, nickel, and ammonia above treatable concentrations.
COBALT REDUCTION DECANT
When cobalt is reduced in a hydrogen autoclave from a cobalt-rich
solution, excess solution, containing significant quantities of
ammonium sulfate, is decanted. Although the one plant currently
generating this waste stream does not discharge it by means of a
by-product recovery operation, it may be discharged at some time
in the future. The need to discharge this waste stream may
result from poor marketability of the by-product or excessive
cost of operating the recovery plant. Water use and discharge
rates for cobalt reduction decant are shown in Table V-2 (page
3849).
No samples were taken of this waste stream; however, +it is
expected to have high concentrations of ammonia (as NH4 ) and
sulfate (as SO4=), along with treatable concentrations of
priority metals, cobalt, and suspended solids. .
3846
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - V
NICKEL REDUCTION DECANT
When nickel is reduced in a hydrogen autoclave from a nickel-rich
solution, the excess solution/ containing significant quantities
of ammonium sulfate, is decanted. Although the one plan?
currently generating this waste stream does not discharge it bv
means of a by-product recovery operation, it may be discharged at
some time in the future. The need to discharge this waste stream
may result from poor marketability of the by-product or excessive
cost of operating the recovery plant. Water use and discharge
races tor this waste stream are shown in Table V-3 (page 3850).
No samples were taken of this waste stream; however, it is
expected to have high concentrations of ammonia (as NH4+) and
sulfate- (as sop, along with treatable concentrations of
priority metals (principally nickel) and suspended solids.
NICKEL WASH WATER ;
After reducing primary nickel raw material to a powder in a
hydrogen autoclave, the nickel may be washed with water. This
*nS SI£ia Saf? Stre*m' •: One Plant reported this waste stream,
?ates Pa9e Y P^sents its water use and discharge
Sampling data were collected on a combined process waste stream
which included nickel wash water. The sampling data are
'5?3!S? ' ^ * V~5 (page 3852>- The data Ihow coppJr?
nickel, and ammonia above treatable concentrations; several
priority organics were detected.
3847
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - V
TABLE V-l
WATER USE AND DISCHAGRE RATES FOR
RAW MATERIAL DUST CONTROL
(1/kkg of copper, nickel and cobalt
in the crushed raw materials)
Plant Percent Recycle
Code or reuse
1062 0
Production Production
Normalized Normalized1
Water Use Flow Discharge Flow
77
77
3848
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - V
TABLE V-2
WATER USE AND DISCHAGRE RATES FOR
COBALT REDUCTION DECANT
(1/kkg of cobalt produced)
Plant
Code
1062
Percent Recycle
or reuse
100
Production
Normalized
Water Use Flow
21398
Production
Normalized
Discharge Flow
0
3849
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - V
TABLE V-3
WATER USE AND DISCHAGRE RATES FOR
NICKEL REDUCTION DECANT
(1/kkg of nickel produced)
Plant Percent Recycle
Code or reuse
1062 100
Production
Normalized
Water Use Flow
12695
Production
Normalized
Discharge Flow
0
3850
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - V
TABLE V-4
WATER USE AND DISCHAGRE RATES FOR
-. ' . NICKEL WASH WATER
(1/kkg of nickel powder washed)
Plant Percent Recycle
Code or reuse
1062 0
Production
Normalized
Production
Normalized
'Water ..Use'Flow . Discharge Flow
33.87 33.87
3851
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
cnl
SECT - V
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PRIMARY NICKEL AND COBALT SUBCATEGORY
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3853
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
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3854
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
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3855
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - V
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PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - V
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PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - V
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PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - V
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3869
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PRIMARY NICKEL AND COBALT SUBCATEGORY
SECT - V
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CN
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C C (=
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3872
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VI
SECTION VI
SELECTION OF POLLUTANTS
v = n/e? n exam?;nes chemical analysis data presented in Section
L? ™?™?"8Se? — f S(Flection or exclusion of priority pollutants
pollu?anKlair m ?fcl?n;; A1S°' conventional and nonconventional
pollutants are selected or excluded for limitation in this
section The basis fo* the regulation of - toxic and other
for no?^- f?ng.^h a discussion of each pollutant selected
for^ potential limitation, is discussed in Section VI of Vol. I
That discussion provides information .about the nature of the
pollutant (i.e., whether it is a naturally occurring substance
processed metal, or a manufactured compound); general physical
K??6^163 ^ thS f°rm °f the PQll^ant; toxiceffects of the
pollutant in humans and other animals; and behavior of the
discharges ^ POTW ^ "^ concentrations expected in indSstria?
The discussion that follows describes the analysis that was
performed to. select or exclude priority pollutants for further
consideration for limitations and standards. The data from
wastewater samples are considered in this analysis. A combined
TnrS^h Sample WaS taken °f the infl^nt to treatment, wJich
iSS «?S currently discharged process wastewater streams?
?Sr fn^hS°n"SC0^ stf?ams: Priority pollutants will be selected
t«atfbH £v°?28X?eratl?n:lf they are Present ^ concentrations
treatable by the technologies considered in this analysis. in
Sections IX through XII, a final selection of the pollutants tS
be limited will be made, based on relative factors.
CONVENTIONAL AND NONCONVENTIONAL POLLUTANT PARAMETERS SELECTED
This study examined samples one primary nickel and cobalt plant
for two conventional pollutant parameters (TSS and PH) and two
nonconventional pollutant parameters (ammonia and cobalt)?
The conventional and nonconventional pollutants or pollutant
parameters selected for limitation in this subcatego?y a?e7
ammonia
cobalt
total suspended solids (TSS)
pH
mn extensively throughout the primary nickel and
n?ckel Jnd onh1?? pr?cess- Two of the wastewater streams,
™ % f" cobalt reduction decants, contain very hiqh
concentrations of ammonia. ; Ammonia is selected for limitation in
^ fh.Sn ? ?g°rX be^ause of its Presence in high concentra??on2
in the nickel and cobalt reduction decant streams.
Cobalt was observed in the one raw wastewater sample in this
3873
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VI
subcateqory at a concentration of 4.6 mg/1. This concentration
fs above the concentration considered achievable by treatment
technology (0.034 mg/1), and cobalt is expected to be present in
the raw wastewater as a result of raw materials used. For these
reasons, cobalt is selected for regulation.
Although total suspended solids (TSS) was not analyzed for in
this subcategory, it is selected for regulation. This is because
TSS il expected to be present in the raw wastewater samples above
treatJb?? concentration (2.6 mg/1), and most of the specific
methods used to remove toxic metals do so by converting these
metals to precipitates, and these toxic-metal7containing
precipitates should not be discharged. Meeting a limitation on
total suspended solids helps ensure that removal of these
precipitated toxic metals has been effective.
The pH value observed was 7.6. Although this pH value is within
thl 775 to 10.0 range considered desirable, effective removal of
toxic metals by precipitation requires careful control of pH.
Also, the combined waste stream may not accurately reflect the pH
values of the raw waste streams which may. be outside the
desirable range. For these reasons, pH is selected for
limitation in this subcategory.
TOXIC PRIORITY POLLUTANTS
The frequency of occurrence of the priority pollutants in the
wastewatSr samples considered in this analysis is presented in
SblS V?-l (pSge 3877). These data provide the basis for the
categorization of specific pollutants, as discussed below. Table
VI-1 is based on the raw wastewater sampling data from stream
367. Stream 364 was sampled after treatment and was not used in
the frequency count.
TOXIC POLLUTANTS NEVER DETECTED ;
The priority pollutants listed in Table VI-2 (page 3881) were not
detected in any wastewater samples from this subcategory
Therefore, they are not selected for consideration in
establishing effluent limitations and standards.
TOXIC POLLUTANTS NEVER FOUND ABOVE THEIR ANALYTICAL
QUANTIFICATION CONCENTRATION
The priority pollutants listed below were never found above their
analytical quantification concentration in any wastewater samples
??om this subcategory; therefore, they,are not selected for
consideration in establishing effluent limitations and standards.
4. benzene
86. toluene
114. antimony
115. arsenic
117. beryllium
119. chromium
3874
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VI
122.
126.
127.
lead
silver
thallium
PRE5ENT BELOW CONCENTRATIONS ACHIEVABLE BY
selected for consideration in
, and standards because they were not
wastewater samples from this subcategory above
0ldered ac*ievable bY existing or9 available^
lis^ P°llut*nts
66. bis (2-ethylhexyl) phthalate ...
118. cadmium
123. mercury !
125. selenium
Bis (27ethylhexyl)
phthalate
S
was detected at its
analytical
and
is not used or formed as
by-product
y phthalate
Cadmium was detected above its analytical quantification limit in
S/l °neTh?^P fnalyzed- The observed concentration was 0.007
mg/1 This value is below the concentration achievable bv
nm?tat?on. (°'°49 ^^ ' T'herefore' c**^™ ^ not seized fo?
Mercury was detected above Its analytical quantification limit in
mS/1 °ne^ample fnalyzed The observed concentration wasTSoSS
mg/1. This value is belbw the concentration achievable bv
Therefore' ^c^ ** not seized for
Selenium
was detected above its analytical quantification limit
mPle analyzed. The observed concentration was 0 18
^alUG 1S less than the treatable concentration (0 20
Therefore, selenium is not selected for limitation?
TOXIC POLLUTANTS SELECTED FOR FURTHER CONSIDERATION IN
ESTABLISHING LIMITATIONS ANp~STANDARDS - ~ . ~
m
The priority
consideration
pollutants listed below are selected for further
in establishing limitations and standards for this
Poll^ants selected are each discuss^
120.
124.
copper
nickel
3875
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VI
122. zinc
Copper was detected above its treatable concentration (0.39 mg/1)
in the one sample analyzed. The observed concentration was 1.43
mq/1. Since copper was present in a concentration exceeding the
concentration achievable by identified treatment technology, it
is selected for consideration for limitation.
Nickel was detected above its treatable concentration (0.22 mg/1)
in the one sample analyzed. The observed concentration was 40.0
mg/1. Since nickel was present in a concentration exceeding the
concentration achievable by identified treatment technology, it
is selected for consideration for limitation.
Zinc was detected above its treatable concentration (0.23 «fg/l)
in the one sample analyzed. The observed concentration was 0.377
mq/1. Since zinc was present in a concentration exceeding the
concentration achievable by identified treatment technology, it
is selected for consideration for limitation.
3876
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VI
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3877
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VI
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3878
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
i i
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SECT - VI
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3879
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VI
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01
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VI
1.
2.
3.
5.
6.
7.
8.
9.
10.,
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.
47.
48.
49.
TABLE VI-2
TOXIC POLLUTANTS NEVER DETECTED
acenaphthene
acrolein
acrylonitrile
benzidine
carbon tetrachloride (tetrachloromethane)
chlorobenzene
1,2,4-trichlorobenzeiie
hexachlorobenzene
1,2-dichloroethane
1,1,1-trichloroethane
hexachloroethane
1r1-dichloroethane
1,1,2-trichloroethane
1.1,2,2-tetrachloroethane
chloroethane
bis (chloromethyl) ether (deleted)
bis (2-chloroethyl) ether
2-chloroethyl vinyl ether (mixed)
2-chloronaphthalene
4,6-trichlorophenol
parachlorometa cresol
chloroform (trichloromethane)
2-chlorophenol
1,2-dichlorobenzene
1,3-dichlorobenzene
1,4-dichlorobenzene
3,3'-dichlorobenzidine
1r1-dichloroethylene
1,2-trans-dichloroethylene
2,4-dichlorophenol
1,2-dichloropropane
1,2-dichloropropylene (1,3-dichloropropene)
2,4-dimethylphenol
2,4-dinitrotoluene
2,6-dinitrotoluene
1/2-diphenylhydrazine
ethylbenzene ,
fluoranthene
4-chlorophenyl phenyl; ether
4-bromophenyl phenyl ether
bis(2-chloroisopropyl) ether
bis(2-choroethoxy) methane
methylene chloride (dichloromethane)
methyl chloride (chloromethane)
methyl bromide (bromomethane)
bromoform (tribromomethane)
dichlorobromomethane :
trichlorofluoromethane (deleted)
3881
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VI
TABLE VI-2 (Continued)
TOXIC POLLUTANTS NEVER DETECTED
50. dichlorodifluoromethane (deleted)
51. chlorodibromomethane
52. hexachlorobutadiene
53. hexachlorocyclopentadiene
54. isophorone
55. naphthalene
56. nitrobenzene
57. 2-nitrophenol
58. 4-nitrophenol
59. 2,6-dinitrophenol
60. 4,6-dinitro-o-cresol
61. N-nitrosodimethylamine
62. N-nitrosodiphenylamine
63. N.nitrosodi-n-propylamine
64. pentachlorophenol
65. phenol
67. butyl benzyl phthalate
68. di-n-butyl phthalate
69. di-n-octyl phthalate
70. diethyl phthalate
71. dimethyl phthalate
72. benzo (a)anthracene (1,2-benzanthracene)
73. benzo (a)pyrene (3,4-benzopyrene)
74. 3,4-benzofluoranthene
75. benzo(k)fluoranthane (11,12-benzofluoranthene)
76. chrysene
77. acenaphthylene
78. anthracene
79. benzo(ghi)perylene (lf11-benzoperylene)
80. fluorene
81. phenanthrene
82. dibenzo (a,h)anthracene (1,2,5,6-dibenzanthracene)
83. indeno (1,2,3-cd)pyrene (w,e,-o-phenylenepyrene)
84. pyrene
85. tetrachloroethylene
87. trichloroethylene
88. vinyl chloride (chloroethylene)
89. aldrin
90. dieldrin .
91. chlordane (technical mixture and metabolites)
92. 4,4'-DDT
93. 4,4 -DDE(p,p'DDX)
94. 4,4'-DDD(p.p'TDE)
9 5. Alpha-endosulfan
96. Beta-endosulfan
97. endosulfan sulfate
98. endrin
99. endrin aldehyde
3882
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VI
TABLE VI-2 (Continued)
TOXIC POLLUTANTS NEVER DETECTED
100. heptachlor ;. .
101. heptachlor epoxide
102. Alpha-BHC
103. Beta-BHC
104. Gamma-BHC (lindane)
105. Delta-BHC • :
106. PCB-1242 (Arochlor 1242)
107. PCB-1254 (Arochlor 1254)
108. PCB-1221 (Arochlor 1221)
109. PCB-1232 (Arochlor 1232)
110. PCB-1248 (Arochlor 1248)
111. PCB-1260 (Arochlor 1260)
112. PCB-1016 (Arochlor 1016)
113. toxaphene
116. asbestos (Fibrous)
121. cyanide*
129. 2,3,7,8-tetra chlorodibenzo-p-dioxin (TCDD)
*We did not analyze for this pollutant in samples of raw
wastewater from this subcategory. This pollutant is not
believed to be present based on the Agency's best engineering
judgment which includes consideration of raw material and
process operations.
3883
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VI
THIS PAGE INTENTIONALLY LEFT BLANK
3884
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VII
: SECTION VII
CONTROL AND, TREATMENT TECHNOLOGIES
eceding sections of this supplement discussed the sources
*nH ™and,-characteristics of the wastewaters from primary nir'--'
and cobalt plants. This section summarizes the description
these wastewaters and indicates the treatment technologies
are currently practiced in the primary nickel and
CURRENT CONTROL AND TREATMENT PRACTICES
«»
<-«^« section presents a summary of the control and treatment
technologies that are currently applied to each of the sources
aeneratmo wastewater in this subcategory. As discussed in
wastewater associated with the primary nickel and
Arrorw ls characterized by the presence of the toxic
and suspended solids. This analysis is
™«h- 'A I r?W (untreated) wastewater data presented for a
combined waste stream in Section V. Generally, these pollutants
are present in each of the waste streams at treatablS
?™f™~ratl0£S' ?nd these waste streams are commonly combined for
o™^ 2 \ Construction of one wastewater treatment system for
comh^H ^r-o^n,^ allows plants to take advantage of economies
ne instances, to combine streams of differinq
to reduce treatment chemical requirements,- The one
treatment ^L^0*^01? currently has a combined wastewater
treatment system, consisting of chemical precipitation
sedimentation, and filtration. Two options have been selected
;MLa?°nSlderawion.for BPT' BAT' N£3PS' and Pretreatment in this
was?e Itreams. 9° C°mbined treatment of these compatible
RAW MATERIAL DUST CONTROL
Copper _matte is crushed and ground as a preliminary step in the
processing of primary nickel and cobalt. Dust and particulateJ
generated by the crushing and grinding operations are? coitrollel
with a dry baghouse, and then slurried with water for
transportation to treatment. One plant treats this waste stream
COBALT REDUCTION DECANT : "
The excess solution from the cobalt reduction autoclave furnace
is discharged, along with the nickel reduction decant, to I by--
product recovery system. rn by-product recovery, the ammonium
3885
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT -VII
sulfate values are recovered in a fertilizer product
no wastewater treatment for this stream.
NICKEL REDUCTION DECANT
There is
stream.
NICKEL WASH WATER
reducing nickel to powder in a hydrogen furnace, the powder
-washed-Cw??hnwSter. The wastewater produced here is combined
with other wastes and treated using lime, settle, and =1J-«r
Schnolog? described for the previous waste stream. Nickel wash
water is discharged directly after treatment.
CONTROL AND TREATMENT OPTIONS
The Agency examined two control ^treatment technology options
SS£.t4Sy. aP?neCaop?ionS ..ESfTSTSv.^'!^ represent a
suDcacegory. __ __.,,*._ treatment technologies applicable to
mi* and end-of-pipe treatment technologies.
these technologies is presented in Section
"X'lUS C-L.JL.^W*--i-v^-**"—' >—•— — — *-»••*- P— ^
VII of the General Development Document.
OPTION A
nnHon A for the primary nickel and cobalt subcategory requires
control and treatment technologies to reduce the discharge of
wastewater pollutant mass.
The Ootion A treatment scheme consists of ammonia steam stripping
ifused to'precipitate metal ions as metal hydroxides. The metal
hydroxides and suspended solids settle out and the sludge is
collected. Vacuum filtration is used to dewater sludge.
OPTION C
nnt-ion C for the primary nickel and cobalt subcategory consists
of Si control and treatment requirements of Option A (ammonia
suspended Solids, including, precipitates of metals, beyond the
concentration attainable by gravity sedimentation. The i-ilter
SSSqSsted is of the gravity, mixed-media type, although other
forms of filters, such as rapid sand filters or pressure filters
woul? perform satisfactorily. The addition of; filters also
3886
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VII
provides consistent removal during periods of time in which there
s3 t P» r 3 n i /"i TT^*-t*-*-\—»-<-**-^*-«4»...cn _-i -»• _ *-^. *. *—
or pollutants to the
3887
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VII
THIS PAGE INTENTIONALLY BLANK
3888
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VIII
SECTION VIII
COSTS, ENERGY AND NONWATER QUALITY ASPECTS
This section presents a summary of compliance costs for the
primary nickel and cobalt subcategory and a description of the
treatment options and subcategory-specific assumptions used to
develop these estimates. Together with the estimated pollutant
reduction performance presented in Sections IX, X, XI, and XII of
this supplement, these cost estimates provide a basis for
evaluating each regulatory option. These cost estimates are also
used in determining .the probable economic impact of regulation on
the subcategory at different pollutant, discharge levels. in
addition, this section addresses nonwater quality environmental
impacts of wastewater treatment and control alternatives
including air pollution, solid wastes, and energy requirements'
which are specific to the primary nickel and cobalt subcategory/
TREATMENT OPTIONS FOR EXISTING SOURCES
As discussed in Section VII, two treatment options have been
developed for existing primary nickel and cobalt sources. The
treatment schemes for each option are summarized below and
schematically presented in Figures X-l and X-2 (pages 3916 and
J .7 -L / J •
OPTION A
Option A consists of ammonia steam stripping preliminary
treatment, where required and chemical precipitation and
sedimentation end-of-pipe technology.
OPTION C
Option C consists of all control and treatment technology for
Option A (ammonia steam stripping preliminary treatment, chemical
precipitation and sedimentation) plus multimedia filtration
technology added at the end of the Option A treatment scheme
COST METHODOLOGY
A detailed discussion of the methodology used to develop the
compliance costs is presented in Section VIII of the General
Development Document. Plant-by-plant compliance costs for the
nonferrous metals manufacturing category have been revised as
necessary following proposal. These revisions calculate
incremental costs, above treatment already in place, necessary to
comply with the promulgated effluent limitations and standards
and are presented in the administrative record supporting this
regulation. A comparison of the costs developed for proposal and
rV
C™tS for the final regulation are presented in Table
-1 (page 3893) for the direct discharger.
3889
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VIII
Each of the general assumptions used to develop compliance costs
is presented in Section VIII of the General Development Document.
E^ch lubcategory contains a unique set of waste ^reama requiring
certain subcategory-specific assumptions to develop compliance
costS The major assumptions relevant to cost estimates for the
primary nickel and cobalt subcategory are discussed briefly
below.
(1)
(2)
(3)
Caustic is used instead of lime in chemical precipita-
tion for this plant, because the one direct discharger
in the subcategory currently uses caustic.
Raw material dust control wastewateris assumed to
have a pH = 5 because of sulfides present, and a
concentration of TSS = 12 mg/1. Nickel wash water is
also assumed to have pH = 5 and a concentration of
TSS = 12 mg/1.
Sampling data indicate that the raw material dust con-
trol and nickel wash waste streams contain treatable
concentrations of ammonia. However, examination of
the processes involved and correspondence with plant
personnel indicate that the reported ammonia level is
not due to the presence of ammonia in the process
streams. Rather, ammonia enters the treatment _ system
influent (sample number 367) through spills in the
process areas. Consequently, these two process
streams do not require ammonia steam stripping.
Revised direct discharge compliance cost estimates for this
subcateaory reflect a correction in the treatment-in-place credit
ionS madl at proposal. Plant 1062 presently operates
plecTpitation, sedimentation, and filtration, and treats
a combined PWastewater consisting of nonferrous metals
manufacturing wastewater and plant stormwater.
-it
, an
the cost to the direct discharger for compliance with the
proposed and promulgated rulemaking EPA ^J^f* fc£nk '***
existing filter can continue to be used if a holding .tank is
installed after lime and settle treatment of raw material dust
slurry water and nickel wash water. The costs for this holding
tank are included in EPA's compliance cost estimate. The revised
compliance cost estimates prepared for promulgation are presented
in Table VIII-1.
NONWATER QUALITY ASPECTS
Nonwater quality impacts specific to the_ primary
cobalt subcategory, including energy requirements,
and air pollution, are discussed below.
nickel and
solid waste
3890
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VIII
ENERGY REQUIREMENTS
The methodology used for determining the energy requirements for
the various options is discussed in Section VIII of the General
Development Document. Energy requirements for the two options
considered are estimated at 20,600 kwh/yr and 28,570 kwh/yr for
Options A and C, respectively. Option C, which includes
nitration, increases energy consumption over Option A bv
approximately 39 percent;. Option C represents less than 1
percent of a typical plant's electrical energy usage. It is
therefore concluded that the energy requirements of the treatment
options considered will have no significant impact on total plant
energy consumption. . yj-emi.
SOLID WASTE ;
Sludge generated in the primary nickel and cobalt subcategory is
due to the precipitation of metal hydroxides and carbonates usinq
lime or various other chemicals. Sludges associated with the
primary nickel and cobalt subcategory will necessarily contain
quantities of toxic metal pollutants. These sludges are not
subject to regulation as hazardous wastes since wastes generated
by primary smelters and refiners are currently exempt from
aJ?/o£o?? YoAC^-°f Congress (Resource Conservation and Recovery
Act (RCRA), Section 3001(b)), as interpreted by EPA. If a small
excess of lime is added during treatment, the Agency does not
believe these sludges would be identified as hazardous under RCRA
in any case. (Compliance costs include this amount of lime )
T2™ judgment is based on the results of Extraction Procedure
(EP) toxicity tests performed on similar sludges (toxic metal-
bearing sludges) generated by other categories such as the iron
and steel industry. A small amount of excess lime was added
during treatment, and the sludges subsequently generated passed
Se4. !ioxicity test- See CFR 8261.24. Thus, the Agency believes
that the wastewater sludges will similarly not be EP toxic if the
recommended technology is applied.
Although it is the Agency's; view that solid wastes generated as a
result of these guidelines are not expected to be hazardous,
generators of these wastes must test the waste to determine if
the wastes meet any of the characteristics of hazardous waste.
If these wastes should be identified or are listed as hazardous,
they will come within the scope of RCRA's "cradle to grave"
hazardous waste management program, requiring regulation, from
the point of generation to point of final disposition. EPA's
gener-ator standards would require generators of hazardous
nonferrous metals manufacturing wastes to meet containerization
labeling, recordkeeping, and reporting requirements; if plants
dispose .of hazardous wastes off-site, they would have to prepare
a manifest which would track the movement of the wastes from the
generator's premises to a permitted off-site treatment, storage,
?oon?1SP° facility. See 40 CFR 262.20, 45 FR 33142 (May 19,
1980), as amended at 45 FR 86973 (December 31, 1980) The
3891
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VIII
transporter regulations require transporters of hazardous wastes
to comply wiS the manifest system to assure that the wastes are
delivered to a permitted facility. See 40 CFR 263.20, 45 PR
. < °as??o^ 4esSb?^3
^January 12, 1981), and 47 FR 32274 (July 26, 1982).
Even if these wastes are not identified as hazardous, they still
mult be disposed of in compliance with the Subtitle D open
dumping standards, implementing 4004 of RCRA See 44 PR 53438
fqentember 13, 1979). The Agency has calculated as part of the
coSts ?or wast4water treatment the cost of hauling and disposing
of these wastes.
Sludge generation for the primary nickel and c°balt subcategory
is estimated at 10.41 metric tons per year when implementing the
promulgater ST technology. Sludge generation for promulgated
BAT is not expected to be significantly different.
AIR POLLUTION
There is no reason to believe that any substantial air pollution
nroblems will result from implementation of ammonia steam
lt?ipp?ng, chemical precipitation, sedimentation, and multimedia
filiation. Ammonia steam stripping yields an aqueous ammonia
stream The other technologies transfer Pollutants to solid
waste and are not likely to transfer pollutants to air.
3892
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VIII
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3893
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PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - VIII
THIS PAGE INTENTIONALLY LEFT BLANK
3894
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - IX
; SECTION IX
BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY AVAILABLE
This section defines the effluent characteristics attainable
through the application pf best practicable control technology
currently available (BPT). BPT reflects the existing performance
bY. , Plants of various -sizes, ages, and manufacturing processes
witnin^the primary nickel and cobalt subcategory, as well as the
established performance of the recommended BPT systems
Particular consideration is given to the treatment already in
place at plants within the-data base.
The factors considered in identifying BPT include the total cost
of applying the technology; in relation to the effluent reduction
benefits from such application, the age of equipment and
facilities involved, the manufacturing processes used, nonwater
quality environmental impacts (including energy requirements)
and other factors the Administrator considers appropriate in
general, the BPT level represents the average of the existing
performances of plants of various ages, sizes, processes, or
other common characteristics. Where existing performance is
uniformly inadequate, BPT may be transferred from a different
.subcategory or category.; Limitations based on transfer of
technology are supported by a rationale concluding that the
technology is, indeed/transferable, and a reasonable prediction
that it will be capable of achieving the prescribed effluent
limits BPT focuses on end-of-pipe treatment rather than process
changes or internal controls, except where such practices are
common industry practice.
TECHNICAL APPROACH TO BPT
The Agency studied the nonferrous metals category to identify the
processes used, the wastewaters generated, and the treatment
processes installed. Information was collected from the category
using data collection portfolios, and specific plants were
sampled and the wastewaters analyzed. In making technical
assessments of data, reviewing manufacturing processes, and
assessing wastewater treatment technology options, both indirect
and direct dischargers have been considered as a single group
An examination of plants and processes did not indicate any
process differences based on the type of discharge, whether it be
direct or indirect. As explained in Section IV, the primary
nickel and cobalt subcategory has been subdivided into four
potential wastewater sources. Since the water use, discharge
rates, and pollutant characteristics of each of these
wastewaters is potentially unique, effluent limitations will be
developed for each of the four subdivisions.
For each of the subdivisions, a specific approach was followed
for the development of ; BPT mass limitations. The first
requirement to calculate these limitations is to account for
3895
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - IX
production and flow variability from plant to plant. Therefore,
a unit of production or production normalizing parameter (PNP)
was determined for each waste stream which could then be related
to the flow from the process to determine a production normalized
flow. Selection of the PNP for each process element is discussed
in Section IV. Each process within the subcategory was then
analyzed to determine which subdivisions were present, the
specific flow rates generated for each subdivision, and the
specific production normalized flows for each subdivision. This
analysis is discussed in detail in Section V. Nonprocess
wastewaters such as rainfall runoff and noncontact cooling water
are not considered in the analysis.
Production normalized flows for each subdivision were then
analyzed to determine the flow to be used as part of the oasis
for BPT mass limitations. The selected flow (sometimes referred
to as a BPT regulatory flow or BPT discharge flow) reflects the
water use controls which are common practices within the
cateqory. The BPT regulatory flow is based on the average of all
applicable data. Plants with normalized flows above the average
may have to implement some method of flow reduction to achieve
the BPT limitations.
The second requirement to calculate mass limitations is the set
of concentrations that are achievable by application of the BPT
level of treatment technology. Section VII discusses the various
control and treatment technologies which are currently in place
for each wastewater source. In most cases, the current control
and treatment technologies consist of chemical precipitation, and
sedimentation (lime and settle technology) and a combination of
reuse and recycle to reduce flow. Ammonia steam stripping is
applied to streams with treatable concentrations of ammonia.
Using these regulatory flows and the achievable concentrations,
the next step is to calculate mass loadings for each wastewater
source or subdivision. This calculation was made on a stream-by
stream basis, primarily because plants in this subcategory may
perform one or more of the operations in various combinations.
The mass loadings (milligrams of pollutant per kilogram of
production - mg/kg) are based on multiplying the BPT regulatory
flow (1/kkg) by the concentration achievable by the BPT level of
treatment technology (mg/1) for each pollutant Parameter to be
limited under BPT. These mass loadings are published in the
Federal Register and in CFR Part 421 as the effluent limitations.
The mass loadings which are allowed under BPT for each plant will
be the sum of the individual mass loadings for the various
wastewater sources which are found at particular plants.
Accordingly, all the wastewater generated within a plant may be
combined for treatment in a single or common treatment system,
but the effluent limitations for these combined wastewaters are
based on the various wastewater sources which actually contribute
to the combined flow. This method accounts for the variety ._ of
combinations of wastewater sources and production processes which
may be found at primary nickel and cobalt plants-.
3896
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - IX
The Agency usually establishes wastewater limitations in terms of
mass rather than concentration. This approach prevents the use
of dilution as a treatment method (except for controlling pH).
The production normalized wastewater flow (1/kkg) is a link
between the production operations and the effluent limitations.
The pollutant discharge attributable to each operation can be
calculated from the normalized flow and effluent concentration
achievable by the treatment technology and summed to derive an
appropriate limitation for each plant.
INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES
In balancing costs in relation to pollutant removal estimates.
EPA considers the volume and nature of existing discharges, the
volume and nature of discharges expected after application of
BPT, the general environmental effects of the pollutants, and the
cost and economic impacts of the required pollution control
level. The Act does not require or permit consideration of water
quality problems attributable to particular point sources or
industries, or water quality improvements in particular water
quality bodies. Accordingly, water quality considerations were
not the basis for selecting the proposed or promulgated BPT.
The methodology for calculating pollutant removal estimates and
plant compliance costs is discussed in Section X. Table X-l
(page 3911) shows the pollutant removal estimates for each
treatment option. Compliance costs are presented in Table X-2
(page 3912).
BPT OPTION SELECTION
The technology basis for the proposed and promulgated BPT
limitations is Option A, chemical precipitation and sedimentation
technology to remove metals and solids from combined wastewaters
and to control pH, and ammonia steam stripping to remove ammonia.
Chemical precipitation and sedimentation technology is already
in-place in the subcategory. The pollutants specifically
promulgated for regulation at BPT are copper, nickel, cobalt,
ammonia, TSS, and pH.
Ammonia steam stripping is demonstrated at six facilities in the
nonferrous metals manufacturing category. These facilities are
treating ammonia-bearing wastewaters associated with the
production of primary tungsten, primary columbium and tantalum,
primary molybdenum, secondary tungsten and cobalt, and primary
zirconium and hafnium. EPA believes that performance data from
the iron and steel manufacturing category provide a valid measure
of this technology's ;performance on nonferrous metals
manufacturing category wastewater because raw wastewater
concentrations of ammonia are of the same order of magnitude in
the respective raw wastewater matrices.
Chemical analysis data were collected of raw waste (treatment
3897
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - IX
influent) and treated waste (treatment effluent) from one coke
plant of the iron and steel manufacturing category. A contractor
for EPA, using EPA sampling and chemical analysis protocols,
collected six paired samples in a two-month period. These data
are the data base for determining the effectiveness of ammonia
steam stripping technology and are contained with the public
record supporting this document. Ammonia treatment at this coke
plant consisted of two steam stripping columns in series with
steam injected countercurrently to the flow of the wastewater. A
lime reactor for pH adjustment separated the two stripping
columns.
The raw untreated wastewater samples from the coke facility
contained ammonia concentrations of 599, 226, 819, 502, 984, and
797 mg/1. Raw untreated wastewater samples from the primary
nickel and cobalt subcategory should have ammonia concentrations
on a similar order of magnitude.
The Agency has verified the promulgated steam stripping
performance values using steam stripping data collected at a
primary zirconium and hafnium plant which has raw ammonia levels
as high as any in the nonferrous metals manufacturing category.
Data collected by the plant represent almost two years of daily
operations, and support the long-term mean used to establish
treatment effectiveness.
In addition, data submitted by a primary columbium-tantalum
plant, which also has significant raw ammonia levels, verifies
the promulgated steam stripping performance values.
Implementation of the promulgated BPT limitations will remove
annually an estimated 241 kg of toxic metals. The Agency
projects capital and annual costs of $71,400 and $27,200 (1982
dollars), respectively for the discharging facility to achieve
the promulgated BPT regulations. The BPT treatment configuration
is presented in Figure IX-1 (page 3904).
More stringent technology options were not selected for BPT since
they require in-process changes or end-of-pipe technologies less
widely practiced in the subcategory, and, therefore, are more
appropriately considered under BAT.
WASTEWATER DISCHARGE RATES , .
A BPT discharge rate is calculated for each subdivision based on
the average of the flows of the existing plants, as determined
from analysis of dcp. The discharge rate is used with the
achievable treatment concentrations to determine BPT effluent
limitations. Since the discharge rate may be different for each
wastewater source, separate production normalized discharge rates
for each of the four wastewater sources are discussed below and
summarized in Table IX-1 (page 3901). The discharge rates are
normalized on a production basis by relating the amount of
wastewater generated to the mass of the intermediate product
which is produced by the process associated with the waste stream
3898
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - IX
in question. These production normalizing parameters, or PNPs,
are also listed in Table IX-1.
Section V of this document.further describes the discharge flow
rates and presents the water use and discharge flow rates for
each subdivision by plant in Tables V-l through V-4.
RAW MATERIAL DUST CONTROL
The BPT wastewater discharge rate used at proposal and
promulgation for raw material dust control is 77 liters/kkg (18.5
gal/ton) of copper, nickel, and cobalt in the crushed raw
material. This rate is allocated only for those plants which
produce nickel and cobalt from an ore concentrate raw material
and transport dust from the baghouse over the crushing and
grinding operations with a water slurry system. Water use and
wastewater discharge rates are presented in Table V-l (page
3848). The BPT flow is based on the reported rate of 77
liters/kkg).
COBALT REDUCTION DECANT
The BPT wastewater discharge rate used at proposal and
promulgation for cobalt reduction decant is 21,398 liters/kkg
(5.128 gal/ton) of cobalt produced. The BPT flow is based on the
water use rate reported, as shown in Table V-2 (page 3849). This
rate is allocated only for those plants which reduce cobalt from
solution in a hydrogen autoclave, and decant excess solution.
NICKEL REDUCTION DECANT
The proposed and promulgated BPT wastewater discharge rate for
nickel reduction decant is 12,695 liters/kkg (3,042 gal/ton) of
nickel produced. The BPT flow is based on the water use rate
reported by the only plant with this process waste stream, as
shown in Table V-3 (page 3850). This rate is allocated only for
those plants which reduce nickel from solution in a hydrogen
autoclave, and decant excess solution.
NICKEL WASH WATER
The proposed and promulgated BPT wastewater discharge rate for
nickel wash water is 33.87 liters/kkg (8.12 gal/ton) of nickel
powder washed. This rate;is allocated only for those plants
which produce nickel from primary sources via a hydrogen
reduction autoclave, and then wash the product with water. Water
use and wastewater discharge rates are presented in Table V-4
(page 3851). The BPT flow is based on the reported rate of 33.87
liters/kkg. - . "
REGULATED POLLUTANT PARAMETERS
The raw wastewater concentrations from individual operations and
the subcategory as a wholje were examined, to select certain
pollutant parameters for limitation. This examination and
3899 .
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - IX
evaluation was presented in Section VI. A total of six
pollutants or pollutant parameters were selected for limitation
under the promulgated BPT and are listed below:
120. copper
124. nickel
ammonia (as N)
cobalt
total suspended solids (TSS)
PH
EFFLUENT LIMITATIONS
The pollutant concentrations achievable by application of the BPT
technology are discussed in Section VII of this supplement. These
achievable concentrations (both one day maximum and monthly
average values) are multiplied by the BPT normalized discharge
flows summarized in Table IX-1 to calculate the mass of
pollutants allowed to be discharged per mass of product. The
results of these calculations in milligrams of pollutant per
kilogram of product represent the BPT effluent limitations and
are presented in Table IX-2 (page 3902) for each individual waste
stream.
3900
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - IX
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PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - IX
TABLE IX-2
BPT MASS LIMITATIONS FOR THE PRIMARY NICKEL
AND COBALT SUBCATEGORY
(a) Raw Material Dust Control BPT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/miliion Ibs) of copper, nickel, and
cobalt in the crushed raw material
*Copper
*Nickel
Zinc
*Ammonia
*Cobalt
*TSS
*pH
0.146
0.148
0.112
10.260
0.016
3.157
Within the range of 7 . 5
0.077
0.098
0.047
4.512
0.007
1.502
to 10.0 at all times
(b) Cobalt Reduction Decant BPT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of cobalt produced
*Copper
*Nickel
Zinc
*Ammonia
*Cobalt
*TSS
*pH
40.660
41.080
31.240
2,852.000
4.494
877.300
Within the range of 7.5
21.400
27.180
13.050
1,254.000
1.926
417.300
to 10.0 at all times
*Regulated Pollutant
3902
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - IX
TABLE IX-2 (Continued)
BPT MASS LIMITATIONS FOR THE PRIMARY NICKEL
AND COBALT SUBCATEGORY
(c) Nickel Reduction Decant BPT
Jfonutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of nickel produced
*Copper
*Nickel
Zinc
*Ammonia
*Cobalt
*TSS
*pH
! 24.120
24.370
18.530
1,692.000
2.666
520.500
12.700
16.120
7.744
743.900
1.143
247.600
rT..,. *••*/.uuu
Within the range of 7.5 to 10.0 at all times
(d) Nickel Wash Water BPT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
*Copper
*Nickel
Zinc
*Ammonia
* Cobalt
*TSS
*pH
mg/kg (Ib/million Ibs) of nickel
; 0.064
0.065
0.050
: 4.515
0.007
1.389
. Within the range of; 7.5 to
powder washed
0.034
0.043
0.021
1.985
0.003
0.660
10.0 at all times
*Regulated Pollutant
3903
-------
r
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - IX
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PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - X
SECTION X
BEST AVAILABLE TECHNOLOGY ECONOMICALLY ACHIEVABLE
"mltatlc>ns are based on the best control and
specific point source within ?he
ren *
The required assessment of BAT considers costs, but does not
in^asleSsJna311?^9 °* ^T ^^ Pollutant removals H^eve?"
in assessing the proposed and promulgated BAT the Aqencv has
technology? antial W6ight tO the econoni^ achievabili?? of thj
TECHNICAL APPROACH TO BAT
vr* the. development of BAT effluent limitations, mass loadings
were calculated for each wastewater source or subdivision in ?he
gUS 1the.sam^ technical approach as deIc?ibeS in
technol°gie^ considered for BAT are summarized
3905
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - X
Option A (Figure X-l, page 3916) is based on:
o Ammonia steam stripping preliminary treatment (where
required)
o Chemical precipitation and sedimentation
Option C (Figure X-2, page 3917) is based on:
o Ammonia steam stripping preliminary treatment (where
required)
o Chemical precipitation and sedimentation
o Multimedia filtration
The first option considered (Option A) is the same as the BPT
nt
sec
Irogress toward ihe reduction of pollutant discharges above and
beyond the progress achievable by BPT.
OPTION A
n«Hnn A for the primary nickel and cobalt subcategory is
sr fc£ ?£• - SLhx^ee^gure? £?£•££."£
discharge rates for Option A are equal to the discharge Lates
allocated to each stream as a BPT discharge flow.
OPTION C
ont-ion C for the primary, nickel and cobalt subcategory consists
of Si control and treatment requirements of Option A (^onia
metals, beyond the concentrations attainable by S^Y^Y
sSdimintation: The filter suggested is of the gravity, mixed
mSdia type? although other forms of filters such as rapid sand
filters or pressure filters, would perform satisfactorily.
INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES
etteo t
asscStated with eacft option. The methodologies are described
below.
POLLUTANT REMOVAL ESTIMATES:
A complete description of the methodology used to calculate the
3906
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - X
estimated pollutant remdval, or benefit, achieved by the
application of the various treatment options is presented in
Section X of Vol. I. in short, sampling data collected during
the tield sampling program were used to characterize the major
waste_ streams considered' for regulation. At each sampled
facility the sampling data were production normalized for each
unit operation, (i.e. mass of. pollutant generated per mass - of
product manufactured). This value, referred to as the raw waste
was used to estimate the mass of toxic pollutants generated
within the primary nickel and cobalt subcategory. The pollutant
removal estimates were calculated for each plant by first
estimating the total mass; of each pollutant in the untreated
wastewater. This was calculated by first multiplying the raw
waste values by the corresponding production value for that
stream and then summing these values for each pollutant for everv
stream generated by the plant.
The volume of wastewater discharged after the application of each
treatment option was estimated for each operation at each plant
by comparing the actual discharge to the regulatory flow. The
smaller of the two values was selected and summed with the other
plant flows. The mass of pollutant discharged was then estimated
by multiplying the achievable concentration values attainable
with the option (mg/1) by the estimated volume of process
wastewater discharged by the subcategory. The mass of pollutant
removed is the difference between the estimated mass of pollutant
generated within the subcategory and the mass of pollutant
discharged after application of the treatment option. The
pollutant removal estimates for direct dischargers in the primary
nickel and cobalt subcategory are presented in Table X-l (page
3911). These pollutant removal estimates are equivalent to those
presented at proposal.
COMPLIANCE COSTS
In estimating subcategory-wide compliance costs, the first step
was to develop a cost estimation model, relating the total costs
associated with installation and operation of wastewater
treatment technologies to,plant process wastewater discharge.
EPA applied the model to each plant. The plant's investment and
operating costs are determined by what treatment it has in place
and by its individual process wastewater discharge flow. As
discussed above, this flow is either the actual or the BAT
regulatory flow, whichever is lesser. The final step was to
annualize the capital costs, and to sum the annualized capital
costs, and the operating and maintenance costs for each plant
yielding the cost of compliance for the subcategory (see Table
X-2, page 3912). These costs were used in assessing economic
achievability. . . " • .
BAT OPTION SELECTION - PROPOSAL
EPA proposed BAT limitations for the primary nickel and cobalt
subcategory based on Option C, preliminary treatment consisting
of ammonia steam stripping followed -by end-of-pipe treatment
3907 . . • • •
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - X
consisting of chemical precipitation, sedimentation, and
filtration. The pollutants specifically proposed for regulation
under BAT were copper, nickel, ammonia, and cobalt.
implementation of the proposed BAT limitations washestimated to
remove 246 kilograms of priority metals annually. The projected
capital and annual costs for the proposed BAT technology were
estimated to be $31,075 and $27,844 (1982 dollars), respectively.
BAT OPTION SELECTION - PROMULGATION
Our promulgated BAT limitations for this Subcategory are based
on Option C, preliminary treatment of ammonia steam stripping
followed by end-of-pipe treatment consisting of chemical
precipitation and sedimentation (BPT technology), and filtration.
Filters are presently utilized by the one plant in this
subcategory.
We are promulgating filtration as part of the _BAT technology
because this technology is demonstrated in the primary nickel and
cobalt subcategory (the one discharger in this subcategory
SeSently has a filter, and a total of 25 facilities in eight
Sonferrous metals manufacturing subcategones currently have
flitersK and results in additional removals of toxic metals. in
addition filtration adds reliability to the treatment system by
making it less susceptible to operator error and to sudden
changes in raw wastewater flows and concentrations.
The pollutants specifically'limited under BAT are cobalt, copper,
nickel, and ammonia. The toxic pollutant zinc was also
considered for regulation because it was found at treatable
concentrations in the raw.wastewaters from this subcategory.
This pollutant was not selected for specific regulation because
it will be effectively controlled when the regulated toxic metals
are treated to the concentrations achievable by the model BAT
technology.
implementation of the promulgated BAT limitations _would remove
annually an estimated 246 kg of priority metals, which is 5 kg of
?oxic metals greater than the estimated BPT removal The Agency
projects capital and annual costs of $86,500 and $31,800 (1982
dollars), respectively for technology required to achieve the
promulgated BAT regulations. The BAT treatment scheme is
presented in Figure X-2.
WASTEWATER DISCHARGE RATES
A BAT discharge rate was calculated for each subdivision based
upon the flows of the existing plants, as determined from
analysis of the data collection portfolios. The discharge rate
is used with the achievable treatment concentrations to determine
BAT effluent limitations. Since the discharge rate may be
different for each wastewater source, separate production
normalized discharge rates for each of the four wastewater
sources were determined and are summarized in Table X-3 (page
3908
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT -.X:
3913). The discharge rates are normalized on a production basis
by relating the amount of wastewater generated to the mass of the
intermediate product which is produced by the process associated
with the waste stream in question. These production normalizing
parameters, or PNPs, are also listed in Table X-3.
The BAT discharge rates reflect .the flow reduction requirements
of the selected BAT option. Since no flow reduction beyond the
flow reduction practices of BPT is required for this subcategory,
BAT discharge rates are identical to BPT discharge rates.
REGULATED POLLUTANT PARAMETERS
The raw wastewater concentrations from individual operations and
the subcategory as a whole were examined to select certain
pollutants and pollutant parameters for limitation. This
examination and evaluation was presented in Section VI. The
Agency, however, has chosen not to regulate all three toxic
pollutants selected in this analysis.
The high cost,associated with analysis for toxic metal pollutants
has prompted EPA to develop an alternative method for regulating
and monitoring toxic pollutant discharges from the nonferrous
metals manufacturing category. Rather than developing specific
effluent mass limitations and standards for each of the toxic
metals found in treatable concentrations in the raw wastewater
from a given subcategory, the Agency is promulgating effluent
mass limitations only for those pollutants generated in the
greatest quantities as shown by the pollutant removal estimates
The pollutants selected for specific limitation are listed below:
120. copper
124. nickel
cobalt
By establishing limitations and standards for certain priority
metal pollutants, discharges will attain the same degree of
control over priority metal pollutants as they would have been
required to achieve had all the priority metal pollutants been
directly limited.
This approach is technically justified since the treatable
concentrations used for chemical precipitation and sedimentation
technology are based on optimized treatment for concomitant
multiple metals removal. Thus, even though metals have somewhat
different theoretical solubilities, they will be removed at very
nearly the same rate in a chemical precipitation and
sedimentation treatment system operated for multiple metals
removal. Filtration as part of the technology basis is likewise
justified because this , technology removes metals non-
preferential ly.
The toxic metal pollutants selected for specific limitation in
the primary nickel and cobalt subcategory to control the
discharges of toxic metal pollutants are copper and nickel. The
3909
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT,- X
following toxic metal pollutant is excluded from limitation on
the basis that it is effectively controlled by the limitations
developed for copper and nickel:
128. zinc
The nonconventional- pollutants ammonia and cobalt will be limited
in the primary nickel and cobalt subcategory along with the
priority pollutants nickel and copper. It,is necessary to limit
ammonia because the treatment technology used to control copper
and nickel (chemical precipitation and sedimentation) does not
remove ammonia. The priority metal pollutants copper and nickel,
as well as the nonconventional metal pollutant cobalt, are
specifically limited to ensure the control of the excluded
priority metal pollutant. These pollutants are indicators of. the
performance of the treatment technology.
EFFLUENT LIMITATIONS . . •
The concentrations achievable by application of BAT are discussed
in Section VII of this supplement. The treatable concentrations
both one day maximum and monthly average values are multiplied by
the BAT normalized discharge flows summarized in Table X-3 to
calculate the mass of pollutants allowed to be discharged per
mass of product. The results of these calculations in milligrams
of pollutant per kilogram of product represent the BAT effluent
limitations and are presented in Table X-4 (page 3914) for each
waste stream. , •
3910
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
SECT - X
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PRIMARY NICKEL AND COBALT SUBCATEGORY
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PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - X
TABLE X-4
BAT MASS LIMITATIONS FOR THE PRIMARY NICKEL
AND' COBALT SUBCATEGORY
(a) Raw Material Dust Control BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of copper, nickel, and cobalt
in the crushed raw material
*Copper
*Nickel
Zinc
* Ammonia
*Cobalt
0.099
0.042
0.079
10.260
0.011
0.047
0.029
0.032
4.512
0.005
(b) Cobalt Reduction Decant BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of cobalt produced
*Copper
*Nickel
Zinc
*Ammonia
*Cobalt
27.390
11.770
21.830
2,852.000
2.996
13.050
7.917
8.987
1,254.000
1.498
*Regulated Pollutant
3914
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - X
TABLE X-4 (Continued)
BAT MASS LIMITATIONS FOR THE PRIMARY NICKEL
AND COBALT SUBCATEGORY
(c) Nickel Reduction Decant BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of nickel produced
* Copper
*Nickel
Zinc
*Ammonia
* Cobalt
16.250
6.982
12.950
1,692.000
1.777
7.744
4.697
5.332
743.900
0.889
(d) Nickel Wash Water BAT
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of nickel powder washed
.*Copper
*Nickel
Zinc
*Ammonia
*Cobalt
0.043
0.019
0.035
4.515
0.005
0.021
0.013
0.014
1.985
0.002
*Regulated Pollutant
3915
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - X
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3916
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
SECT - X
t>H
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - X
THIS PAGE INTENTIONALLY LEFT BLANK
3918
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - XI
SECTION XI
NEW SOURCE PERFORMANCE STANDARDS
The basis for new source performance standards (NSPS) is the best
available demonstrated technology (BDT). New plants have the
opportunity to design the best and most efficient production
processes and wastewater treatment technologies without facing
the added costs and restrictions encountered in retrofitting an
existing plant. Therefore, EPA has considered the best
demonstrated process changes, in-plant controls, and end-of-pipe
treatment technologies which reduce pollution to the maximum
extent feasible.
This section describes the technologies for treatment of
wastewater from new sources and presents mass discharge standards
for regulated pollutants for NSPS in the primary nickel and
cobalt subcategory, based on the selected treatment technology.
TECHNICAL APPROACH TO NSPS
New source performance standards are equivalent to the best
available technology (BAT) selected for currently existing
primary nickel and cobalt plants. This result is a consequence of
careful review by the Agency of a wide range of technical options
for_ new source treatment systems. There was nothing found to
indicate that the wastewater flows and characteristics of new
plants would not be similar to those from existing plants, since
the processes used by new sources are not expected to differ from
those used at existing sources. Consequently, BAT production
normalized discharge rates,, which are based on the best existing
practices of the subcategory, can also be applied to new sources.
These rates are presented in Table XI—1< (page 3921).
Treatment technologies considered for the NSPS options are
identical to the treatment technologies considered for the BAT
options. These options are:
OPTION A
Preliminary treatment with ammonia steam stripping
(where required)
Chemical precipitation and sedimentation
OPTION C
o Preliminary treatment with ammonia steam stripping
(where required)
o Chemical precipitation and sedimentation
o Multimedia filtration
3919
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - XI
NSPS OPTION SELECTION - PROPOSAL
EPA proposed that the technology basis for NSPS be equal to that
for BAT (preliminary treatment consisting of ammonia steam
stripping/ chemical precipitation, sedimentation, and
filtration). The same pollutants were proposed for regulation at
NSPS as at BAT, and the proposed wastewater discharge rates for
NSPS were equivalent to those proposed for BAT.
NSPS OPTION SELECTION - PROMULGATION
We are promulgating NSPS equal to BAT. We believe that new
could not achieve any flow reduction beyond the
s promulgated for BAT. Because NSPS is equal to BAT we
believe that the promulgated NSPS will not pose a barrier to the
entry of new plants into this subcategory.
REGULATED POLLUTANT PARAMETERS
The Agency has no reason to believe that the pollutants that will
be found in treatable concentrations in processes within new
sources will be any different than with existing sources.
Accordingly; pollutants and pollutant parameters selected for
UmitSSon 'under NSPS, in .accordance with the rationale of
Sections VI and X, are identical to those selected for BAT. Tne
conventional pollutant parameters TSS and PH are also selected
for limitation.
NEW SOURCE PERFORMANCE STANDARDS
The NSPS discharge flows for each wastewater source are the same
as the discharge rates for BAT and are shown in Table XI-1. The
miss of pollutant allowed to be discharged per mass of product is
baled onthe product of the appropriate treatable concentration
(ma/1) and the production normalized wastewater discharge flows
1/kiccrt The results of these calculations are the production-
based9)new sourcl performance standards. These standards are
presented in Table XI-2 (page 3922).
3920
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - XI
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-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - XI
Table XI-2
NSPS FOR THE PRIMARY NICKEL AND COBALT SUBCATEGORY
(a) Raw Material Dust Control NSPS
Pollutant or
pollutant property
Maximum for
'any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of copper, nickel, and
cobalt in the crushed raw material
* Copper
*Nickel
Zinc
*Ammonia
*Cobalt
*TSS
*pH
0.099
0.042
0.079
10.260
0.011
1.155
Within the range of 7.5
0.047
0.029
0.032
4.512
0.005
0.924
to 10.0 at all times
(b) Cobalt Reduction Decant NSPS
Pollutant or
pollutant property
Maximum for
i any one day
Maximum for
monthly average
* Copper
*Nickel
Zinc
* Ammonia
*Cobalt
*TSS
*pH
mg/kg (Ib/million Ibs) of
27.390
11.770
21.830
2,852.000
2.996
321.000
Within the range of 7.
cobalt produced
13.050
7.917
8.987
1,254.000
1.498
256.800
5 to 10.0 at all times
*Regulated Pollutant
3922
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - XI
TABLE XI-2 (Continued)
NSPS FOR THE PRIMARY NICKEL AND COBALT SUBCATEGORY
(c) Nickel Reduction Decant NSPS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
* Copper
*Nickel
Zinc
*Ammonia
*Cobalt
*TSS
*pH
mg/kg { Ib/million Ibs) of nickel
16.250
6.982
". 12.950
1,692.000
1.777
190.400
Within the range of 7.5 to 10
produced
7.744
4.697
5.332
743.900
0.889
152.300
. 0 at all times
(d) Nickel Wash Water NSPS
Maximum for
any one day
Pollutant or
pollutant property
Maximum for
monthly average
* Copper
*Nickel
Zinc
*Ammonia
*Cobalt
*TSS
*pH
mg/kg (Ib/million Ibs) of nickel
0.043
0.019
0.035
4.515
0.005
0.508
Within the range of 7.5 to
powder washed
0.021
0.013
0.014
1.985
0.002
0.406
10.0 at all times
*Regulated Pollutant
3923
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - XI
THIS PAGE INTENTIONALLY LEFT BLANK
3924
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - XII
SECTION XII
PRETREATMENT STANDARDS
PSES are designed to prevent the discharge of pollutants which
pass through, interfere with, or are otherwise incompatible with
the operation of publicly owned treatment works (POTW). The
Clean Water Act requires pretreatment for pollutants, such as
toxic metals, that limit POTW sludge management alternatives.
New_ indirect discharge facilities, like new direct discharge
facilities, have the opportunity to incorporate the best
available demonstrated .technologies including process changes
in-plant controls, and end-of-pipe treatment technologies, and to
use plant site selection co ensure adequate treatment system
installation. Pretreatment standards are to be technology based,
analogous to the best available technology for removal of toxic
pollutants.
EPA is not promulgating/pretreatment standards for existing
sources in this subcategory because no indirect dischargers
exist. However, EPA is promulgating pretreatment standards for
new sources because plants .may be constructed in the future which
may discharge to a POTW.
This section describes the control and treatment technologies for
pretreatment of process 'wastewaters from new sources in the
primary nickel and cobalt .subcategory. Pretreatment standards
for regulated pollutants are presented based on the selected
control and treatment technology.
TECHNICAL APPROACH TO PRETREATMENT
Before proposing and promulgating pretreatment standards, the
Agency examines whether the pollutants discharged by the industry
pass through the POTW or interfere with the POTW operation or its
chosen sludge disposal practices. In determining whether
pollutants pass through a well-operated POTW achieving secondary
treatment, the Agency compares the percentage of a pollutant
removed by POTW with the percentage removed by direct dischargers
aPp!ying the best available technology economically achievable.
A pollutant is deemed to pass through the POTW when the average
percentage removed nationwide by well-operated POTW meeting
secondary treatment requirements, is less than the percentage
removed by direct dischargers complying with BAT effluent
limitations guidelines for that pollutant.
This definition of pass through satisfies the two competing
objectives set by Congress that standards for indirect
dischargers be equivalent!to standards for direct dischargers
while at the same time, the treatment capability and performance
of the POTW be recognized and taken into account in regulating
the discharge of pollutants from indirect dischargers.
The Agency compares percentage removal rather than the mass or
3925
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - XII
concentration of pollutants discharged because the latter would
not take into account the mass of pollutants discharged to the
POTW from non-industrial sources or the dilution of the
pollutants in the POTW effluent to lower concentrations due to
the addition of large amounts of non-industrial wastewater.
PRETREATMENT STANDARDS FOR NEW SOURCES
Options for pretreatment of wastewaters from new sources are
based on inc?easing the effectiveness of end-of-pipe treatment
technologies. All in-plant changes and applicable end-of-pipe
treatment processes have been discussed previously in Sections X
and XI. The options for PSNS are the same as the BAT and NSPS
options discussed in Sections X and XI, respectively.
A description of each option is presented in Section X, while a
more detailed discussion, including pollutants controlled by each
treatment process is presented in Section VII of the General
Development Document.
Treatment technologies considered for the PSNS options are:
OPTION A
o Preliminary treatment with ammonia steam stripping (where
required)
o Chemical precipitation and sedimentation
OPTION C
o Preliminary treatment with ammonia steam stripping (where
required) ; ,..,_,_•
o Chemical precipitation and sedimentation
o Multimedia filtration ,
PSNS OPTION SELECTION - PROPOSAL
EPA proposed the technology basis for PSNS equal to _BAT
(preliminary treatment consisting of ammonia steam stripping,
chemical precipitation, sedimentation, and filtration).
pollutants were proposed for regulation at PSNS as at
the proposed wastewater discharge rates for PSNS were
to those proposed for BAT.
PSNS OPTION SELECTION - PROMULGATION
We are promulgating PSNS equal to BAT and NSPS for this
subcategory. It is necessary to promulgate PSNS to prevent pass-
through of copper, nickel, cobalt, and ammonia. These toxic
pollutants are removed by a well-operated POTW at an Average of
26 percent, while BAT technology removes approximately 58
percent.
The same
BAT, and
equivalent
3926
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - XII
The_technology basis for PSNS thus is chemical precipitation and
sedimentation, ammonia steam stripping, and filtration. The
achievable concentration for ammonia steam stripping is based on
iron and steel manufacturing category data, as explained in the
discussion of BPT for this subcategory.
We believe that the proposed PSNS are achievable, and that they
are not a barrier to entry of new plants into this subcategory.
The PSNS discharge rates are shown in Table XII-1 (page 3928).
REGULATED POLLUTANT PARAMETERS
Pollutants selected for limitation, in accordance with the
rationale of Sections VI and X, are identical to those selected
for limitation for BAT. It is necessary to promulgate PSNS to
prevent the pass-through of copper, nickel, ammonia, and cobalt.
PRETREATMENT STANDARDS FOR NEW SOURCES
Pretreatment standards for new sources are based on the treatable
concentrations from the selected treatment technology, (Option
C), and the discharge rates determined in Sections X and XI for
BAT and NSPS, respectively. A mass of pollutant per mass of
product (mg/kg) allocation is given for each subdivision within
the subcategory. This pollutant allocation is based on the
product of the treatable concentration from the promulgated
treatment (mg/1) and the production normalized wastewater
discharge rate (1/kkg). The achievable treatment concentrations
for PSNS are identical to those for BAT. PSNS are presented in
Table XII-2 (page 3929).
3927
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY
SECT - XII
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-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - XII
TABLE XII-2
PSNS FOR THE PRIMARY NICKEL AND COBALT SUBCATEGORY
(a) Raw Material Dust Control PSNS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
rag/kg (Ib/million Ibs) of copper, nickel, and
cobalt in the crushed raw material
*Copper
*Nickel
Zinc
*Anu-nonia
*Cobalt
0.099
0.042
0.079
10.260
0.011
0.047
0.029
0.032
4.512
0.005
Cobalt Reduction Decant PSNS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of cobalt produced
* Copper
*Nickel
Zinc
*Ammonia
*Cobalt
27.390
11.770
21.830
2,852.000
2.996
13.050
7.917
8.987
1,254.000
1.498
*Regulated Pollutant
3929
-------
PRIMARY NICKEL!AND COBALT SUBCATEGORY SECT - XII
TABLE XI1-2 (Continued)
PSNS FOR THE PRIMARY NICKEL AND COBALT SUBCATEGORY
(c) Nickel Reduction Decant PSNS
Pollutant or
pollutant property
Maximum for
monthly average
mg/kg (Ib/million Ibs) of nickel produced
*Copper
*Nickel
Zinc
*Ammonia
*Cobalt
16.250
6.982
12.950
1,692.000
1.777
7.744
4.697
5.332
743.900
0.889
(d) Nickel Wash Water |PSNS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
__———— ——
mg/kg (Ib/million Ibs) of nickel powder washed
*Copper
*Nickel
Zinc
*Ammonia
*Cobalt
*Regulated Pollutant
0.043
0.019
0.035
4.515
0.005
0.021
0.013
0.014
1.985
0.002
3930
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY .. SECT - XIII
SECTION XIII
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY
EPA is not promulgating best conventional pollutant control
technology (BCT) for the primary nickel and cobalt subcategory at
this time. , •"
3931
-------
PRIMARY NICKEL AND COBALT SUBCATEGORY SECT - XIII
THIS PAGE INTENTIONALLY LEFT BLANK
3932
-------
NONFERROUS METALS MANUFACTURING POINT SOURCE CATEGORY
DEVELOPMENT DOCUMENT SUPPLEMENT
for the
Secondary Nickel Subcategory
William K. Reilly
Administrator
Rebecca Hanmer
Acting Assistant Administrator for Water
Martha Prothro, Director
Office of Water Regulations and Standards
Thomas P. O'Farrell, Director
Industrial Technology Division
Ernst P. Hall, P.E., Chief
Metals! Industry Branch
' and
Technical Project Officer
May 1989
U.S. Environmental Protection Agency
Office of Water
Office of Water;Regulations and Standards
Industrial Technology Division
Washington, D. C. 20460
3933
-------
3934
-------
SECONDARY NICKEL SUBCATEGORY
Section
TABLE OP CONTENTS
I
II
III
IV
V
VI
SUMMARY
CONCLUSIONS \ '
SUBCATEGORY PROFILE
Description of Secondary Nickel Production
Raw Materials
Slag Reclamation
Acid Reclamation
Scrap Reclamation
Process Wastewater Sources
Other Wastewater Sources
Age, Production, and Process Profile
SUBCATEGORIZATION
Factors Considered in Subdividing the Secondary
Nickel Subcategory
Other Factors
Production Normalizing Parameters
WATER USE AND WASTEWATER CHARACTERISTICS
Wastewater Flow Rates
Wastewater Characteristics Data
Data Collection Portfolios
Field Sampling Data
Wastewater Characteristics and Flow by
Subdivision
Slag Reclaim Tailings
Acid Reclaim Leaching Filtrate
Acid Reclaim Leaching Belt Filter Backwash
SELECTION OF POLLUTANTS
Conventional and Nonconventional Pollutant
Parameters Selected
Toxic Priority Pollutants
Toxic Pollutants Never Detected
Toxic Pollutants :Never Found Above Their
Analytical Quantification Concentration
Toxic Pollutants Selected for for Further
Consideration in Establishing Limitations
and Standards
3941
3943
3947
3947
3947
3947
3948
3948
3948
3948
3948
3955
3955
3956
3956
3959
3958
3958
3958
3959
3960
3960
3960
3960
3975
3975
3976
3976
3976
3976
3935
-------
SECONDARY NICKEL SUBCATEGORY
TABLE OF CONTENTS (Continued)
Section
VII
VIII
IX
X
XI
CONTROL AND TREATMENT TECHNOLOGIES
Current Control and Treatment Practices
Slag Reclaim Tailings
Acid Reclaim Leaching Filtrate
Acid Reclaim Leaching Belt Filter Backwash
Control and Treatment Options
Option A
Option C
COSTS, ENERGY, AND NONWATER QUALITY ASPECTS
Treatment Options for Existing Sources
Option A
Option C
Cost Methodology
Nonwater Quality Aspects
Energy Requirements
Solid Waste
Air Pollution
BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
AVAILABLE
BEST AVAILABLE TECHNOLOGY ECONOMICALLY
ACHIEVABLE
NEW SOURCE PERFORMANCE STANDARDS
[
Technical Approach to NSPS
Pollutant Removal Estimates
Compliance Costs
NSPS Option Selection - Proposal
NSPS Option Selection - Promulgation
Wastewater Discharge Rates
Slag Reclaim Tailings
Acid Reclaim Leaching Filtrate
Acid Reclaim Leaching Belt Filter Backwash
Regulated Pollutant Parameters
New Source Performance Standards
3983
3983
3983
3983
3984
3984
3984
3984
3985
3985
3985
3985
3985
3986
3986
3986
3998
3991
3991
3993
3993
3995
3996
3996
3996
3997
3997
3997
3997
3997
3999
3936
-------
SECONDARY NICKEL SUBCATEGORY
Section
XII
TABLE OF CONTENTS (Continued)
PRETREATMENT STANDARDS
Technical Approach to Pretreatment
Industry Cost and Pollutant Removal Estimates
Pretreatment Standards for Existing and New
Sources
PSES Option Selection •
PSES Option Selection •
PSNS Option Selection •
PSNS Option Selection •
Pretreatment Standards
Proposal
Promulgation
Proposal
Promulgation
Page
4003
4003
4004
4004
4004
4005
4005
4005
4006
XIII
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY 4013
3937
-------
SECONDARY NICKEL SUBCATEGORY
LIST OP TABLES
Table Title
III-l Initial Operating Year Summary of Plants in the
Secondary Nickel Subcategory by Discharge Type
III-2 Production Ranges; for the Secondary Nickel
Subcategory '{
III-3 Summary of Secondary Nickel Subcategory
Processes and Associated Waste Streams
V-l Water Use and Discharge Rates for Slag Reclaim
Tailings I
V-2 Water Use and Discharge Rates for Acid Reclaim
Leaching Filtrate
V-3 Water Use and Discharge Rates for Acid Reclaim
Leaching Belt filter Removal
V-4 Secondary Nickel Sampling Data Slag Reclaim
Tailings Pond Influent Raw Wastewater
Sampling Data
V-5 Secondary Nickel!Sampling Data Slag Reclaim
Tailings Pond Effluent Raw Wastewater
Sampling Data
V-6 Secondary Nickel Sampling Data Acid Reclaim
Leaching Filtrate Raw Wastewater Sampling Data
V-7 Secondary Nickel Sampling Data Acid Reclaim
Leaching Belt Filter Backwash Raw Wastewater
Sampling Data
VI-1 Frequency of Occurrence of Priority Pollutants
Secondary Nickel Subcategory Raw Wastewater
VI-2 Toxic Pollutants Never Detected
VIII-1 Cost of Compliance for the Secondary Nickel
Subcategory Indirect Dischargers
XI-1 NSPS Wastewater ;Discharge Rates for the
Secondary Nickel Subcategory
Page
3950
3951
3952
3962
3963
3964
3965
3965
3970
3972
3978
3979
3989
4000
3938
-------
SECONDARY NICKEL SUBCATEGORY
LIST OF TABLES (Continued)
Table
XI-2
XII-1
XII--2
XII-3
XII-4
XII-5
Title
NSPS for the Secondary Nickel Subcategory
Pollutant Removal Estimates for Indirect
Dischargers in the Secondary Nickel Subcategory
Cost of Compliance for the Secondary Nickel
Subcategory Indirect Dischargers
PSES and PSNS Wastewater Discharge Rates for the 4011
Secondary Nickel Subcategory
PSES for the Secondary Nickel Subcategory 4012
PSNS for the Secondary Nickel Subcategory 4013
Page
4001
4009
4010
3939
-------
SECONDARY NICKEL SUBCATEGORY
LIST OF FIGURES
Figure
III-l
III-2
V-l
XI-1
XI-2
XI-3
Title
Secondary Nickel;Manufacturing Processes
Geographic Locations of Secondary Nickel
Subcategory Plants
Sampling Sites at Secondary Nickel Plant A
NSPS Treatment Scheme for Option A
NSPS Treatment Scheme for Option C
NSPS Treatment Scheme for Option C Without
Filtration for Slag Reclaim Tailings
Page
3953
3954
3974
4002
4003
4004
3940
-------
SECONDARY NICKEL SUBCATEGORY SECT - I
SECTION I
SUMMARY
This document provides the technical basis for promulgating
pretreatment standards for existing indirect dischargers (PSES)
pretreatment standards for new indirect dischargers (PSNS), and
standards of performance for new source direct dischargers
(NSPS)for plants in the secondary nickel subcategory.
The secondary nickel subcategory consists of two plants. One of
the two plants discharges to a publicly-owned treatment works,
and one achieves zero discharge of process wastewater. There are
no plants discharging directly to rivers, streams, or lakes.
EPA first studied the secondary nickel subcategory to determine
whether differences in raw materials, final products,
manufacturing processes, equipment, age and size of plants, or
water usage, required the development of separate effluent
limitations and standards for different segments of the
subcategory. This involved a detailed analysis of wastewater
discharge and treated effluent characteristics, including the
sources and volume of water used, the processes used, the sources
of pollutants and wastewaters in the plant, and the constituents
of wastewaters, including toxic pollutants. As a result, three
subdivisions have been identified for this subcategory that
warrant separate effluent limitations. These include:
o Slag reclaim tailings,
o Acid reclaim leaching filtrate, and
o Acid reclaim leaching belt filter backwash.
Several distinct control and treatment technologies (both in
plant and end-of-pipe) applicable to the secondary nickel
subcategory were identified. The Agency analyzed both historical
and newly generated data on the performance of these
technologies, including their nonwater quality environmental
impacts and air quality, solid waste generation, and energy
requirements. EPA also studied various flow reduction techniques
reported in the data collection portfolios (dcp) and plant
visits.
Engineering costs were prepared for each of the control and
treatment options considered for the subcategory. These costs
were than used by the Agency to estimate the impact of
implementing the various options on the subcategory. For each
control and treatment option that the Agency found to be most
effective and technically feasible in controlling the discharge
of pollutants, the number of potential closures, number of
employees affected, and impact on price were estimated. These
results are reported in a separate document entitled "The
Economic Impact Analysis of Effluent Limitations and Standards
3941
-------
SECONDARY NICKEL SUBCATEGORY
SECT - I
for the Nonferrous Metals Manufacturing Industry."
Because there are no direct dischargers in the secondary nickel
subcategory, EPA is not promulgating BPT, BAT or BCT.
After examining the various treatment technologies, the Agency
°n ssss
an annual cost of $161,200
NSPS is equivalent to PSES technology. In selecting NSPS, EPA
recognizeSqthat new plants have the opportunity to «;Ple»«£ the
best and most efficient manufacturing Processes and treatment
technology. As such, the technology basis of PSES has been
determined as the best demonstrated technology.
For PSNS, the Agency selected end-of-pipe treatment equivalent to
NSPS.
The best conventional technology (BCT) replaces BAT for the
control of conventional pollutants. Although the methodology for
BCT has not yet been finalized, BCT is not promulgated for this
subcategory because there are no direct discharges.
The mass limitations and standards for NSPS, PSES, and PSNS are
presented in Section II.
3942
-------
SECONDARY NICKEL SUBCATEGORY SECT - II
: SECTION ,ii
CONCLUSIONS
EPA has divided the secondary nickel subcategory into three
subdivisions or building blocks for the purpose of effluent
limitations and standards. These subdivisions are:
(a) Slag reclaim tailings,
(b) Acid reclaim leaching filtrate, and
(c) Acid reclaim leaching belt filter backwash.
BPT is not promulgated for! this subcategory because there are no
direct dischargers.
BAT is not promulgated because there are no direct dischargers.
NSPS are promulgated based on the performance achievable by the
application of chemical precipitation and sedimentation
technology (lime and settle). The following new source
performance standards are promulgated:
(a) Slag Reclaim Tailings NSPS
~"PollutantMaximum For'Maximum For
Pollutant Property Any One Day Monthly Average
mg/kg (Ib/million Ibs) of slag input to reclaim process
Chromium (total) 5.653 2.313
Copper 124.410 12.850
Nickel 24.670 16.320
TSS 526.800 250.500
pH Within the range of 7.5 to 10.0 at all times
(b) Acid Reclaim Leaching Filtrate NSPS
Pollutant~Maximum ForMaximum For
Pollutant Property Any One Day Monthly Average
mg/kg (Ib/million Ibs)of acid reclaim nickel produced
Chromium (total)
2.198 0.089
9.491 4.995
Copper
Nickel 9.590 6.344
TSS 214.800 8,7.400
pH Within the range of 7.5 to 10.0 at all times
3943
-------
SECONDARY NICKEL SUBCATEGORY
SECT - II
(c) Acid Reclaim Leaching Belt Filter Backwash NSPS
Pollutant
Pollutant Property
Maximum For
Any One Day
Maximum For
Monthly Average
mg/kg (Ib/million Ibs) of acid reclaim nickel produced
Chromium (total)
Copper
Nickel
TSS
pH
0.528
2.278
2.302
49.160
0.216
1.199
1.523
23.380
Within the range of 7.5 to 10.0 at all times
PSES are promulgated based on the performance achievable by the
application of chemical precipitation and sedimentation
technology (lime and settle). The following pretreatment
standards for existing sources are promulgated:
(a) Slag Reclaim Tailings PSES
Pollutant
Pollutant Property
Maximum For
Any One Day
Maximum For
Monthly Average
mg/kg (Ib/million Ibs) of slag input to reclaim process
Chromium (total)
Copper
Nickel
5.653
24.410
24;670
2.313
12.850
16.320
(b) Acid Reclaim Leaching Filtrate PSES
Pollutant
Pollutant Property
Maximum For
Any One Day
Maximum For
Monthly Average
mg/kg (Ib/million Ibs) of acid reclaim nickel produced
Chromium (total)
Copper
Nickel
2.198
9.491
9.590
0.899
4.995
6.344
3944
-------
SECONDARY NICKEL SUBCATEGORY SECT - II
(c) Acid Reclaim Leaching Belt Filter Backwash PSES
Pollutant
Pollutant Property
Maximum For
Any One Day
Maximum For
Monthly Average
mg/kg (Ib/million Ibs) of acid reclaim nickel produced
Chromium (total)
Copper
Nickel
0.528
2.278
2.302
0.216
1.199
1..523
™- Promulgated based on the performance achievable by
settle? 10n™5 f6?10?1' Precipitation and sedimentation (liml and
b0llOWingPretreatmen^
(a) Slag Reclaim Tailings!
PSNS
Pollutant
Pollutant Property
Maximum For
Any One Day
Maximum For
Monthly Average
mg/kg (Ib/million Ibs;) of slag input to reclaim process
Chromium (total)
Copper
Nickel
5.653
24.410
24.670
2.313
12.850
16.320
(b) Acid Reclaim Leaching Filtrate
PSNS
Pollutant
Pollutant Property
Maximum For
Any One Day
Maximum For
Monthly Average
mg/kg (Ib/million Ibs) of acid reclaim nickel produced
Chromium (total)
Copper
Nickel
2.198
9.491
9.590
0.899
4.995
6.344
(c) Acid Reclaim Leaching Belt Filter Backwash
PSNS
Pollutant
Pollutant Property
Maximum For
Any One Day
Maximum For
Monthly Average
mg/kg (Ib/million Ibs) of acid reclaim nickel produced
Chromium (total)
Copper
Nickel
0.528
2.278
2.302
0.216
1.199
1.523
BCT is not promulgated for this subcategory at this time,
3945
-------
SECONDARY NICKEL SUBCATEGORY SECT - II
THIS PAGE INTENTIONALLY LEFT BLANK
3946
-------
SECONDARY NICKEL SUBCATEGORY SECT - III
SECTION III
i -.; -
SUBCATEGORY PROFILE
This section of the secondary nickel supplement describes the raw
materials and processes used in smelting and refining secondary
nickel and presents a profile of the secondary nickel plants
identified in this study.
DESCRIPTION OF SECONDARY NICKEL PRODUCTION
Secondary nickel production can be divided into three distinct
operations —-slag reclamation, acid reclamation, and scrap
reclamation. Slag reclamation is a wet mechanical granulation
operation. Acid reclamation and scrap reclamation are
hydrometallurgical refining processes. One plant in the U.S.
reclaims nickel from slag and pickling acids, and a second plant
reclaims nickel from scrap. Secondary nickel production
processes are presented schematically in Figure III-l (Page 3953)
and described below. '
RAW MATERIALS |
Secondary nickel is reclaimed from three raw materials; nickel
melt furnace slag, nickel carbonate produced from waste pickling
acids and wastewater treatment sludges from nickel forming
operations, and solid nickel scrap from other manufacturing
operations. Nickel alloy scrap generated at steel mills may also
be recycled within the mills however, no refining of the nickel
scrap takes place prior to recycle and therefore, direct recycle
of nickel scrap is not considered within this subcategory.
SLAG RECLAMATION
The objective of slag reclamation is to recover the nickel values
from the dross or slag produced in nickel melt furnaces. When
the nickel ingots are smelted in the presence of fluxing agents,
the oxidized metals and impurities rise to the surface of the
liquid metal and are removed from the furnace. This slag
contains approximately 10 percent metalllcs.
The dross or slag is first air cooled and solidified, and then
mechanically granulated with a jaw crusher and a wet rod mill. It
is then fed onto a wet mineral jig, which uses specific gravity
differences to recover a nickel concentrate product. The mineral
jig is a shaking table. Large volumes of water wash over the
crushed slag on the table carrying away the lighter (less dense)
non-metallics. The denser, nickel-containing solids are the
product. A large volume of; tailings wastewater is produced. The
nickel product is returned to the melt furnace and the wastewater
is discharged. :
3947
-------
SECONDARY NICKEL SUBCATEGORY
SECT - III
ACID RECLAMATION
In the acid reclamation process, spent pickling acids and
wastewater treatment sludges from nickel forming operations are
Introduced into a vessll with soda ash (Na2CO3) which
p?ecipitates the nickel as nickel carbonate. The impure nickel
carbonate, which is separated from the liquid phase by
filtration, is the raw material for the acid reclaim process.
impure nickel carbonate is slurried with water to produce a
homogeneous solution, and then roasted in an open hearth furnace
to produce nickel oxide. The nickel oxide produced by roasting
is then leached with water to remove impurities, and filtered.
The leaching filtrate may be discharged as a waste stream. After
filtering the filter is backwashed and the backwash water may
also be discharged as a waste stream. The nickel oxide product
is approximately 35 percent nickel, and is returned to the nickel
melting furnaces. ;
SCRAP RECLAMATION
Scrap resulting from the manufacture of nickel products may be
recycled to recover the nickel values. The scrap is fed into a
digestion unit with nitric acid and water. The acid removes
silver and other impurities, and a 95 percent nickel product is
either sold or returned to the manufacturing facility. The
resultant solution, which contains significant silver values, is
routed to a silver recovery process. The silver recovery process
and resultant wastewater* are covered by the regulations for
Secondary silver refining which is part of the nonferrous metals
SSSSfactJring category! There are no wastewater streams
SSociated with nickel scrap reclamation which are within the
scope of the secondary nickel subcategory.
PROCESS WASTEWATER SOURCES i
Although a variety of processes are involved in secondary nickel
production, the significant wastewater sources that are
alsoctaied with the secondary nickel subcategory can be
subdivided into the following building blocks:
1. Slag reclaim tailings,
2. Acid reclaim leaching filtrate, and
3. Acid reclaim leaching belt filter backwash.
OTHER WASTEWATER SOURCES
There may be other wastewater streams associated with the
secondar/nickel subcategory. These streams include but are not
limited to stormwater runoff, maintenance and cleanup water, and
noncontact cooling water. These wastewater streams are not
Sonsideted as a part of this rulemaking. EPA believes that the
??Sws and pollutant loadings associated with these wastewaters
are insignificant relative to waste streams selected and are best
handled by the appropriate permit authority on a case-by-case
3948
-------
SECONDARY NICKEL SUBCATEGORY SECT - III
basis under authority of Section 403 of the Clean Water Act.
AGE, PRODUCTION, AND PROCESS PROFILE
II13>2 (pa9e 3954) shows the locations of the two secondary
Plants operating in the United States. Both are located
1PP1 ™ • mr the indusr
« . e ocae
western Penn;yiJIniI?1PP1 ^™ • mr the industr-1 centers of
Table Ili-l (Page 3950) illustrates the relative aqe and
ei;;*argen status of the secondary nickel plants in the United
States. One plant was built in 1923, and the other was built in
From Table III-2 (Page 3951) it can be seen that of the two
fnS i non ? reclaim nickel, one plant reclaims between 500
and 1,000 tons per year, and the other less than 50 tons per
year
III-3 (Page 3952) provides a summary of the number of
»•«-», generating wastewater for the waste streams associated
ni2L«« various Processes and the number of plants with the
pJ-OCGSS •
3949
-------
SECONDARY NICKEL ' SUBCATEGORY
SECT - III
TABLE III-l
INITIAL OPERATING YEAR SUMMARY OF PLANTS IN THE
SECONDARY NICKEL SUBCATEGORY BY DISCHARGE TYPE
Initial Operating Year
(Plant Age in Years)
Type of
Plant
Direct
Indirect
Zero
Total
1982-
1966
(0-15)
0
0
1
1
1965-
1946
(15-35)
! 0
0
0
0
1945-
1926
(35-55)
0
0
0
0
1925-
1906
(55-75)
0
1
0
1
Total
0
1
1
2
3950
-------
SECONDARY NICKEL SUBCATEGORY SECT - III
TABLE III-2
PRODUCTION RANGES FOR THE SECONDARY NICKEL SUBCATEGORY
Production Ranges fojr 1982
(Tons/Year)a
0 - 50
50 - 100
500 - 1,000
Total
Number of Plants
1.
0
1
2
(a) Based on production of reclaimed nickel
3951
-------
SECONDARY NICKEL SUBCATEGORY
SECT - III
C/3
00
C
4-1 O
O O C
Q.O
S-i CO
3 C C CO
CO
CO
en
SJ
en
O
o
CO CO
4-1 CO
c
CL 3
CO -Q
>
JS CO
3952
-------
SECONDARY NICKEL SUBCATEGORY
SECT - III
i.) Slag Reclaim
H20
Slag or Dross
S malting
Furnace
Mechanical
Granulation
i
Mineral
Jig
' • Tailings
to Pond
Nickel Concencrace
1 Product
ii) Acid Reclaim
Spent Acids
Waste Treatment
Sludge
Pickling Wastes
Evaporate
H20
Nickel
Carbonate *
pH
Adjustment
Filter
1
r
H?0
Open
Hearth
Furnace
Nicke.
Oxide
L "
Leaching
Recycle
Solids
t
Soda Ash
~
Sickel Forming
Uastewacer
<4
Leaching
Filtrate
-------
SECONDARY NICKEL SUBCATEGORY
SECT - III
g
«J
t-f «
0 4=
u
l-i CO
(U -H
iJ Q
cn
z
^
^J
_
M^
«) ?«
5 >-t o£
-•
I—I g^
0) Z
^ O
00 td
•H cn
tL,
o
en
CJ
S
o
M
3=
i
o
o
Sd
O
3954
-------
SECONDARY NICKEL SUBCATEGORY SECT - IV
i SECTION IV
SUBCATEGORI ZATION
This section summarizes the factors considered durinq the
designation of the subdivision of the secondary nickel
subcategory. Production normalizing parameters for each
subdivision are also discussed. : .• * eacn
FACTORS CONSIDERED IN SUBDIVIDING THE SECONDARY NICKEL
SUBCATEGORY ~~ - ; - : — --- : -- --
S2i ffct°rs listed for 'general ' sub-categorization were each
evaluated when considering subdivision of the secondary nickel
subcategory. In the discussion that follows, the factors will be
described as they pertain to this particular subcategory.
The rationale for considering segmentation of the secondary
nickel subcategory is based primarily on differences in the
production processes and raw materials used. Within this
subcategory,- a number of different operations are performed,
™S?r5a?hSr'?li;yK??tKhaV? a *ater use or discharge, and which may
require the establishment of separate effluent limitations. While
secondary nickel is considered a single subcategory, a more
thorough examination of the production processes has illustrated
the need for limitations arid standards based on a specific set of
waste streams. Limitations will be based on specific flow
allowances for the following subdivisions:
1. Slag reclaim tailings,
2. Acid reclaim leaching filtrate, and
3. Acid reclaim leaching belt filter backwash.
These subdivisions follow directly from differences between the '
processing steps of secondary nickel production. Slag reclaim
and acid reclaim both have various steps which generate
W3S t GWcl t G IT • -• -
Slag reclamation establishes the need for the first subdivision
slag reclaim tailings. After crushing and milling the nickel
rich slag, a nickel concentrate is separated from impurities with
a wet mineral jig. This produces a tailings waste stream which
is discharged.
Acid reclamation establishes the need for the second and third
subdivisions -- acid reclairj! leaching filtrate, and acid reclaim
leaching belt filter backwash. Spent pickling acids and
wastewater treatment sludges are added to a tank containing soda
ash in order to precipitate nickel as nickel carbonate. After
filtration, the precipitate ; is slurried with water and roasted in
an ope.ni hearth furnace in order to oxidize the nickel. The nickel
oxide is leached with water to remove impurities and then
filtered on a belt- filter. The acid reclaim leaching filtrate is
discharged as a waste stream. The belt filter is backwashed with
3955
-------
SECONDARY NICKEL SUBCATEGORY SECT - IV
water, and the backwash water is also discharged as a waste
stream.
OTHER FACTORS
The other factors considere^in this evaluation wereshow^to^be
--ass-SB
subcategory. :
PRODUCTION NORMALIZING PARAMETERS
discharge of specific pollutant PJ^JJJ various production
regulations to be aPP^fJ ^o ?1 JJ^s with va re?ated to a
capacities, the mass of P?1J;U|*£ ? is known as the production
' fo^the three subdivisions
PNP
slag input to reclaim
process
acid reclaim nickel
produced
acid reclaim nickel
produced
are as follows:
Subdivision
i
1. Slag reclaim tailings ;
2. Acid reclaim leaching filtrate
3. Acid reclaim leaching belt filter
backwash
ne
th ene»
concluded that the generation of slag
is more closely related to
reclaim process.
o the
for slag
of slag inpu?
reclaim
reclaim
to the
3956
-------
SECONDARY NICKEL SUBCATEGORY SECT - V
' SECTION V
I
WATER USE AND 'WASTEWATER CHARACTERISTICS
This section describes the characteristics of the wastewaters
associated with the secondary nickel subcategory. Water use and
discharge rates are explained and then summarized in tables at
the end of this section. Data used to characterize the
wastewaters are presented. Finally, the specific source, water
use and discharge flows, and wastewater characteristics for each
separate wastewater source are discussed.
The two principal data sources used in the development of
effluent limitations and standards for this subcategory are data
collection portfolios and field sampling results. Data
collection portfolios contain information regarding wastewater
flows and production levelis.
In order to quantify the pollutant discharge from secondary
nickel plants, a field sampling program was conducted. A
complete list of the pollutants considered and a summary of the
techniques used in the sampling and laboratory analyses are
included in. Section V of Vol. I. Samples were analyzed for 124 of
the 126 priority pollutants and other pollutants deemed
appropriate. Because the analytical standard for TCDD was judged
to be too hazardous to be made generally available, samples were
never analyzed for this pollutant, samples were also not analyzed
for asbestos. There is no, reason to expect that TCDD or asbestos
would be present in nonferrous metals manufacturing wastewater.
One plant was selected for sampling in the secondary nickel
subcategory. In general, the samples were analyzed for three
classes of pollutants: toxic organic pollutants, toxic metal
pollutants. and criteria pollutants (which includes both
conventional and nonconventional pollutants).
No additional sampling data for this subcategory were obtained
from EPA sampling efforts|or industry comments between proposal
and promulgation. Characterization of secondary nickel
subcategory wastewaters (Section V), and selection of pollutant
parameters for limitation (Section VI) has been based on the same
data used at proposal. '
As described in Section IV of this supplement, the secondary
nickel subcategory has been divided into three subdivisions, so
that the promulgated regulation contains mass discharge
limitations and standards for three unit processes discharging
process wastewater. Differences in the wastewater
characteristics associated with these subdivisions are to be
expected. For this reason, wastewater streams corresponding to
each subdivision are addressed separately in the discussions that
follow. These wastewater sources are:
3957
-------
SECONDARY NICKEL SUBCATEGORY SECT - V
1. Slag reclaim tailings,
2. Acid reclaim leaching filtrate, and
3. Acid reclaim leaching belt filter backwash.
WASTEWATER FLOW RATES
Data supplied by dcp responses were evaluated, and two flow-to-
productioS ratios were calculated for each stream. The two
iratios, water use and .wastewater discharge flow, are
differentiated by the flow value used in calculation. Water use
is defined as the volume of water required for a given Process
per mass of nickel product and is therefore based on the sum of
?ecycle and make-up flows to a given process. Wastewater flow
discharged after pretreatment or recycle (if these are Present)
is used in calculating the production normalized flow -- the
volume of wastewater discharged from a given process to farther
treatment, disposal, or discharge per mass of nickel produced.
Differences between the water use and wastewater flows associated
with a given stream result from recycle, evaporation, and
carry-ove? on the product. The production values used in
calculation correspond to the production normalizing parameter,
PNP, assigned to each stream, as outlined in Section IV. As, an
example, acid reclaim leaching filtrate wastewater flow is
related to acid reclaim nickel production As such, the
discharge rate is expressed in liters of leaching fiJ-V"^
wastewater discharged per metric ton of acid reclaim nickel
production.
The production normalized flows were compiled and_ statistically
analyzed by stream type. These production normalized water use
and discharge flows are presented by subdivision in Tables V-l
throuqh V-3 (pages 3962 -396;4). Where appropriate, an attempt was
made to identify factors that could account for variations in
water use. This information is summarized in this section. A
similar analysis of factors affecting the wastewater values is
presented ^Sections XI arid XII where representative NSPS and
pretreatment discharge flows' are selected for use in calculating
the effluent limitations and standards.
WASTEWATER CHARACTERISTICS DATA
Data used to characterize the various wastewaters associated with
secondary nickel production come from two sources --data
collection portfolios and .analytical data from field sampling
trips.
DATA COLLECTION PORTFOLIOS :
In the data collection portfolios,, plants were asked to indicate
whether or not any of the priority pollutants were present in
their effluent. The one discharging plant indicated that most
toxic organic pollutants were believed to be absent from their
effluent. The plant indicated that a few of the priority organic
pollu^nts are believed to be present in its effluent The plant
stated that some of the priority metals were known to be present
3958
-------
SECONDARY NICKEL SUBCATEGORY SECT - V
in their effluent. The! responses for the toxic metals are
summarized below. ;
Pollutant
Known Present
Believed Present
Antimony
Arsenic
Beryllium
Cadmium
Chromium
Copper
Lead ;
Mercury
Nickel
Selenium
Silver
Thallium
Zinc
FIELD SAMPLING DATA
0
0
0
0
1
1
0
0
1
0
0
0
1
0
0
0
0
1
1
0
0
1
0
0
0
1
In order to quantify the concentrations of pollutants present in
wastewater from secondary nickel plants, wastewater samples were
collected at one plant. A diagram indicating the sampling sites
and contributing production processes is shown in Piqure V-l
(Page 3974). ^
The sampling data for the secondary nickel subcategory are
presented in Tables V-4 through V-7 (pages 3965 - 3972) The
stream codes displayed in Tables V.4 through V-7 may be used to
identify the location of each of the samples on process flow
diagrams in Figure V.I. Where no data are listed for a specific
day of sampling, the wastewater samples for the stream were not
collected. - ;
The detection limits shown on the data tables are not the same in
all cases as the published .detection limits for these pollutants
by the same analytical methods. The detection limits used were
reported with the analytical data and hence are the appropriate
limits to apply to the data. Detection limit variation can occur
as a result of a number! of laboratory-specific, equipment-
specific, and daily operator-specific factors. These factors can
include day-to-day differences in machine calibration, variation
in stock solutions, and variation in operators.
The statistical analysis of data includes some samples measured
at concentrations considered not quantifiable. Priority metal
and conventional and nonconventional pollutant values reported as
less than a certain value were considered as not quantifiable and
a value of zero is used in the calculation of the average.
Appropriate source water concentrations are presented with the
summaries of the sampling data. The method by which each sample
was collected is indicated by number, as follows:
3959
-------
SECONDARY NICKEL |SUBCATEGORY SECT - V
2 - Sanua^composite during intermittent process operation
3 - 8-hour manual composite
4 - 8-hour automatic composite
5 - 24-hour manual composite
6-24 hour automatic composite
WASTEWATER CHARACTERISTICS AND FLOWS BY SUBDIVISION
discussed.
SLAG RECLAIM TAILINGS
Nickel is recovered from ;dross or slag generated in nickel
discharge rates are presented in Table V-l (Page 3962).
effluent is presented in Table V-5 (page 3967).
ACID RECLAIM LEACHING FILTRATE
(page 3963).
sampling data for acid j--^^"""^.^.*"1^™ is
o resfortreatable concentrations of
caracee o
chromium, copper, nickel, and suspended solids.
ACID RECLAIM LEACHING BELT FILTER BACKWASH
3960
-------
SECONDARY NICKEL SUBCATEGORY SECT - V
generating this waste stream, and its water use and discharge
rates are presented in Tattle V-3 (page 3964). *><-n«arge
of
3961
-------
SECONDARY NICKEL SUBCATEGORY SECT - V
I
: TABLE V-l
WATER USE AND DISCHARGED RATES FOR SLAG RECLAIM TAILINGS
(1/kkg of slag input to reclaim process)
Plant
Code
1169
Percent Recycle
or Reuse
Production
Normalized
Water Use Flow
12,848
Production
Normalized
Discharge Flow
12,848
3962
-------
SECONDARY NICKEL SUBCATEGORY SECT - V
i TABLE V-2
WATER USE AND DISCHARGE RATES FOR
ACID RECLAIM LEACHING FILTRATE
i ' --....
(1/kkg of acid reclaim nickel produced)
Plant Percent Recycle
Code or Reuse
1169 0
Production
Normalized
Water Use Flow
4,995
Production
Normalized
Discharge Flow
4,995
3963
-------
SECONDARY NICKEL :SUBCATEGORY SECT - V
TABLE V-3
WATER USE AND DISCHARGE RATES FOR
ACID RECLAIM LEACHING BELT FILTER BACKWASH
(1/kkg of acid reclaim nickel produced)
Plant Percent Recycle
Code or Reuse
1169 0
Production
Normalized
Water Use Flow
1,199
Production
Normalized
Discharge Flow
1,199
3964
-------
SECOJ&EIARY NICKEL SUBCATEGORY SECT - V
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3965
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SECONDARY NICKEL SUBCATEGORY SECT - V
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3966
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SECONDARY NICKEL SUBCATEGORY
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3967
-------
SECONDARY NICKEL SUBCATEGORY
SECT - V
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3969
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SECONDARY NICKEL SUBCATEGORY SECT - V
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3970
-------
SECONDARY, NICKEL SUBCATEGORY
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SECONDARY NICKEL SUBCATEGORY
SECT - V
Source
River
«acer
Slag
Reclaim
Tailings
Acid
Reclaim
Leaching
Filtrate
tailings
Pond
"X9 "'*» Discharge
"129 * Discharge
Acid
Reclaim
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Fllcar
Backwash
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Figure V-l
SAMPLING SITES AT SECONDARY NICKEL PLANT A
3973
-------
SECONDARY NICKEL SUBCATEGORY SECT - V
THIS PAGE INTENTIONALLY LEFT BLANK
3974
-------
SECONDARY NICKEL SUBCATEGORY SECT - VI
SECTION VI
i -
SELECTION OF POLLUTANTS
This section examines chemical analysis presented in Section V
and discusses the selection or exclusion of priority pollutants
for potential limitation;. Conventional and nonconventional
pollutants are selected or excluded for regulation in this
section. The basis for the selection of toxic and other
pollutants, along with a discussion of each pollutant selected
for potential limitation, is discussed in Section VI of Vol. I.
That discussion provides information about the nature of the
pollutant (i.e., whether it is a naturally occurring substance,
processed metal, or a manufactured compound), general physical
properties and the form of the pollutant, toxic effects of the
pollutants in humans and other animals, and behavior of the
pollutant in POTW at the concentrations expected in industrial
discharges.
i •
The discussion that follows describes the analysis that was
performed to select or exclude priority pollutants for further
consideration for limitations and standards. The data from three
wastewater samples collected at one nickel plant were considered
in this analysis. All : samples are raw wastewater samples
collected on one day at one of the plants. Pollutants will be
selected for further consideration if they are present in
concentrations treatable by the technologies considered in this
analysis. In Sections IX 'through XII, a final selection of the
pollutants to be limited will be made, based on relative factors.
CONVENTIONAL AND NONCONVENTIONAL POLLUTANT PARAMETERS SELECTED
. - i •
This study examine'd samples from secondary nickel plants for
conventional pollutant parameters (oil and grease, total
suspended solids, and pH) . The conventional and nonconventional
pollutants or pollutant parameters selected for limitation in
this subcategory are:
total suspended solids (TSS)
' '
Total suspended solids (TSS) concentrations in the three samples
ranged from 350 mg/1 to 16,000 mg/1. All of the observed
concentrations are above the 2.6 mg/1 concentration considered
achievable by identified treatment technology. Furthermore, most
of the technologies used to remove toxic metals do so by
converting these metals to precipitates. A limitation on total
suspended solids ensures that sedimentation to remove
precipitated toxic metals is effectively operating. For these
reasons, total suspended solids is a pollutant parameter selected
for limitation in this subcategory.
The pH values observed ranged from, 6.6 to 11.4. Effective
3975
-------
SECONDARY NICKEL SUBCATEGORY SECT - VI
removal of toxic metals by precipitation requires careful control
of pH. Therefore pH is selected for limitation in this
subcategory
TOXIC PRIORITY POLLUTANTS
II —I- '•— I I ,— II.IH— — [
The frequency of occurrence of the toxic pollutants in the
wastewater samples considered in this analysis ^presented in
Table VI-1 (Page 3978). These data provide the basis for the
cateqorization of specific pollutants, as discussed below. Table
categorization o^ ^ ^ w*stewater sampling data from streams
986. 004. and 005. Stream 987 was sampled after settling and was
not used in the frequency count.
TOXIC POLLUTANTS NEVER DETECTED
The toxic pollutants listed in table VI-2 (page 3979) were not
Selected in any raw wastewater samples from this subcategory;
therefore, they are not selected for consideration in
establishing limitations:
TOXIC POLLUTANTS NEVER FOUND ABOVE THEIR ANALYTICAL
QUANTIFICATION CONCENTRATION
The nrioritv pollutants listed below were never found above their
SSlytiSS quantification concentration in any wastewater samples
from this subcategory; therefore, they are not selected for
consideration in establishing effluent limitations and standards.
114.
117.
118.
121.
122.
123.
125.
126.
127.
antimony
beryllium
cadmium
cyanide
lead
mercury
selenium
silver
thallium
TOXIC POLLUTANTS SELECTED FOR FURTHER CONSIDERATION IN
ESTABLISHING LIMITATIONS AND STANDARDS
The toxic pollutants selected for further consideration in
es?abl?2hingP limitations and standards for this subcategory are
listed below:
115. arsenic
119. chromium '
120. copper ;
124. nickel
128. zinc
was detected above its treatable concentration (0.34
in one of three samples. The quantifiable concentrations
3976
-------
SECONDARY NICKEL SUBCATEGORY SECT - VI
ranged from 0.013 mg/1 to 0.93 mg/1. Since arsenic was present
in concentrations exceeding the concentration achievable by
identified treatment technology, it is selected for consideration
for limitation.
Chromium was detected above its treatable concentration (0.07
mg/1) in three of three samples. The quantifiable concentrations
ranged from 0.88 mg/1 to 5.35 mg/1. Since chromium was present
in concentrations exceeding the concentration achievable by
identified treatment technology, it is selected for consideration
for limitation.
Copper was detected above its treatable concentration (0.39 mg/1)
in three of three samples. The quantifiable concentrations
ranged from 0.59 mg/1 to 60 mg/1. Since copper was present in
concentrations exceeding the concentration achievable by
identified treatment technology, it is selected for consideration
for limitation. ;
Nickel was detected above its treatable concentration (0.22 mg/1)
in three of three samples The quantifiable concentrations
ranged from 7.5 mg/1 to 96 mg/1. Since nickel was present in
concentrations exceeding1 the concentration achievable by
identified treatment technology, it is selected for consideration
for limitation.
Zinc was detected above its treatable concentration (0.23 mg/1)
in One of three samples. The quantifiable concentrations ranged
from 0.12 mg/1 to 0.26 mg/1. Since zinc was present in
concentrations exceeding the concentration achievable by
identified treatment technology, it is selected for consideration
for limitation.
3977
-------
SECONDARY NICKEL. SUBCATEGORY
P
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SECT - VI
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3978
-------
SECONDARY NICKEL SUBCATEGORY SECT - VI
; TABLE VI-2
TOXIC POLLUTANTS NEVER DETECTED
1. acenaphthene*
2. acrolein*
3. acrylonitrile*
4. benzene*
5. benzedine*
6. carbon tetrachloride (tetrachloromethane)*
7. chlorobenzene*
8. 1,2,4-thrichlorobenzene*
9. hexachlorobenzene*
10. 1,2,-dichloroethane*
11. 1,1,1,-thrichloroethane*
12. hexachloroethane*
13. 1,1-dichloroethane*
14. 1,1,2-thrichloroethane*
15. 1,1,2-tetrachloroethane*
16. chloroethane*
17. bis (chloromethyl) ether (deleted)*
18. bis (2-chloroethyl) ether*
19. 2-chlordethyl vinyl ether (mixed)*
20. 2-chloronaphthalene*
21. 2,4,6-trichlorophenol*
22. para-chloro meta-cresol*
23. chloroform (trichloromethane)*
24. 2-chlorophenol*
25. 1,2-dichlorobenzene*
26. 1,3-dichlorobenzene*
27. 1,4-dichlorobenzene*
28. 3/3-dichlorobenzidine*
29. 1,1-dichloroethylene*
30. 1,2-trans-dichloroethylene*
31. 2,4-dichlorophenol*
32. 1,2-dichloropropane*
33. 1,3-dichloropropylene (1,3-dichloropropene)*
34. 2,4-dime:rhylphenol*
35. 2,4-dinitrotoluene*
36. 2,6-dinitrotoluene*
37. 1,2-diphenylhydrazine* ,
38. ethylbenzene*
39. fluoranrhene*
40. 4-chlorophenyl phenyl ether*
41. 4^bromophenyl phenyl ether*
42. bis (2-chloroisopropyl) ether*
43. bis (2-chloroethoxy) methane*
44 methylene chloride (dichloromethane)*
45. methyl chloride (chloromethane)*
46. methyl bromide (bromomethane)* :
47. bromoform (tribromomethahe)*
48. dichlorobromomethane*
49. trichlorofluoromethane (deleted)*
3979
-------
SECONDARY NICKEL SUBCATEGORY SECT - VI
50.
51.
52.
53.
54.
55.
56,
57.
58.
59.
60.
61.
62.
63.
64.
65.
66.
67.
68.
69.
70.
71.
72.
73.
74.
75.
76.
77.
7 ft
79!
80.
81.
82.
83.
84.
85.
86.
87.
88.
89.
90.
91.
92.
93.
94.
95.
96.
97.
98.
99.
TABLE VI-2 (Continued)
TOXIC POLLUTANTS NEVER DETECTED
dichlorodifluoromethane (deleted)*
chlorodibromomerliane*
hexachlorobutadijene*
hexachlorocyclopenradiene*
isophorone*
naphthalene*
nitrobenzene*
2-nitrophenol*
4-nitrophenol*
2,4-dinitrophenol*
4,5-dinirro-o-cresol*
N-nitrosodimethylamine*
N-nitrosodiphenylamine*
N-nitrosodi-n-propylamine*
pentachlorophenol*
phenol*
bis (2-ethylhexyl) phthalate*
buryl benzyl phthalate*
di-n-butyl phthalate*
di-n-octyl phthalate*
diethyl phthalate*
dimethyl phthalare*
benzo (a) anthracene (1, 2-benzanthracene) *
benzo (a) pyrene (3,4-benzopyrene) *
3,4-benzofluoranthene*
benzo (k) f luoranthene*
chrysene*
acenaphthylene*
benzo (ghi) perylene (1,12-benzoperylene)*
fluorene* '
phenanthrene* ;
dibenzo (a,h) anthracene (1,2 5,o-dibenzanthracene) *
ideno (1,2,3-cd) pyrene ( 2, 3,-o-phenylenepyrene) *
pyrene* ;
tetrachloroethylene*
roluene. j
trichloroethylehe*
vinyl chloride (chloroethylene) *
aldrin*
dieldrin*
chlordan'e (technical mixture and metabclites) *
4, 4 '-DDT*
4,4'-DDE (p,p'DDX)*
4,4'-DDD (pfp'TDE)*
Alpha-endosulfah*
Beta-endosulfan*
endosulfan sulfate*
endrin* \
endrin aldehyde!*
3980
-------
SECONDARY NICKEL SUBCATEGORY SECT - VI
i
TABLE VI-2 (Continued)
TOXIC POLLUTANTS NEVER DETECTED
100.
101.
102.
103.
104.
105.
106.
107.
108.
109.
110.
111.
112.
113.
116.
129.
heptachlor*
heptachlor epoxide*
Alpha-8HC*
Beta-BHC*
Gamma-BHC (lindane)*
Delta-BHC*
PCB-1242 (Arochlor
(Arochlor
(Arochlor
(Arochlor 1232)*
(Arochlor 1248)*
(Arochlor
(Arochlor
1242)*
1254)*
1221)*
FCB-1254
PCB. 12-21
PCB-1232
PCB-1248
PCB-1260
PCB-1016
toxaphene*
asbestos
2,3,7,8-tetrachlorodibenzo-p-dioxin (TCDD)
1260)*
1016)*
*The Agency did not analyze for these pollutants in samples of
raw wastewater from this subcategory. These pollutants are not
believed to be present based on the Agency's best engineering
judgment which includes consideration of raw materials and
process operations.
3981
-------
SECONDARY NICKEL SUBCATEGORY SECT - VI
THIS PAGE INTENTIONALLY LEFT BLANK
3982
-------
SECONDARY NICKEL SUBCATEGORY
SECT - VII
' SECTION VII
CONTROL AND TREATMENT TECHNOLOGIES
The preceding sections of this supplement discussed the sources,
flows, and characteristics of the wastewaters from secondary
nickel plants. This section summarizes the description of these
wastewaters and indicates; the treatment technologies which are
currently practiced in the-secondary nickel subcategory for each
waste stream. Secondly, this section presents the control and
treatment technology options which were examined by the Agency
for possible application to the secondary nickel subcategory.
CURRENT CONTROL AND TREATMENT PRACTICES
This section presents a summary of the control and treatment
technologies that are currently being applied to each of the
sources generating wastewater in this subcategory. As discussed
in Section V, wastewater;associated with the secondary nickel
subcategory is characterized by the presence of the toxic metal
pollutants and suspended solids. This analysis is supported by
the raw (untreated) wastewater data presented for specific
sources as well as combined waste streams in Section V.
Generally, these pollutants are present in each of the waste
streams at concentrations above treatability, and these waste
streams are commonly combined for treatment. Construction of one
wastewater treatment system for combined treatment allows plants
to take advantage of economic scale and in some instances to
combine streams of different alkalinity to reduce treatment
chemical requirements. The one discharging plant in this
subcategory currently has a combined wastewater treatment system
treating nickel forming and acid reclaim wastewater, consisting
of lime precipitation and sedimentation. Two options have been
selected for consideration for NSPS and pretreatment based on
combined treatment of these compatible waste streams.
SLAG RECLAIM TAILINGS "
Slag or dross from a nickel smelting furnace may be reclaimed for
its nickel values with a wet granulation operation. The tailings
generated by this operation are discharged to a railings pond
where solids are settled. The tailings pond overflows and
discharges to a POTW. The tailings pond acts as a primary
settling unit, and no additional treatment is performed on this
wastewater. One plant has 'this waste stream and treatment. The
raw waste is characterized :by toxic metals and suspended solids.
ACID RECLAIM LEACHING FILTRATE .
After nickel , is: precipitated from spent pickling acids with
sodium carbonate and roasted to produce nickel oxide, the nickel
oxide is leached with water to remove impurities and then
dewatered on a belt filter. One plant discharges the resultant
leaching filtrate without treatment to a POTW.
3983
-------
SECONDARY NICKEL SUBCATEGORY SECT - VII
ACID RECLAIM LEACHING BELT FILTER BACKWASH
In the acid reclaim process, rafter the dewatered nickel oxide is
scraped from the belt filter, the filter is backwashed with
water. The resultant backwash water is treated as a combined
waste stream along with nickel forming wastewaters in a lime
precipitation and sedimentation system prior to discharge.
Recycle is not practiced on I these three wastewater streams and
all are indirectly discharged. All have toxic metals and
suspended solids above treatable concentrations.
CONTROL AND TREATMENT OPTIONS
The Agency examined two control and treatment technology options
that are applicable to the!secondary nickel subcategory. The
options selected for evaluation represent a combination of
preliminary treatment technologies applicable fc° Jndl^u*l ^e
Streams and end-of-pipe treatment technologies. The effectiveness
of these technologies is presented in Section VII of the General
Development Document.
OPTION A
Option A for the secondary nickel subcategory requires control
and treatment technologies to reduce the discharge of wastewater
pollutant mass.
The Option A treatment scheme consists of chemical precipitation
and sedimentation technology. Specifically, lime or some other
chemical is used to precipitate metal ions as metal hydroxides.
Ste Setal hydroxide? and suspended solids settle out and the
sludge is collected. Vacuum filtration is used to dewater
sludge.
Slag reclaim and acid reclaim wastewaters are treated separately
because of economic considerations.
OPTION C
Option C for the secondary nickel subcategory consists of ^all
control and treatment requirements of Option A (chemical
precipitation and sedimentation, separate treatment of slag and
Icid reclaim wastewater) plus multimedia filtration technology
added at the end of the OptJion A treatment scheme. Multimedia
filtration is used to remove suspended solids including
precipitates of metals, beyond the concentration attainable by
gravity sedimentation. The filter suggested is of the gravity,
mixed-media type, although other forms of filters, such as rapid
sand filters or pressure filters would perform satisfactorily
The addition of filters also provides consistent removal during
periods of time in which there are rapid increases in flows or
loadings of pollutants to the treatment system.
3984
-------
SECONDARY NICKEL SUBCATEGORY SECT - VIII
;SECTION VIII
COSTS, ENERGY, AND NONWATER QUALITY ASPECTS
This section presents a summary of compliance costs for the
secondary nickel subcategbry and a description of the treatment
options and subcategory-specific assumptions used to develop
these estimates. Together with the estimated pollutant reduction
performance presented in Sections XI and XII of this supplement,
these cost estimates provide a basis for evaluating each
regulatory option. These cost estimates are also used in
determining the probable economic impact of regulation on the
subcategory at different pollutant discharge levels. m
addition, this section addresses nonwater quality environmental
impacts of wastewater treatment and control alternatives
including air pollution, solid wastes, and energy requirements!
which are specific to the secondary nickel subcategory?
TREATMENT OPTIONS FOR EXISTING SOURCES
As discussed in Section VII, two treatment options have been
developed for existing secondary nickel sources. The treatment
schemes for each option are summarized below and schematically
presented in Figures Xl-l and XI-2 (pages 4002 - 4003)
OPTION A
Option A consists of chemical precipitation and sedimentation
end-of-pipe technology. Slag reclaim tailings is treated
separately from acid reclaim wastewater.
OPTION C
=o^£n C.0011313^ of Option A (chemical precipitation and
sedimentation, and separate treatment of slag and acid reclaim
wastewater with the addition of multimedia filtration to the end
of the Option A treatment scheme.
COST METHODOLOGY
Plant-by-plant compliance costs for the nonferrous metals
manufacturing category have been revised following proposal
because of new flow and production data for slag reclaim
wastewater received through industry comments. These revisions
calculate incremental costs, above treatment already in place
necessary to comply with the promulgated effluent limitations and
standards and are presented in the administrative record
supporting this regulation. A comparison of the costs developed
tor proposal and the revised costs for the final regulation are
SKSKr-2 'n .Hable V^II~1
-------
SECONDARY NICKEL SUBCATEGORY SECT - VIII
the
weighting the integrate^' treatment costs.
to recycle this stream without success.
'SLhed^u-sln^Su ?uric aSfafthe P-cipitant rather
?han limSdue to the high PH of the influent (PH 11).
NONWATER QUALITY ASPECTS '
metals category is
Development Document. Nonwater
secondary nickel subcategory, -..- ---. . _•, "
solid waste and air pollution are discussed below.
ENERGY REQUIREMENTS
The methodology used for
kwh/yr for Options A and^C, ^f^iveiy. ^ (UP electrical energy
energy
have
t £IS ^ ^ c»ci ^*m^ iii* ^'f ** "** '*"' """^ i . i
impact on total plant energy consumption.
SOLID WASTE
wastes under
3001 of the
3986
-------
SECONDARY NICKEL SUBCATEGORY SECT - VIII
Resource Conservation and Recovery Act. The one exception to
this is solid wastes generated by cyanide precipitation. These
sludges are expected to be hazardous and this judgment was
included in this study.. None of the non-cyanide wastes are
listed specifically as hazardous. Nor are they likely to exhibit
a characteristic of hazardous waste. This judgment is made based
Pn the recommended technology of lime precipitation and
filtration. By the addition of a small excess of lime during
treatment, similar sludges, specifically toxic metal bearing
sludges, generated by other industries such as the iron and steel
industry passed the Extraction Procedure (EP) toxicity test. See
40 CFR $261.24. Thus, the Agency believes that the wastewater
sludges will similarly hot be EP toxic if the recommended
technology is applied.
i
Although it is the Agency's view that solid wastes generated as a
result of these guidelines are not expected to be hazardous,
generators of these wastes must test the waste to determine if
the wastes meet any of the characteristics of hazardous waste
(see 40 CFR $262.11). ;
If these wastes identified should be or are listed as hazardous,
they will come within the scope of RCRA's "cradle to grave"
hazardous waste management;program, requiring regulation from the
point of generation to :point of final disposition. EPA's
generator standards would require generators of hazardous
nonferrous metals manufacturing wastes to meet containerization,
labeling, recordkeeping, and reporting requirements; if plants
dispose of hazardous wastes off-site, they would have to prepare
a manifest which would track the movement of the wastes from the
generator's premises to a permitted off-site treatment, storage,
or disposal facility. See 40 CFR $262.20 [45 FR 33142 (May 19,
1980), as amended at 45 FR 86973 (December 31, 1980)]. The
transporter regulations require transporters of hazardous waste
to comply with the manifest system to assure that the wastes are
delivered to a permitted;facility. See 40 CFR $263.20 [45 FR
33151 (May 19, 1980), as amended at 45 FR 86973 (December 31,
1980)]. Finally, RCRA regulations establish standards for
hazardous waste treatment, storage, and disposal facilities
allowed to receive such wastes. See 40 CFR Part 464 [46 FR 2802
(January 12, 1981), 47 FR 32274 (July 26, 1982)].
Even if these wastes are not identified as hazardous, they still
must be disposed of in compliance with the Subtitle D open
dumping standards, implementing S4004 of RCRA. See 44 FR 53438
(September 13, 1979). The Agency has calculated as part of the
costs for wastewater treatment the cost of hauling and disposing
of these wastes. !
The Agency estimates that the promulgated PSES regulation for
secondary nickel manufacturing facilities will generate 423
metric tons of solid waste's (wet basis) in 1982 as a result of
wastewater treatment.
! . , ..
AIR POLLUTION ;
3987
-------
SECONDARY NICKEL &UBCATEGORY SECT - VIII
There is no reason to believe that any substantial air pollution
problems will result ftom implementation of chemical
precipitation, sedimentation, and multimedia filtration. These
technologies transfer pollutants to solid waste
likely to transfer pollutants to air.
and are not
3988
-------
SECONDARY NICKEL SUBCATEGORY
SECT - VIII
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3989
-------
SECONDARY NICKEL SUBCATEGORY SECT - X
THIS PAGE INTENTIONALLY LEFT BLANK
3992
-------
SECONDARY NICKEL SUBCATEGORY SECT - XI
: SECTION XI
NEW SOURCE PERFORMANCE STANDARDS
This section describes the technologies for treatment of
wastewater from new sources and presents mass discharge standards
for regulated pollutants for NSPS in the secondary nickel
subcategory, based on the selected treatment technology. The
basis for new source performance standards (NSPS) is the best
available demonstrated" technology (BDT). New plants have the
opportunity to design the best and most efficient production
processes and wastewater treatment technologies without facing
the added costs and restrictions encountered in retrofitting an
existing plant. Therefore, EPA has considered the best
demonstrated process changes, in-plant controls, and end-of-pipe
treatment technologies Which reduce pollution to the maximum
extent feasible.
TECHNICAL APPROACH TO NSPS
New source performance standards are based on the most effective
and beneficial technologies currently available. The Agency
reviewed and evaluated a wide range of technology options for new
sources. The Agency elected to examine two technology options.
applied to combined wastewater streams, which could be applied to
the secondary nickel subcategory as alternatives for the basis of
NSPS.
Treatment technologies considered for the NSPS options are
summarized below:
OPTION A (Figure XI-1, page 4000) is based on:
Chemical precipitation and sedimentation
Separate treatment of slag reclaim tailings wastewater
OPTION C (Figure XI-2, page 4001) is based on:
Chemical precipitation and sedimentation
Multimedia filtration
Separate treatment of slag reclaim tailings wastewater
As explained in Section IV, the secondary nickel subcategory has
been subdivided into three potential wastewater sources or
building blocks. Since .the water use. discharge rates, and
pollutant characteristics of each of these wastewaters is
potentially unique, effluent limitations will be developed for
each of the three subdivisions.
For each of the building blocks a specific approach was followed
for the development of NSPS. The first requirement to calculate
these limitations is to; account for production and flow
3993
-------
SECONDARY NICKEL SUBCATEGORY SECT - XI
variability from plant to plant. Therefore, a unit of production
or production normalizing parameter (PNP) was determined for each
waste stream which could then be related to the flow from the
process to determine a production normalized flow. Selection of
the PNP for each process element is discussed in Section IV. Eacn
plant within the subcategory was then analyzed to determine which
subdivisions were present, specific flow rates generated for each
subdivision, and the specific production normalized flows for
each subdivision. This analysis is discussed in detail in
Section V. Nonprocess wastewater such as rainfall runort and
noncontact cooling water is riot considered in the analysis.
Production normalized flows for each subdivision were analyzed to
determine which flow was to be used as part of the basis £or
NSPS The selected flow (sometimes referred to as a NSPS
regulatory flow or NSPS discharge flow) reflected the water ^use
controls which are common practice within the industry, The NSPS
normalized flow is based on the average of all applicable data.
Nothing was found to indicate that the wastewater flows and
characteristics of new plants would not be similar to those from
existing plants, since the processes used by new sources are not
expected to differ from those used at existing sources.
The second requirement to calculate new source performance
standards is the set of concentrations that are achievable by
application of NSPS level treatment technology. Section VII
discusses the various control and treatment technologies which
are currently in place for each wastewater source. In most cases,
the current control and treatment technologies consist oi:
chemical precipitation andi sedimentation (lime and settle)
technology.
Using theses regulatory flows and the achievable concentrations,
the next step is to calculate mass loadings for each wastewater
source by subdivision or building block. This calculation was
made on a stream by stream basis primarily because plants in this
subcategory may perform one or more of the operations in various
combinations. The mass loadings (milligrams of pollutant per
metric ton — mg/kkg) were; calculated by multiplying the NSPS
regulatory flow (1/kkg) by the concentration achievable by the
NSPS level of treatment technology (mg/1) for each pollutant
parameter limited under NSPS- These mass loadings are published
in the Federal Register and; in 40 CFR part 421 as the effluent
limitations. ;
The mass loadings which are allowed under NSPS for each plant
will be the sum of the individual mass loadings for the various
wastewater sources which are found at particular plants.
Accordingly, all the wastewater generated within a plant may be
combined for treatment in a single or common treatment system,
but the effluent limitations for these combined wastewaters_ are
based on the various wastewater sources which actually contribute
to the combined flow. This method accounts for the variety of
combinations of wastewater. sources and production processes which
may be found at secondary nickel plants.
3994
-------
SECONDARY NICKEL SUBCATEGORY SECT - XI
The Agency usually establishes wastewater limitations in terms of
mass _rather than concentration. This approach prevents the use
ot dilution as a treatment method (except for controlling pH)
The production normalized wastewater flow (1/kkg) is a link
between the production operations and the effluent limitations.
The pollutant discharge attributable to each operation can be
calculated from the normalized flow and effluent concentration
achievable by the treatment technology and summed to derive an
appropriate limitation for each subcategory.
PpLLUTANT REMOVAL ESTIMATES
As one means of evaluating each technology option, EPA developed
estimates of the pollutant removal and the compliance costs
associated with each option. Since there are no existing direct
dischargers in the secondary nickel subcategory/ the estimated
pollutant removal analysis was only carried out for indirect
dischargers. '
A complete description,of the methodology used to calculate the
estimated pollutant rembyal, or benefit, achieved by the
application of the various treatment options is presented in
Section X of Vol. I. Sampling data collected during the field
sampling program were used to characterize the major waste
streams considered for regulation. At each sampled facility, the
sampling data was production normalized for each unit operation
(i.e., mass of pollutant generated per mass of product
manufactured). This value, referred to as the raw waste, was
used to estimate the mass of toxic pollutants generated within
the secondary nickel subcategory. The pollutant removal
estimates were calculated for each plant by first estimating the
total mass of each pollutant in the untreated wastewater. This
was calculated by first multiplying the raw waste values by the
corresponding production value for that stream and then summing
these values for each pollutant for every stream generated by the
plant. :
The volume of wastewater discharged after the application of each
treatment option was estimated for each operation at each plant
by comparing the actual discharge to the regulatory flow. The
smaller of the two values was selected and summed with the other
plant flows. The mass of pollutant discharged was then estimated
by multiplying the achievable concentration values attainable
with the option , (ing/1) :by the estimated volume of process
wastewater discharged by the subcategory. The mass of pollutant
removed is the difference between the estimated mass of pollutant
generated within the subcategory and the mass of. pollutant
discharged after application of the treatment option. The
pollutant removal estimates for indirect dischargers in the
secondary nickel subcategory have been revised since proposal
based on new flow and production data and are presented in Table
XII-1 (Page 4009).' '
3995
-------
SECONDARY NICKEL SUBCATEGORY
SECT - XI
COMPLIANCE COSTS -
Tnlst costsPwere Led in assessing economic achievabllity.
NSPS OPTION SELECTION - PROPOSAL
fSr s?ag reclli^tailings wa'stewater because it was not found to
be cost effective.
S.-SLJSS:
the waste streams
generated
s:
this
onid«ed feasible for
subcategory.
NSPS OPTION SELECTION - PROMULGATION
lime
technology.
s assssg
SSSTJS:
5
3996
-------
SECONDARY NICKEL S0BCATEGORY SECT - XI
equal to PSES, we believe that the promulgated NSPS will not have
a detrimental impact on the entry of new plants into this
subcategory.
WASTEWATER DISCHARGE RATES:
A NSPS discharge rate is calculated for each subdivision based on
the average of the flows of the existing plants, as determined
from analysis of dcp. :The discharge rate is used with the
achievable treatment concentrations to determine NSPS effluent
limitations. Since the discharge rate may be different for each
wastewater source, separate production normalized discharge rates
for each of the three wastewater sources are discussed below and
summarized in Table XI - l:(Page 4002). The discharge rates are
normalized on a production basis by relating the amount of
wastewater generated to the mass of the product which is produced
by the process associated with the wastewater stream in question.
These production normalizing parameters, or PNPs, are also listed
in Table XI - 1. ;
Section V of this document further describes the discharge flow
rates and presents water use and discharge flow rates for each
plant by subdivision in Tables V - 1 through V - 3 (Pages 3962 -
*i y o 4 j • !
SLAG RECLAIM TAILINGS
NSPS wastewater discharge allowance at proposal for slag reclaim
tailings was 85,600 1/kkg (20,513 gal/ton) of slag reclaim nickel
produced. The NSPS allowances were based on the discharge rate
at the only plant reporting this stream. Since proposal, industry
comments which included flow and production information enabled
EPA to recalculate the production normalized flow. In addition,
industry comments prompted EPA to reconsider the production
normalizing parameter for this stream. Based on the new
information submitted, EPA concluded that the generation of slag
reclaim tailings wastewater is related more closely to raw
material input, to the reclaim process than to the quantity of
nickel produced from the process.
The NSPS wastewater discharge allowance used at promulgation for
slag reclaim tailings is 12,848 1/kkg (3,079 gal/ton) of slag
input to the reclaim process. This rate is allocated only for
those plants that reclaim: nickel from slag generated in melt
furnaces with a wet granulation process. The water use and
wastewater discharge rates are presented in Table V - 1 (Page
j y D £» j •
ACID RECLAIM LEACHING FILTRATE
The NSPS wastewater discharge allowance used for both proposal
and promulgation for acid reclaim leaching filtrate is 4,995
1/kkg (1,197 gal/ton) of acid reclaim nickel produced. This rate
is_allocated only for those;plants that reclaim nickel from spent
acids, pickling wastes, and wastewater treatment sludges by
3997
-------
SECONDARY NICKEL SUBCATEGORY SECT - XI
nrecipitation or nickel carbonate, followed by roasting to
police nickel oxide and leaching with water. The water use and
wastewater discharge rates are presented in Table V - 2 (Page
3963). I
ACID RECLAIM LEACHING BELT FJLTER BACKWASH
ule and wastewater discharg^ rates are presented in Table V - 3
(Page 3964) .
REGULATED POLLUTANT PARAMETERS
The raw wastewater concentrations form individual °Pe"£ions and
^o
under NSPS and are listed below:
119. chromium !
120. copper
124. nickel
TSS
pH
The Agency has chosen not to regulate all five priority
po?lutan?syselected in Section VI for further consideration.
The high cost associated' with analysis for priority metal
snecific effluent mass limitations and standards for eacn or cne
Siority metals found above treatable concentrations in the raw
was?ewater from a given subcategory, the Agency is promulgating
effluent mass limitations oKly for those pollutants generated in
the SreatSIt quantities ks* shown by the pollutant removal
analysis. \
BV establishing limitations and standards for certain priority
directly limited.
3998
-------
SECONDARY NICKEL SUBCATEGORY SECT -r XI
multiple metals removal. Thus, even though metals have somewhat
different theoretical solubilities, they will be removed at very
nearly the same, rate, in a chemical precipitation and
sedimentation treatment system operated for multiple metals
removal.
NEW SOURCE PERFORMANCE STANDARDS
The pollutant concentrations achievable by application of the
NSPS technology are discussed in Section VII of this supplement.
These achievable concentrations (both one day maximum and monthly
average values) are multiplied by the NSPS normalized discharge
flows summarized in Table XI-1 (Page 4000) to calculate the mass
of pollutants allowed to be discharged per mass of product. The
results of these calculations in milligrams of pollutant per
kilogram of product represent the new source performance
standards and are presented in Table XI-2 (Page 4001) for each
individual building block.'
3999
-------
SECONDARY NICKEL SUBCATEGORY SECT - XI
TABLE XI-1
NSPS WASTEWATER DISCHARGE RATES FOR THE
SECONDARY NICKEL SUBCATEGORY
Building Block
Slag Reclaim Tailings
Acid reclaim Leaching
Filtrate
Acid Reclaim Leaching
Belt Filter Backwash
NSPS Normalized
'Discharge Rate
(1/kkg) (gal/ton)
12,848
4,995
l
1,199
3,079
1,197
287
Production
Normalizing
Parameter
slag input to
reclaim process
acid reclaim
nickel produced
acid reclaim
nickel produced
4000
-------
SECONDARY NICKEL SUBCATEGORY SECT - XI
TABLE XI-2
NSPS FOR THE SECONDARY NICKEL SUBCATEGORY
(a) Slag Reclaim Tailings : NSPS
Pollutant orMaximum forMaximum for
pollutant property any one day monthly average
mg/kg (Ib/million Ibs) of slag input to reclaim process
Arsenic 26.850 11.950
*Chromium 5.653 2.313
*Copper ' 24.410 12.850
*Nickel 24.670 16.320
Zinc 18.760 7.837
*TSS 526.800 250.500
*pH Within the range of 7.5 to 10.0 at all times
(b) Acid Reclaim Leaching Filtrate NSPS
Pollutant orMaximum forMaximum for
pollutant property any one day monthly average
mg/kg (Ib/million Ibs) of acid reclaim nickel produced
Arsenic ' 10.440 4.645
*Chromium 2.198 0.899
*Copper 9.491 4.995
*Nickel ' 9.590 6.344
Zinc 7.293 3.047
*TSS ; 204.800 97.400
*pH Within the range of 7.5 to 10.0 at all times
(c) Acid Reclaim Leaching Belt Filter Backwash NSPS
Pollutant orMaximum forMaximum for
pollutant property any one day monthly average
mg/kg (Ib/million Ibs) of acid reclaim nickel produced
Arsenic 2.506 1.115
*Chromium ; 0.528 0.216
*Copper 2.278 1.199
*Nickel 2.302 1.523
Zinc 1.751 0.731
*TSS 49.160 23.380
*pH Within the range of 7.5 to 10.0 at all times
*Regulated Pollutant
4001
-------
SECONDARY NICKEL SUBCATEGORY
SECT - XI
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SECONDARY NICKEL SUBCATEGORY
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4003
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SECONDARY NICKEL;SUBCATEGORY
SECT - XI
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4004
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SECONDARY NICKEL SUBCATEGORY SECT - XII
:SECTION XII
!
PRETREATMENT STANDARDS
This section describes the control and treatment technologies for
pretreatment of process wastewaters from existing sources and new
sources in the secondary nickel subcategory. PSES are designed
to prevent the discharge of pollutants which pass through,
interfere with, or are otherwise incompatible with the operation
of publicly owned treatment works (POTW). The Clean Water Act
requires pretreatment for pollutants, such as toxic metals, that
limit POTW sludge management alternatives. New indirect
discharge facilities, like new direct discharge facilities, have
the opportunity to incorporate the best available demonstrated
technologies, including process changes, in-plant controls, and
end-of-pipe treatment technologies, and to use plant site
selection to ensure adequate treatment system installation.
Pretreatment standards are to be technology based, analogous to
the best available or best demonstrated technology for removal of
toxic pollutants.
Pretreatment standards for regulated pollutants are presented
based on the selected control and treatment technology.
TECHNICAL APPROACH TO PRETREATMENT
Before proposing or promulgating pretreatment standards, the
Agency examines whether the pollutants discharged by the industry
pass through the POTW or interfere with the POTW operation or its
chosen sludge disposal practices. In determining whether
pollutants pass through a well-operated POTW achieving secondary
treatment, the Agency compares the percentage of a pollutant
removed by POTW with the percentage removed by direct dischargers
applying the best available; technology economically achievable. A
pollutant is deemed to pass through the POTW when the average
percentage removed nationwide by well-operated POTW meeting
secondary treatment requirements, is less than the percentage
removed by direct dischargers complying with BAT effluent
limitations guidelines for that pollutant.
This definition of pass through satisfies two competing
objectives set by Congress that standards for indirect
dischargers be equivalent to standards for direct dischargers,
while at the same time, the treatment capability and performance
of the POTW be recognized and taken into account in regulating
the discharge of pollutants; from indirect dischargers.
The Agency compares percentage removal rather than the mass or
concentration of pollutants discharged because the latter would
not take into account the mass of pollutants discharged to the
POTW from non-industrial sources or the dilution of the
pollutants in the POTW effluent to lower concentrations due to
the addition of large amounts of non-industrial wastewater.
4005
-------
SECONDARY NICKEL SUBCATEGORY SECT - XII
INDUSTRY COST AND POLLUTANT REMOVAL ESTIMATES
The industry cost and pollutant removal estimates of each
treatment option were used to determine the most cost-effective
option. The methodology applied in calculating pollutant removal
estimates and plant compliance costs is discussed in Section XI.
The compliance costs and pollutant removal estimates have been
recalculated since proposal based on new flow and production data
for the slag reclaim tailings stream obtained through industry
comments. Table XII-1 (Page 4009) shows the revised *?"? £f
removal estimates for indirect dischargers. A Comparison of
proposal and promulgatiob compliance costs for indirect
dischargers is presented in Table XII-2 (Page 4010).
PRETREATMENT STANDARDS FOR EXISTING AND NEW SOURCES
Options for pretreatment of wastewaters from both existing and
new sources are based on increasing the effectiveness of end-of-
pipe treatment technologies. All in-plant changes and applicable
end-of-pipe treatment processes have been discussed previously in
Section XI. The options fo'r PSNS and PSES, therefore, are ^the
slme as the NSPS options discussed^in Section XI. A description
of each option is presented |in Section XI.
Treatment technologies considered for the PSES and PSNS options
are:
OPTION A
o
o
Chemical precipitation and sedimentation
Separate treatment of slag reclaim tailings wastewater
OPTION C
o Chemical precipitation and sedimentation
o Multimedia filtration • . ' t
o Separate treatment of slag reclaim tailings wastewater
PSES OPTION SELECTION PROPOSAL
EPA proposed PSES for the secondary nickel subcategory based on
Option C (chemical precipitation, sedimentation, and multimedia
filtration). Filtration was proposed for acid reclaim leaching
filtrate and acid reclaim leaching filter backwash wastewaters,
but not for slag reclaim failings wastewater. Filtration for
slag reclaim tailings wastewater was not found to be cost
effective. ;
Implementation of the proposed PSES limitations was estimated to
remove 1?113 kilograms of toxic metal pollutants annually.
clpital and annual costs of $286,549 and $119,616 (1982 dollars),
respectively, were estimated in order to achieve the proposed
PSES. i
4006
-------
SECONDARY NICKEL SUBCATEGORY
SECT •-.XII
PSES OPTION SELECTION - PROMULGATION
EPA is promulgating PSES for this subcategory based on Option A,
chemical precipitation and sedimentation. Filtration was not
found to be cost effective for any subdivisions in .this
subcategory because it would not remove much additional pollutant
beyond that removed with lime and settle treatment. The
pollutants specifically regulated under PSES are chromium,
copper, and nickel. The toxic pollutants arsenic and zinc were
also considered for regulation because they are present at
treatable concentrations in the raw" wastewaters from this
subcategory. These pollutants were not selected for specific
regulation because they will be effectively controlled when the
regulated toxic metals are treated to the levels achievable by
the model technology. We are promulgating PSES to prevent • pass-
through of chromium, copper, and nickel. These priority
pollutants are_removed by a well-operated POTW at an average of
32 percent while PSES technology removes approximately 84
percent.
Implementation of the promulgated PSES limitations will remove
annually an estimated 1,625 kg of priority metals. We estimate a
capital cost of $320,100 and an annualized cost of $161,200 (1982
dollars) to achieve the promulgated PSES. The promulgated PSES
will not result in adverse-economic impacts.
PSNS OPTION SELECTION - PROPOSAL
EPA proposed PSNS for the1secondary nickel subcategory based on
Option C (chemical precipitation, sedimentation, and multimedia
filtration). Filtration , was not proposed for slag reclaim
tailings wastewater, however, because it was not shown to be cost
effective for this waste stream.
Wastewater discharge rates for PSNS were proposed equivalent to
the PSES discharge rates.
PSNS OPTION SELECTION - PROMULGATION
EPA is promulgating PSNS equivalent to promulgated NSPS and PSES.
The same pollutants pass through at PSNS as at PSES, for the same
reasons. ;
The PSES flow allowances ;are based on minimization
wastewater wherever possible.
of process
The Agency believes that the promulgated PSNS are achievable, and
that they are not a barrier to entry of new plants into this
subcategory.
The wastewater discharge
discharge rates for each
are shown in Table XII-3 (:
rates
waste
for PSNS are identical to the NSPS
stream. The PSNS discharge rates
Table 4012).
4007
-------
SECONDARY NICKEL SUpCATEGORY SECT - XII
PRETREATMENT STANDARDS :
Pretreatment standards are based on the achievable concentrations
?rom ?hTselected treatment technology and the discharge rates
determined in Section XI for| NSPS and shown in Table XII-3. A
mis! o£ pollu?ant per mass of product (mg/kg) allo^^ont)yi^^?
for Pach subdivision within the subcategory. This pollutant
rom ^model
anf^SNS. SSSS and PSNS are presented in Table XII-4 and XII-5,
respectively (pages 4012 - 4013).
4008
-------
SECONDARY NICKEL SUBCATEGORY SECT - XII
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4009
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SECONDARY NICKEL|SUBCATEGORY SECT - XII
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4010
-------
SECONDARY NICKEL; SUBCATEGORY
SECT - XII
; TABLE XI1-3
PSES AND PSNS WASTEWATER DISCHARGE RATES FOR THE
SECONDARY NICKEL SUBCATEGORY
Wcistewater Stream
Slag Reclaim Tailings
Acicl reclaim Leaching
Filtrate
Acid Reclaim Leaching
Belt Filter Backwash
PSES and PSNS
Normalized
Discharge Rate
(1/kkg) (gal/ton)
12,848
4,995
1,199
3.079
1,197
287
Production
Normalizing
Parameter
slag input to
reclaim process
acid reclaim
nickel produced
acid reclaim
nickel produced
4011
-------
SECONDARY NICKEL SUBCATEGORY
SECT - XII
TABLE XI1-4
PSES FOR THE SECONDARY NICKEL SUBCATEGORY
(a) Slag Reclaim Tailings PSES
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of slag input to reclaim process
Arsenic
*Chromium
*Copper
*Nickel
Zinc
26.850
5.653
24.410
24.670
18.760
11.950
2.313
12.850
16.320
7.837
(b) Acid Reclaim Leaching Filtrate PSES
Pollutant or
pollutant property
Maxilnum for
any One day
Maximum for
monthly average
mg/kg (Ib/million Ibs), of acid reclaim nickel produced
Arsenic
*Chromium
*Copper
*Nickel
Zinc
10.440
2.198
9.491
9.590
7.293
4.645
0.899
4.995
6.344
3.047
(c) Acid Reclaim Leaching gelt Filter Backwash PSES
Pollutant or
pollutant property
Maximum for
any ;one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of acid reclaim nickel produced
Arsenic
*Chromium
*Copper
*Nickel
Zinc
2.506
0.528
2.278
2.302
1.751
1.115
0.216
1.199
1.523
0.731
*Regulated Pollutant
4012
-------
SECONDARY NICKEL SUBCATEGORY
SECT - XII
: TABLE XII-5
PSNS FOR THE SECONDARY NICKEL SUBCATEGORY
(a) Slag Reclaim Tailings PSNS
Pollutant or
pollutant property
Maximum for
any one day
Maximum for
monthly average
mg/kg (Ib/million Ibs) of slag input to reclaim process
Arsenic
*Chromium
*Copper
*Nickel
Zinc
26.850
5.653
24.410
24.670
18.760
11.950
2.313
12.850
16.320
7.837
(b) Acid Reclaim Leaching Filtrate PSNS
Pollutant or
pollutant property
Maximum for
any;one day
Maximum for
monthly average
(Ib/million Ibs) of acid reclaim nickel produced
Arsenic
*Chromium
*Copper
*Nickel
Zinc
10.440
2.198
9.491
9.590
7.293
4.645
0.899
4.995
6.344
3.047
(c) Acid Reclaim Leaching Belt Filter Backwash PSNS
Pollutant or
pollutant property
Maximum for
any ^one day
Maximum for
monthly average
(Ib/million Ibs) of acid reclaim nickel produced
Arsenic
*Chromium
*Copper
*Nickel
Zinc
2.506
0.528
2.278
2.302
1.751
1.115
0.216
1.199
1.523
0.731
*Regulated Pollutant
4013
-------
SECONDARY NICKEL SUBCATEGORY SECT - XII
THIS PAGE INTENTIONALLY LEFT BLANK
4014
-------
SECONDARY NICKEL SUBCATEGORY SECT - XIII
SECTION XIII
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY
EPA is not promulgating best conventional pollutant control for
the secondary nickel subcategory at this time.
4015
-------
SECONDARY NICKEL SUBCATEGORY SECT - XIII
THIS PAGE INTENTIONALLY LEFT BLANK
Pages 4017 and 4018 are omitted,
4016
-------
NONFERROUS METALS MANUFACTURING POINT SOURCE CATEGORY
DEVELOPMENT DOCUMENT SUPPLEMENT
for the
Secondary Tin Subcategory
William K. Reilly
Administrator
R|ebecca Hanmer
Acting Assistant Administrator for Water
Martha Prothro, Director
Office of Water Regulations and Standards
Thomas Pi. O'Farrell, Director
Industrial Technology Division
Ernst P. Hall, P.E., Chief
Metals Industry Branch
and
Technical Project Officer
May 1989
U.S. Environmental Protection Agency
Office of Water
Office of Water Regulations and Standards
Industrial Technology Division
Washington, D. C. 20460
4019
-------
4020
-------
Section
SECONDARY TIN SUBCATEGORY
TABLE OF CONTENTS
I
II
III
IV
V
SUMMARY 4029
CONCLUSIONS 4031
SUBCATEGORY PROFILE 4045
Description of Secondary Tin Production 4045
Raw Materials 4045
Tin Smelting : 4046
Alkaline Detinning 4046
Electrowihning 4047
Precipitation of Tin Hydroxide 4047
Reduction to Tin Metal 4047
Process Wastewater Sources 4948
Other Wastewater '• Sources 4048
Age, Production, and Process Profile 4048
SUBCATEGORIZATIQN 4055
Factors Considered in Subdividing the Secondary 4055
Tin Subcategory
Other Factors 4Q57
Production Normalizing Parameters 4057
WATER AND WASTEWATER CHARACTERISTICS 4059
Wastewater Flow Rates 4060
Wastewater Characteristics Data 4061
Data Collection Portfolios 406,1
Field Sampling Data 4062
Wastewater Characteristics and Flows by 4063
Subdivision
Tin Smelter SO2 Scrubber 4063
Dealuminizing Ririse 4063
Tin Mud Acid Neutralization Filtrate 4064
Tin Hydroxide Wash 4064
Spent Electrowinriing Solution From New Scrap 4064
Spent Electrowinning Solution From Municipal 4065
Solid Waste
Tin Hydroxide Supernatant From Scrap 4065
Tin Hydroxide Supernatant From Plating 4066
Solutions and Sludges
Tin Hydroxide Filtrate 4066
4Q21
-------
SECONDARY TIN SUBCATEGORY
TABLE OF CONTENTS (Continued)
Section
VI
VII
VIII
SELECTION OF POLLJCJTANT PARAMETERS
Conventional and ^lonconventional Pollutant
Parameters Selejcted
Toxic Priority Pollutants
Toxic Pollutants toever Detected
Toxic Pollutants Clever Found Above Their
Analytical Quantification Concentration
Toxic Pollutants jPresent Below Concentrations
Achievable by Treatment
Toxic Pollutants Detected in a Small Number
of Sources
Toxic Pollutants .Selected for Further
Consideration in Establishing Limitations and
Standards
CONTROL AND TREATMENT TECHNOLOGIES
I
Current Control and Treatment Practices
Tin Smelter SO2 Scrubber
Dealuminizing Rinse
Tin Mud Acid Neutralization Filtrate
Tin Hydroxide Wash .
Spent Electrowinning Solution From New Scrap
Spent Electrowinning Solution From Municipal
Solid Waste I
Tin Hydroxide Supernatant From Scrap
Tin Hydroxide Supernatant From Plating Solutions
and Sludges .!
Tin Hydroxide Filtrate
Control and Treatment Options
Option A r
Option C
COST OF WASTEWATER TREATMENT AND CONTROL
Treatment Options for Existing Sources
Option A
Option C. ;
Cost Methodologyi
Nonwater .QualityjAspects
Energy Requirements . . ;
Solid Waste
Air Pollution ,
Page
4215
4215
4217
4217
4217
4218
4218
4220
4229
4229
4229
4229
4230
4230
4230
4230
4231
4231
4231
4231
4231
4232
4233
4233
4233
4233
4234
4234
4235
4235
4236
4022
-------
SECONDARY TIN SUBCATEGORY
Section
IX
XI
TABLE OF CONTENTS (Continued)
BEST PRACTICABLE CONTROL TECHNOLOGY CURRENTLY
AVAILABLE
Technical Approach to BPT 4239
Industry Cost and Pollutant Removal Estimates 4241
BPT Option Selection 4241
Wastewater Discharge Rates 4242
Tin Smelter SO2 Scrubber 4242
Dealuminizing- Rinse 4243
Tin Mud Acid Neutralization Filtrate 4243
Tin Hydroxide Wash 4243
Spent Electrowinnihg Solution From New Scrap 4243
Spent Electrowinning Solution From Municipal 2444
Solid Waste
Tin Hydroxide Supernatant From Scrap 4244
Tin Hydroxide Supernatant From Plating Solutions 4244
and Sludges
Tin Hydroxide Filtrate 4245
Regulated Pollutant Parameters 4245
Effluent Limitations 4245
BEST AVAILABLE TECHNOLOGY ECONOMICALLY
ACHIEVABLE ,
Technical Approach to BAT
Option A
Option C
Industry Cost and Pollutant Removal Estimates
Pollutant Removal Estimates
Compliance Costs
BAT Option Selection - Proposal
BAT Option Selection - Promulgation
Wastewater Discharge Rates
Regulated Pollutant Parameters
Effluent Limitations
NEW SOURCE PERFORMANCE STANDARDS
Technical Approach to NSPS
NSPS Option Selection - Proposal
NSPS Option Selection - Promulgation
Regulated Pollutant Parameters
New Source Performance Standards
4259
4259
4260
4260
4260
4260
4261
4261
4262
4263
4263
4264
4281
4281
4282
4282
4282
4282
4023
-------
SECONDARY TIN SUBCATEGORY
TABLE OF CONTENTS (Continued)
Section
XII
XIII
PRETREATMENT STANDARDS
Technical Approach to Pretreatment
Industry Cost an4 Pollutant Removal Estimates
Pretreatment Standards for Existing and New
Sources
PSES and PSNS Option Selection
Regulated Pollutant Parameters
Pretreatment Standards
BEST CONVENTIONAL POLLUTANT CONTROL TECHNOLOGY 4317
Page
4293
4293
4293
4294
4294
4295
4295
4024
-------
SECONDARY TIN SUBCATEGORY
LIST OF TABLES
Table
III-l
III-2
III-3
V-l
V-2
V-3
V-4
V-5
V-6
V-7
V-8
V-9
V-10
V-ll
V-12
Title page
Initial Operating Year (Range) Summary of Plants 4049
in the Secondary Tin Subcategory By
Discharge Type
Production Ranges for Secondary Tin Plants 4050
for 1982
Summary of Secondary Tin Subcategory Processes 4051
and Associated Waste Streams
Water Use and Discharge Rates Tin Smelter SO2 4068
Scrubber
Water Use and Discharge Rates Dealuminizing 4068
Rinse
! . ' -
Water Use and Discharge Rates Tin Mud Acid 4068
Neutralization Filtrate
Use and Discharge Rates Tin Hydroxide Wash 4069
Water Use and Discharge Rates Spent , 4069
Electrowinning Solution From New Scrap
Water Use and Discharge Rates Spent 4069
Electrowinning Solution From Municipal
Solid Waste
Water Use and Discharge Rates Tin Hydroxide 4070
Supernatant From Scrap
Water Use and Discharge Rates Tin Hydroxide 4070
Supernatant From Plating Solutions and Sludges
Water Use and Discharge Rates Tin Hydroxide 4071
Filtrate
Scrubber Slowdown Raw Wastewater Sampling Data 4071
Spent Electrowinning Solution Raw Wastewater 4082
Sampling Data
Tin Hydroxide Precipitation Supernatant (From 4102
Scrap) Raw Wastewater Sampling Data
4025
-------
SECONDARY TIN SUBCATEGORY
LIST OF TABLES (Continued)
Table
V-13
V-14
V-15
V-16
V-17
V-18
V-19
V-20
V-21
V-22
V-23
VI-1
VI-2
VIII-1
Title
Tin Hydroxide Precipitation Supernatant (From
Spent Plating Solution and Sludges) Raw
Wastewater Sampling Data
Tin Hydroxide Filtrate Raw Wastewater Sampling
Data
Mud Pond Supernatant Raw Wastewater Sampling
Data :
Electrowinning Solution After Chlorination -
Plant C Treated VJJastewater Sampling Data
Electrowinning Solution After Chlorination and
Neutralization -!Plant C Treated Wastewater
Sampling Data
Electrowinning Solution After Chlorination,
Neutralization, and Sedimentation - Plant C
Treated Wastewater Sampling Data
Final Effluent -.Plant C Treated Wastewater
Sampling Data I
Electrowinning Solution After Carbonation -
Plant D Treated ^astewater Sampling Data
i
Influent to Treatment - Plant E Raw Wastewater
Sampling Data :
Treated Effluent - Plant E Treated Wastewater
Sampling Data
Secondary Tin Sampling Data, Raw Wastewater
from Self Sampling Data
Frequency of Occurrence of Priority Pollutants
Secondary Tin Subcategory Raw Wastewater
Toxic Pollutants; Never Detected
Cost of Compliance for the Secondary Tin
Subcategory Direct Dischargers
VIII-2 Cost of Compliance for the Secondary Tin
Subcategory Indirect Dischargers
Page
4113
4129
4140
4151
4161
4181
4181
4191
4201
4205
4209
4223
4227
4237
4237
4026
-------
SECONDARY TIN SDBCATEGORY
Table
IX--1
IX--2
X-l
X-2
X-3
X-4
XI-1
XI-2
XII-1
XII-2
XII-3
XII-4
XII-5
LIST OF TABLES (Continued)
Title
BPT Wastewater Discharge Rates for the
Secondary Tin Subcategory
BPT Mass Limitations for the Secondary Tin
Subcategory
Secondary Tin Subcategory Pollutant Removal
Estimates Direct Dischargers
Cost of Compliance for the Secondary Tin
Subcategory Direct Dischargers
BAT Wastewater Discharge Rates for the
Secondary Tin Subcategory
BAT Mass Limitations for the Secondary Tin
Subcategory
NSPS Wastewater Discharge Rates for the
Secondary Tin Subcategory
NSPS for the Secondary Tin Subcategory
Secondary Tin Subcategory Pollutant Removal
Estimates Indirect Dischargers
Cost of Compliance for the Secondary Tin
Subcategory indirect Dischargers
I
PSES and PSNS Wastewater Discharge Rates for the
Secondary Tin Subcategory
PSES for the Secondary Tin Subcategory
PSNS for the Secondary Tin Subcategory
Page
4247
4266
4268
4269
4283
4284
4296
4297
4298
4299
4308
4027
-------
SECONDARY TIN SUBGATEGORY
LIST OF FIGURES
Title
Figure
III-l Tin Smelting Production Process
III-2 Other Tin Production Processes
HI-3 Geographic Locations of the Secondary Tin
Subcategory Plants
V-l Sampling Sites at Secondary Tin Plant A
V-2 Sampling Sites at Secondary Tin Plant B
V-3 Sampling Sites at Secondary Tin Plant C
V-4 Sampling Sites at Secondary Tin Plant D
V-5 Sampling Sites at Secondary Tin Plant E
XI-1 BPT Treatment Scheme for Option A
s
X-l BAT Treatment Scheme for Option A
X-2 • BAT Treatment Scheme for Option C
Page
4052
4053
4054
4210
4211
4212
4213
4214
4257
4279
4280
4028
-------
SECONDARY TIjN SUBCATEGORY SECT - I
|
; SECTION i
SUMMARY
This document provides the technical basis for promulgating
effluent limitations based1 on best practicable technology (BPT)
and best available technology (BAT) for existing direct
dischargers, pretreatment standards for existing indirect
dischargers (PSES), pretreatment standards for new indirect
dischargers (PSNS), and standards of performance for new source
direct dischargers (NSPS).
The secondary tin subcategory consists of twelve plants. Of the
twelve plants, three discharge directly to rivers,
lakes, or streams; one discharges to a publicly owned
treatment works (POTW); and eight achieve zero discharge of
process wastewater. "';..,
EPA first studied the secondary tin subcategory to determine
whether differences in raw materials, final products,
manufacturing processes, ^equipment, age and size of plants, or
water usage, required the development of separate effluent
limitations and standards for different segments of the
subcategory. This involved a detailed analysis of wastewater
discharge and treated effluent characteristics, including the
sources and volume of water used, the processes used, the
sources of pollutants and wastewaters in the plant, and the
constituents of wastewaters, including toxic priority
pollutants. As a result, nine subdivisions or building blocks
have been identified for this subcategory that warrant
separate effluent limitations. These include:
(a) Tin smelter SO2 scrubber,
(b) Dealuminizirig rinse,
(c) Tin mud acid neutralization filtrate,
(d) Tin hydroxide wash, ;
(e) Spent electrowinning solution from new scrap,
(f) Spent electrowinning solution from municipal solid waste,
(g) Tin hydroxide supernatant from scrap,
(h) Tin hydroxide supernatant from plating solutions and sludqes
and
(i) Tin hydroxide filtrate*
EPA also identified several distinct control and treatment
technologies (both in-plant and end-of-pipe) applicable to the
secondary tin subcategory. The Agency analyzed both historical
and newly generated data on the performance of these
technologies, including their nonwater quality environmental
impacts and air quality, solid waste generation, and energy
requirements. EPA also studied various flow reduction techniques
reported in the data collection portfolios (dcp) and plant
visits*
4029
-------
SECONDARY TIN SUBCATEGORY SECT - I
.Engineering costs were prepared for each of the control and
treatment options consideredjfor the subcategory. These costs
wert then used by the Agency to estimate the impact of
implementing the various options on the subcategory. For each
control and treatment option that the Agency found to be most
effective and technically feasible in controlling the discharge
of pollutants, we estimated the number of potential closures,
numbe? of employees affected and impact on price. These results
Sre reported ina separate document entitled "The Economic Impact
Analysis of Effluent Limitations and Standards for the Nonferrous
Metals Manufacturing Industry."
After examining the various treatment technologies, the Agency
has identified BPT to represent the average of the best existing
technology. Metals removal based on chemical precipitation and
sedimentation technology is the basis for the BPT limitations.
Syanide precipitation wal selected as the basis for cyanide
limitations. To meet the BPT effluent limitations based on-this
technology"? the secondary tin subcategory is expected to^ incur
capital and annual costs.! However, these costs are not
presented here because the|y are based on information claimed to
be confidential. |
For BAT, the Agency has built upon the BPT technology basis by
adding filtration as a'n effluent polishing step to the
emi-of-pipe treatment scheme. To meet the BAT effluent
limitations based on this technology, the secondary tin
subcategory is estimated to incur capital and annual costs.
loweverT these costs are not presented here because the data on
which they are based has been claimed to be confidential.
NSPS, which are based on best demonstrated technology, are
equivalent to BAT. In selecting NSPS, EPA recognizes that new
plants have the opportunity to implement the best and most
efficient manufacturing processes and treatment technology.
However, the technology basis of BAT has been determined as the
best demonstrated technology for this subcategory.
The technology basis for PSES is equivalent to BAT. To meet the
preWelSent Standards for | existing sources the secondary
tin subcategory is estimated to incur a capital cost of $160,187
and In annual cost of $50,044. For PSNS, the Agency selected
end-of-pipe treatment and | in-process flow reduction control
techniques equivalent to NSPS.
The mass limitations'and ^tandards for BPT, BAT, NSPS, PSES and
PSNS are presented in Section II. .
4030
-------
SECONDARY TIN SUBCATEGORY
SECT - II
iSECTION II
CONCLUSIONS
EPA _ has divided the secondary tin subcategory into nine
subdivisions for the purpose of effluent limitations and
standards. These subdivisions are:
(a) Tin smelter SO2 scrubber,
(b) Dealuminizing rinse,.
(c) Tin mud acid neutralization filtrate,
(d) Tin hydroxide wash,
(e) Spent electrowinning solution from new scrap,
(f) Spent electrowinning solution from municipal solid waste,
(g) Tin hydroxide supernatant from scrap,
(h) Tin hydroxide supernatant from plating solutions and sludqes,
and ^
(i) Tin hydroxide filtrate.
BPT is promulgated based on the performance achievable by the
application of chemical precipitation and sedimentation (lime and
settle) technology, along with preliminary treatment consisting
of cyanide precipitation for selected waste streams. The
following BPT limitations are promulgated:
(a) Tin Smelter
Scrubber BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
(Ib/million Ibs) of crude tapped tin produced
Arsenic
Lead
Iron
Tin
TSS
pH
19.220
3.863
11.040
3.495
377.100
8.554
1.840
5.611
2.024
179.400
Within ,the range of 7.5 to 10.0 at all times
4031
-------
SECONDARY TIN SUBCATEGORY
SECT - II
(b) Dealuminizing Rinse BPT
Pollutant or
Pollutant Property
Maximum for
Any Oiie Day
Maximum for
Monthly Average
rug/kg (Ib/million Ibs) of dealuminxsed scrap proaucea
Lead
Cyanide (total)
Fluoride
Tin
TSS
pH
OiOlS
OiOlO
Ii225
0*013
1,435
0.007
0.004
0.700
0.008
0.683
Within the rknge of 7.5 to 10.0 at all times
(c) Tin Mud Acid Neutralization Filtrate BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum £or
Monthly Average
mg/kg (Ib/million Ibs) of neutralized dewaterea tin mud produced
Lead
Cyanide (total)
Fluoride
Tin
TSS
pH
2!.120
1;.464
176'.600
1.918
206!.900
1.009
0.606
100.400
1.110
98.420
Within the ra'nge of 7.5 to 10.0 at all times
(d) Tin Hydroxide Wash BPT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million,Ibs) of tin hydroxide wasnea
Lead
Cyanide (total)
Fluoride
Tin
TSS
pH
5.020
3.466
418.400
4.542
490.100
2.391
1.434
237.900
2.630
233.100
Within the range of 7.5 to 10.0 at all times
4032
-------
SECONDARY TIN 'SUBCATEGORY SECT - II
(e) Spent Electrowinning Solution from New Scrap BPT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
- mg/kg (Ib/million Ibs) of cathode tin produced
Lead , !7.056 3.360
Cyanide (total) 4.872 2.016
Fluoride 508.000 334.300
Tin 6.384 3.696
TSS 688.800 327.600
pH Within the range of 7.5 to 10.0 at all times
(f) Spent Electrowinning Solution from Municipal Solid
Waste BPT ;
Pollutant orMaximum forMaximum for
Pollutant Property Any pne Day Monthly Average
mg/kg (Ib/million Ibs) of MSW scrap used as raw material
Lead 0.050 0.024
Cyanide (total) ;0.035 0.014
Fluoride 4.165 2.368
Tin 0.045 0.026
TSS 4.879 2.321
pH Within the range of 7.5 to 10.0 at all times
(g) Tin Hydroxide Supernatant from Scrap BPT
Pollutant or Maxiinum for Maximum for
Pollutant Property Any One Day Monthly Average
mg/kg (Ib/million Ibs),of tin metal recovered from scrap
Lead 23.370 11.130
Cyanide (total) 16.140 6.677
Fluoride 1,947.000 1,107.000
Tin 21.140 12.240
TSS 2,281.000 1,085.000
pH Within the range of 7.5'to 10.0 at all times
4033
-------
SECONDARY TIN SUBCATEGORY SECT - II
(h) Tin Hydroxide Supernatarit from Plating
Solutions and Sludges BPT
I
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/kg (Ib/million Ibs); of tin metal recovered from
plating solutions and sludges
Lead 48.300 23.000
Cyanide (total) 33.350 I3'*°n°n
Fluoride 4,025.000 2,289.000
Tin 43.700 25.300
TSS 4,715.000 2,243.000
pH Within the range of 7.5 to 10.0 at all times
(i) Tin Hydroxide Filtrate BPT
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/kg (Ib/million Ibs) of tin metal produced
Lead 10.520 5.009
Cyanide (total) 7.263 3.005
Fluoride 876.500 498.400
Tin 9.517 5.510
TSS 1,027.000 488.400
pH Within the range of 7.5 to 10.0 at all times
BAT is promulgated based on the performance achievable by the
application of chemical precipitation, sedimentation, and
multimedia filtration (lime,: settle, and filter) technology along
with preliminary treatment consisting cyanide precipitation for
selected waste streams. The following BAT effluent limitations
are promulgated: ;
(a) Tin Smelter SO? Scrubber BAT
Pollutant or Maximufr for Maximum for
Pollutant Property Any One Day Monthly Average
mg/kg (Ib/million Ibsj) of crude tapped tin produced
Arsenic
Lead
Iron
Tin
12.790
2.575
11.040
3.495
5.703
1.196
5.611
2.024
4034
-------
SECONDARY TIN SUBCATEGORY
SECT - II
{b} Dealuminizing Rinse BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of dealuminized scrap produced
Lead
Cyanide (total)
Fluoride
Tin
iD.OlO
0.007
1.225
;0.013
0.005
0.0028
0.697
0.008
(c) Tin Mud Acid Neutralization Filtrate BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
(Ib/million Ibs) of neutralized dewatered tin
mud produced
Lead
Cyanide (total)
Fluoride
Tin
1.413
1.009
176.600
1.918
0.656
0.404
100.400
1.110
(d) Tin Hydroxide Wash BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million; Ibs) of tin hydroxide washed
Lead
Cyanide (total)
Fluoride
Tin
3-347
2.391
418.400
4.542
1.554
0.956
237.900
2.630
(e) Spent Electrowinning Solution from New Scrap BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of cathode tin produced
Lead
Cyanide (total)
Fluoride'
Tin
4.704
3.360
588.000
6.384
2.184
1.344
334.300
3.696
4035
-------
SECONDARY Tlft SUBCATEGORY
SECT - II
) Spent Electrowinning Solution from Municipal Solid
Waste BAT ' •
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibis) of MSW scrap used as raw material
Lead
Cyanide (total)
Fluoride
Tin
0.033
0.024
4.165
0.045
0.015
0.010
2.368
0.026
(9) Tin Hydroxide Supernatant from Scrap BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of tin metal recovered from scrap
Lead
Cyanide (total)
Fluoride
Tin
, 15.580
! 11.130
1>947.000
21.140
7.233
4.451
1,107.000
12.240
(h) Tin Hydroxide Supernatant from Plating
Solutions and Sludges BAT
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of tin metal recover
plating solutions and sludges
ed from
Lead
Cyanide (total)
Fluoride
Tin
32.200
23.000
4[,025.000
' 43.700
14.950
9.200
2,289.000
25.300
(i) Tin Hydroxide Filtrate BAT
Pollutant or
Pollutant Property
Maximum.for
A!ny One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of tin metal produced
Lead
Cyanide (total)
Fluoride
Tin
7.012
5.009
876.500
9.517
3.256
2.004
498.400
5.510
4036
-------
SECONDARY TIN SUBCATEGORY
SECT - II
NSPS are based on the performance achievable by the
application of chemical precipitation, sedimentation, and
multimedia filtration (lime, settle and filter) technology, along
with preliminary treatment;consisting of cyanide precipitation
for, selected waste streams,. The following effluent standards are
promulgated.for new sources:
(a) Tin Smelter SO? Scrubber NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg
Arsenic
Lead
Iron
Tin
TSS
pH
(Ib/million Ibs) of
12.790
2.575
11.040
3.495
138.000
Within the range of
crude tapped
• '." ..• . 5
1
5
2
110
7.5 to 10.0
tin produced
.703
.196
.611
.024
.400
at all times
(b) Dealuminizing Rinse NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs)of dealuminized scrap produced
Lead
Cyanide (total)
Fluoride
Tin
TSS
pH
0.010
0.007
1.225
0.013
0.525
0.005
0.003
0.697
0.008
0.420
Within the r|ange of 7.5 to 10.0 at all times
(c) Tin Mud Acid Neutralization Filtrate NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg(Ib/million Ibs) of neutralized dewatered tin
mud produced
Lead
Cyanide (total)
Fluoride
Tin
TSS
I. 413
1.009
176.600
1.918
75.710
0.656
0.404
100.400
1.110
60.560
pH
Within the range of 7.5 to 10.0 at all times
4037
-------
SECONDARY TJIN SUBCATEGORY
SECT - II
(d) Tin Hydroxide Wash NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of tin hydroxide washed
Lead
Cyanide (total)
Fluoride
Tin
TSS
pH
3.347
2.391
418.400
4.542
179.300
1.554
0.956
237.900
2.630
143.400
Within the range of 7.5 to 10.0 at all times
(e) Spent Electrowinning Solution from New Scrap NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of cathode tin produced
Lead
Cyanide (total)
Fluoride
Tin
TSS
PH
4.704
3.360
588.000
6.384
252.000
2.184
1.344
334.300
3.696
201.600
Within the range of 7.5 to 10.0 at all times
(f) spent Electrowinning Solution from Municipal Solid
Waste NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of MSW scrap used as raw material
Lead
Cyanide (total)
Fluoride
Tin
TSS
pH
0.033
0.024
4.165
0.045
1.785
0.015
0.001
2.368
0.026
1.428
Within the range of 7.5 to 10.0 at all times
4038
-------
SECONDARY TIN SUBCATEGORY
SECT - II
(g) Tin Hydroxide Supernatant from Scrap NSPS
Pollutant or
Pollutant Property
Maxijmum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of tin metal recovered from scrap
Lead
Cyanide (total)
Fluoride
Tin
TSS
pH
15.580
11.130
1,947.000
21.140
834.600
7.233
4.451
1,107.000
12.240
667.700
Within tire range of 7.5 to 10.0 at all times
(h) Tin Hydroxide Supernatant from Plating
Solutions and Sludges NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of tin metal recovered from
plating solutions and sludges
Lead
Cyanide (total)
Fluoride
Tin
TSS
PH
32.200
23.000
4,025.000
43.700
1,725.000
14.950
9.200
2,289.000
25.300
1,380.000
Within the range of 7.5 to 10.0 at all times
(i) Tin Hydroxide Filtrate NSPS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of tin metal produced
Lead
Cyanide (total)
Fluoride
Tin
TSS
pH
7.012
5.009
876.500
9.517
375.700
3.256
2.004
498.400
5.510
300.500
Within the range of 7.5 to 10.0 at all times
PSES_ are promulgated based on the performance achievable by the
application of chemical , precipitation, sedimentation, and
multimedia filtration (lime, settle and filter) technology, along
with preliminary treatment consisting of cyanide precipitation
for selected waste streams. The following pretreatment standards
are promulgated for existing sources:
4039
-------
SECONDARY TIN SUBCATEGORY
SECT - II
(a) Tin Smelter SO? Scrubber PSES
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (lb/million Ibs) of crude tapped tin produced
Arsenic
Lead
Iron
Tin
: 12.790
2.575
: 11.040
3.495
5.703
1.196
5.611
2.024
(b) Dealuminizing Rinse PSES
Pollutant orMaximum forMaximum for
Pollutant Property Any One Day Monthly Average
mg/kg (Ib/milliori Ibs) of dealuminized scrap produced
Lead
Cyanide (total)
Fluoride
Tin
0.010
0.007
1.225
0.013
0.005
0.003.
0.697
0.008
(c) Tin Mud Acid Neutralization Filtrate PSES
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/millicon Ibs) of neutralized dewatered tin
mud produced
Lead
Cyanide (total)
Fluoride
Tin
1.413
1.009
176.600
1.918
0.656
0.404
100.400
1.110
(d) Tin Hydroxide Wasfc PSES
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (lb/million Ibs) of tin hydroxide washed
Lead
Cyanide (total)
Fluoride
Tin
3.347
2.391
418.400
4.542
1.554
0.956
237.900
2.630
4040
-------
SECONDARY TIN SUBCATEGORY
SECT - II
(e) Spent Electrowinning Solution from New Scrap PSES
Pollutant or
Pollutant Property
Maximum for Maximum for
Any'One Day Monthly Average
mg/kg (Ib/million Ibs) of cathode tin produced
Lead
Cyanide (total)
Fluoride
Tin
:4.704
,3.360
588.000
6.384
2.184
1.344
334.300
3.696
(f) Spent Electrowinning:Solution from Municipal Solid
Waste PSES
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of-MSW scrap used as raw material
Lead
Cyanide (total)
Fluoride
Tin
0.033
0.024
4.165
;0.045
0.015
0.010
2.368
0.026
(g) Tin Hydroxide Supernatant from Scrap PSES
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of tin metal recovered from scrap
Lead
Cyanide (total)
Fluoride
Tin
15.580
11.130
1,947.000
2|1.140
7.233
4.451
1,107.000
12.240
(h) Tin Hydroxide Supernatant from Plating
Solutions and Sludges: PSES
Pollutant or
Pollutant,Property
Maximum for
Any One Day
Maximum for
Monthly Average.
(Ib/million Ibs) of tin metal recovered from
plating solutions and sludges
Lead
Cyanide (total)
Fluoride
Tin
32.200
23.000
4,025.000
43.700
.14.9.50
9.200
2,289.000
25.300
4041
-------
SECONDARY TIN SUBCATEGORY SECT - II
i
(i) Tin Hydroxide Filtrate PSES
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of tin| metal produced
Lead
Cyanide (total)
Fluoride
Tin
7.0J12
5.009
876.5;00
9. 5|17
3.256
2.004
498.400
5.510
PSNS are promulgated based on the performance achievable by
the application of chemical precipitation, sedimentation, and
multimedia filtration (lime, [settle and filter) technology, along
with preliminary treatment consisting of cyanide precipitation
for selected waste streams. The following pretreatment standards
are promulgated for new sourc.es.
f
(a) Tin Smelter SO? Scrubber PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of crude tapped tin produced
Arsenic
Lead
Iron
Tin
12.790
2.575
11.040
3.495
5.703
1.196
5.611
2.024
(b) Dealuminizing Rinse PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs)jof dealuminized scrap produced
Lead
Cyanide (total)
Fluoride
Tin
0.010
0.007
1.225
0.013
0.005
0.003
0.697
0.008
4042
-------
SECONDARY TIN SUBCATEGORY
SECT - II
(c) Tin Mud Acid Neutralization Filtrate PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of neutralized dewatered tin
imud produced
Lead
Cyanide (total)
Fluoride
Tin
1.413
1.009
176.600
1.918
0.656
0.404
100.400
1.110
d) Tin Hydroxide Wash PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/milliori Ibs) of tin hydroxide washed
Lead
Cyanide (total)
Fluoride
Tin
3.347
2.391
418.400
4.542
1.554
0.956
237.900
2.630
e) Spent Electrowinning Solution from New Scrap PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of cathode tin produced
Lead
Cyanide (total)
Fluoride
Tin
4.704
3.360
588.000
6.384
2.184
1.344
334.300
3.696
f) Spent Electrowinning Solution from Municipal Solid
Waste PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of MSW scrap used as
raw material
Lead
Cyanide (total)
Fluoride
Tin
0.033
0.024
4.165
0.045
0.015
0.010
2.368
0.026
4043
-------
SECONDARY TIN SUBCATEGORY
SECT - II
(g) Tin Hydroxide Supernatant from Scrap PSNS
Pollutant or
Pollutant Property
Maximtim for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of tin metal recovered from scrap
Lead
Cyanide (total)
Fluoride
Tin
15.580
11.130
1,947;.000
21.140
7.233
4.451
1,107.000
12.240
(h) Tin Hydroxide Supernatant from Plating
Solutions and Sludges : PSNS
Pollutant or
Pollutant Property
Maxiirium for
Any Qne Day
Maximum for
Monthly Average
mg/kg (Ib/million lt>s) of tin metal recovered from
plating solutions and sludges
Lead
Cyanide (total)
Fluoride
Tin
32.200
23.000
4,025.000
43.700
14.950
9.200
2,289.000
25.300
(i) Tin Hydroxide Filtrate PSNS
Pollutant or
Pollutant Property
Maximum for
Any One Day
Maximum for
Monthly Average
mg/kg (Ib/million Ibs) of tin metal produced
Lead
Cyanide (total)
Fluoride
Tin
7.012
5.009
876.500
9.517
3.256
2.004
498.400
5.510
EPA is not promulgating BCT for the secondary tin subcategory at
this time. i
4044
-------
SECONDARY TIN SUBCATEGORY SECT -III
SECTION III ••'..
SUBCATEGORY PROFILE
This section of the secondary tin supplement describes
the raw materials and processes used in the production of
secondary tin and presents a profile of the secondary tin
plants identified in this, study.
The largest total use of tin is in solders which are manufactured
from both primary tin and secondary tin. The low melting point
of tin (232°C) makes it ideal for this application. Tin plated
steel products represent the second largest use of tin. Only
primary tin is used for this application.
i '
Tin is also used in a number of alloys such as brass, bronze,
and white metal alloys including babbitt. White metal alloys
are low melting point alloys consisting primarily of tin or
lead. These alloys may also contain lesser amounts of copper,
zinc and antimony and are used primarily in bearings.
DESCRIPTION OF SECONDARY TIN PRODUCTION
Tin is produced by smelting tin concentrates with
limestone and coke. The ;crude tin is then electrolytically
refined and cast. The process is presented schematically in
Figure III-l (page 4052).
Tin may also be produced by smelting tin residues, particularly
detinners mud from secondary tin recovery operations. Most
secondary tin, however, is produced by dissolving tin from tin
plated steel scrap, and recovering the tin by electrowinning. Tin
may also be recovered from solution by precipitation of tin as
tin hydroxide, Sn(OH)4. A smaller amount of secondary tin is
recovered from tin plating sludges which are generated by tin
plated steel production operations. These secondary tin
production operations can be divided into four major operations:
alkaline detinning, electrowinning, tin hydroxide precipitation,
and reduction to tin metal. These operations are shown
schematically in Figure III-2 (page 4053).
RAW MATERIALS ;
Tin concentrates: used in tin production are imported from South
America and Malaysia. EPA considers these tin concentrates to be
secondary raw materials for the purpose of establishing effluent
limitations. There are no tin producing facilities in the United
States that manufacture tin from concentrates alone.
The other principal raw material for the secondary tin industry
is tin plated steel scrap. Virtually all of this scrap
comes from fabrication plants which produce cans and a variety of
; 4045
-------
SECONDARY TIN SUBCATEGORY
SECT - III
other tin plated steel products. Such scrap may include
punched sheets, rolls and bundles. One producer also reported
tin recovery from tin plated steel separated from municipal
solid waste. Two producers ; reported that they recovered tin
from spent tin electroplating solutions and plating sludges.
TIN SMELTING
There is currently one tin smelter in the United States. Tin
residues (and sometimes concentrates) are smelted in a kaldo
furnace with limestone, magnesium oxide, and coke at 2,000 to
2,400°P. When the tin content of the residual slag reaches 5 to 7
percent, pyrite is added to liberate additional tin as volatile
tin sulfide. The tin sulfide is contacted with atmospheric
oxygen which results in the generation of sulfur dioxide and tin
oxide particles which are captured in a baghouse and later
recycled to the furnace. Sulfur dioxide emissions from the
smelting furnace are controlled with a scrubber employing a
slurry of finely ground aragonite and water as the scrubbing
solution. Crude molten tin is periodically tapped from the
furnace, fire refined and cast into anodes. The anodes are
consumed in an electrolytic jrefining process and the purified tin
is cast into ingots.
ALKALINE DETINNING :
The first step in recovering tin from tin plated scrap is hot
alkaline detinning. Tin plated scrap is loaded into perforated
steel detinning baskets and placed in a detinning tank which
contains a solution of sodiiim hydroxide and sodium nitrate. The
solution is heated to neat the boiling point and the tin
dissolves into solution as sodium stannate,
Na2SnO3- The chemical react jlon is as follows:
9Sn
6NaN03
9Na2SnO3 • H2O
12NaOH
2NH3; + 2N2
9H2O
3H2O
The detinning cycle is complete after 4 to 12 hours. Scrap
containing aluminum is pretreated in a solution of sodium
hydroxide, in which the aluminum dissolves. After rinsing, the
dealuminized scrap is sent tp the detinning tanks.
i
There are two variations of the alkaline detinning process: the
saturated process and the unsaturated process. In the saturated
process, the sodium stannate solution is allowed to become
supersaturated and sodium stannate crystals precipitate from
solution. The sodium stannate is recovered from the solution in
a filter press and the solution is returned to the detinning
tanks. The sodium stannate filter cake may then be sold as a
product or redissolved in water for further processing or
electrowinning .
In the unsaturated process, the sodium stannate concentration in
the solution is kept below the saturation point and the solution
4046
-------
SECONDARY TIN SUBCATEGORY SECT - III
is pumped directly to further processing or electrowinning. In
both the saturated and the unsaturated process, the sodium
stannate solution is purified by adding sodium sulfide, Na2S or
sodium hydrosulfide, NaHS, to precipitate lead and other
metal impurities as insoluble metal sulfides. The precipitated
residue is called tin mud or detinners mud and is sold to tin
smelters.
Detinners mud may also include residues removed from the bottoms
of detinning tanks. This mud contains 3 to 5 percent tin and is
sold as a by-product to tin smelters. The tin mud is usually
rinsed to recover any soluble tin which may be present. The
rinse water is recycled to the detinning tanks. One producer
reported an acid neutralization step in which sulfuric acid is
added to the mud. The neutralized mud is then dewatered in a
filter press and sold as a by-product containing approximately
10 percent tin. ,
When the detinning cycle is complete, the detinned steel is
removed from the detinning tanks. The steel is then rinsed to
recover any tin solution which may be adhering to it, pressed or
baled, and sold as a product. The rinse water is recycled to the
detinning tanks to recover tin.
ELECTROWINNING
: -
The purified sodium stannate solution is sent to electrolytic
cells where pure tin metal is deposited onto cathodes. The tin
is then removed from the cathodes, melted and cast. The
electrowinning solution is then recycled to the detinning tanks.
A blowdown stream must periodically be discharged from the
electrowinning circuit in order to control the concentration of
aluminum, carbonates, and other impurities in the solution.
One producer reported the :use of tin hydroxide, Sn(OH)4, as a
raw material. The tin hydroxide is first washed with water
and then dissolved in a solution of sodium hydroxide. The
resultant sodium stannate solution is then purified and added to
the sodium stannate solution from alkaline detinning and
the combined solution enters the electrowinning tanks.
PRECIPITATION OF TIN HYDROXIDE
As an alternative to electrowinning, tin can be recovered from
solution as tin hydroxide, Sn(OH)4. Sulfuric acid is added to
lower the pH to 7 and sodium carbonate is then added to raise the
pH to 7.8. At this point tin hydroxide will precipitate from the
solution. The one plant which uses this process precipitates tin
from a solution which i;s a mixture of alkaline detinning
solution, spent, plating solution, and a solution generated by
dissolving tin electroplating sludge in water.
REDUCTION TO TIN METAL '
The tin hydroxide is dried and calcined in a furnace to produce
4047
-------
SECONDARY TIN SUBCATEGORY
SECT - III
tin dioxide, SnO2- The tin dioxide is then charged to a
reduction furnace with carbon where it is reduced to tin metal.
PROCESS WASTEWATER SOURCES :
Although a variety of processes are involved in secondary
tin production, the process.wastewater sources can be subdivided
as follows:
(a) Tin smelter SO2 scrubber,
(b) Dealuminizing rinse, ;
(c) Tin mud acid neutralization filtrate,
(d) Tin hydroxide wash,
(e) Spent electrowinning solution from new scrap,
(f) Spent electrowinning solution from municipal solid waste,
(g) Tin hydroxide supernatant from scrap,
(h) Tin hydroxide supernatant from plating solutions and sludges,
and
(i) Tin hydroxide filtrate.
OTHER WASTEWATER SOURCES
There may be other wasjte streams associated with the
secondary tin subcategory. These streams may include noncontact
cooling water, stormwater runoff, and maintenance and cleanup
water. These wastewater sjtreams are not considered as a
part of this rulemaking.j EPA believes that the flows and
pollutant loadings associated with these streams are
insignificant relative to th|e wastewater streams selected and
are best handled by the appropriate permit authority on
a case-by-case basis under authority of Section 403 of the
Clean Water Act.
AGE, PRODUCTION, AND PROCESS PROFILE
Table III-l (page 4049) s|hows the relative age and discharge
status of the secondary ; tin plants. The average plant
age is between 16 and 25 [years. All of the plants have been
built since 1940. Table ! III-2 (page 4050) shows the 1982
production for secondary tin. Eleven of the 12 secondary
tin plants have production levels less than 1,000 kkg/yr. One
tin producer has a production level between 1,000 and 5,000
kkg/yr.
Table III-3 (page 4051) provides a summary of the number of
plants with the various production processes and the number
of plants which-generate wastewater from each process.
Alkaline detinning is practiced by 10 of the 12 secondary tin
plants. Of these 10 plants, eight also practice electrowinning.
Figure III-3 (page 4054) shows the geographic locations of the
secondary tin facilities , in the United States by discharge
status.
4048
-------
SECONDARY TIN SUBCATEGORY
SECT— III
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1
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-------
SECONDARY TIN SUBCATEGORY
SECT - III
TAJBLE III-2
PRODUCTION RANGES FOR SECONDARY TIN PLANTS FOR 1982
Discharge
Tvoe
•*• Jr lrc
Direct
Indirect
Zero
Total
Production Range —
0-100 100-1000
* [*
1 0
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[
KKg/yr
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12
* Direct discharge production data ^ve been withheld because 'b!
information on which they are based has been claimed to be
confidential. |
4050
-------
SECONDARY.TIN SUBCATEGORY
SECT - III
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VH
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4051
-------
SECONDARY TIN SUBCATEGORY SECT - III
Tin Concentrates
and Residues
Coke
Limestone
Pyrite
Smelter
Gas
1
Crude
Tin
Fire
Refining
and
Anode
Casting
Alkaline
,Slurry
i
SO- Scrubber
Gas
Electrolytic Refining
T
Casting
Tin Ingots
Figure III-1
TIN SMELTING PRODUCTION PROCESS
4052
-------
SECONDARY TIN-SUBCATEGORY SECT - III
oo
•H
H
O
§
CM
8
u
t>
Q
O
t«
CM
H
EH
EH
O
4053
-------
SECONDARY TIN SUBCATEGORY
SECT - III
-------
SECONDARY TIN SUBCATEGORY
SECT - IV
; SECTION IV
SUBCATEGORIZATION
This section summarizes the factors considered during the
designation of the related subdivisions or building blocks
of the secondary tin subcategory. Following proposal/ the Agency
decided to revise the name:of this subcategory to Secondary Tin,
instead of Primary and Secondary Tin, to more accurately
reflect the nature of the raw materials used in this
subcategory. The same plants and operations that were included
in this Subcategory. at proposal are included for
promulgation.
FACTORS CONSIDERED IN SUBDIVIDING THE SECONDARY TIN
SUBCATEGORY
The factors listed for general subcategorization were each
evaluated when considering subdivision of the secondary
tin subcategory. In the discussion that follows, the factors
will be described as they pertain to this particular subcategory.
The rationale for considering segmentation of the
secondary tin subcategory ; is based primarily on differences in
the production processes and raw materials used. Within this
subcategory, a number of Different operations are performed,
which may or may not have a water use or discharge, and which may
require the establishment of separate effluent limitations.
While secondary tin is still considered a single
subcategory, a more thorough examination of the production
processes has illustrated the need for limitations and standards
based on a specific set of waste streams. Limitations will be
based on specific flow allowances for the following subdivisions:
(a) Tin smelter SO2 scrubber,
(b) Dealuminizing rinse,
(c) Tin mud acid neutralization filtrate,
(d) Tin hydroxide wash,
(e) Spent electrowinning solution from new scrap,
(f) Spent electrowinning solution from municipal solid waste,
(g) Tin hydroxide supernatant from scrap,
(h) Tin hydroxide supernatant from plating solutions and sludges,
and
(i) Tin hydroxide filtrate.
These subdivisions follow directly from differences within the
five production processes which may be used in the
production of secondary tin: tin smelting, alkaline detinning,
electrowinning, precipitation and reduction.
The smelting of tin gives rise to the first subdivision. The
control of sulfur dioxide emissions from smelter flue gases is
accomplished through the use of a wet alkaline scrubbing system.
Slowdown of scrubbing solution comprises the wastewater stream
4055
-------
SECONDARY TIN SUBCATEGORY
SECT - IV
associated with this subdivision.
Although alkaline detinning is a net consumer of water because of
evaporation losses, a number of wastewater streams may be
generated. When tin scrap containing aluminum is used, the scrap
is leached with a sodium hydroxide solution prior to entering the
detinning tanks. The aluminum dissolves in the caustic solution
and the scrap is then rinsed with water. The spent caustic
leaching solution and rinse ;water are discharged as a waste
stream.
Another wastewater stream associated with alkaline detinning is
tin mud acid neutralization filtrate. Tin mud may consist of
residues from the detinning tanks, precipitates formed when
sodium sulfide or sodium hydirosulfide is added to the sodium
stannate solution to precipitate base metal impurities, or a
combination of the two. This "detinners mud" typically contains
from 3 to 5 percent tin by weight. The mud is rinsed with fresh
water to recover soluble tinl compounds which are returned to the
detinning tanks. The rinsefr mud is filtered and eventually sold
to smelters. One producer neutralizes this mud with sulfuric
acid prior to dewatering ; in a pressure filter. The filtrate
cannot be returned to the I detinning tanks and is therefore
discharged as a waste stream. The mud has been upgraded to a
product that is approximately 10 percent tin.
Electrowinning is the principal means of recovering tin from the
sodium stannate solution which is generated in alkaline detinning
operations. One producer reported the use of tin hydroxide as an
additional raw material to the electrowinning solution. Prior_to
being dissolved in the sodium stannate solution the tin hydroxide
is washed with water to iremove impurities. The wash water is
then discharged as a wastewater stream. The most significant
wastewater stream associated with electrowinning is spent
electrowinning solution. The partially depleted sodium stannate
solution is recycled to the; detinning tanks where additional tin
is taken into solution. A b;leed stream is required, however, in
order to control the buildup of impurities, particularly aluminum
and carbonates, in the solution. This bleed stream comprises a
wastewater stream associated with the electrowinning operation.
When municipal solid waste i;s used as a raw material to alkaline
detinning operations, a ; much larger discharge of spent
electrowinning solution results. This larger blowdown stream is
necessitated by impurities which are introduced into the sodium
stannate solution by the raw material. Consequently, _spent
electrowinning solution from municipal solid waste processing is
identified as a separate subdivision.
As an alternative to electrdwinning, tin may be precipitated from
solution as tin hydroxide. :The tin hydroxide sludge is dewatered
in a filter press, dried and sold or calcined to tin oxide in a
furnace, and reduced with carbon in a reduction furnace to
produce tin metal. The [supernatant and filtrate streams
associated with tin hydroxide precipitation comprise wastewater
4056
-------
SECONDARY TIN .SUBCATEGORY
SECT - IV
streams associated with this operation.
The flow rates and characteristics
identied
identified
*«*
and sludges.
of the tin hydroxide
depending on ?he rK
H seParate subdivisions have been
tin hydroxide supernatant from each of two types
ls: tin plated steel scrap, and plating solution!
Tin hydroxide filtrate from dewatlring ?he
is also designated ^sTseparatl
ProPosa1' the Agency decided to combine tin hydroxide
n- spent plating solutions and tin plating s?udgl
into one subdivision because there is only one Slant
discharging these streams, -as discussed in Section vT P
OTHER FACTORS :
The Bother factors considered in this evaluation were shown
to be inappropriate bases for subdivision. Air Dilution
control methods, treatment costs, and total enerav
flctorre^?,iare fU2Ct.i0nS °f the sel*cted subca?egoriJa?I^
factors— metal product, raw materials, and production
andCeSdoS* nnfThe^f°P'^hey are not independent5 factors
develonSd A.,* S?t the,subcategorization which has been
developed. As discussed in Section IV of the Gen<*r*\
Development Document, certain other factors, such as plant age
^d de^?l'nJnd. thK nVmber of employees, were also SvaluSted
«n° •aet.ernuned to be inappropriate for use as bases for
subdivision of nonferrous metals plants. oases for
PRODUCTION NORMALIZING PARAMETERS
r « . .
capacities, the mass of pollutant discharged must be related to a
unit of production. This factor is known as the production
normalizing parameter (PNP), p^oauccipn
ss-isis '
PNP
Building Block
1. Tin smelter SC>2 scrubber
produced
2. Dealuminizing rinse
produced
PNP
kkg of crude tapped tin
kkg of dealuminized scrap
4057
-------
SECONDARY TIN SUBGATEGORY
SECT
IV
3. Tin mud acid neutralization
filtrate j
4. Tin hydroxide wash
5. Spent electrowinning solution
from new scrap \
6. Spent electrowinning
solution from municipalj
solid waste
7. Tin hydroxide supernatant from
scrap
8. Tin hydroxide supernatant from
plating solutions and
sludges ;
9. Tin hydroxide filtrate
The PNP for subdivision 1, tin
kkg of neutralized, dewatered
tin mud produced
kkg of tin hydroxide washed
kkg of cathode tin produced
kkg of MSW scrap
used as raw material
kkg of tin metal recovered
kkg of tin metal recovered
from plating solutions and
sludges
kkg of tin metal produced
smelter SC-2 scrubber, has
-
during a visit to a facility,,generating this wastewater stream
Subdivision 8, tin hydroxide; supernatant from plating solutions
and sedges, is a newYsubdivi!sionfor Promulgation, consisting of
the proposed subdivisions 8: and 9. As such, the PNP ror
Subdivision 8 is a combination of the proposed PNPs for
Subdivisions 8 and 9; that is. kkg of tin metal recovered from
plating solutions and sludges.
4058
-------
SECONDARY TIN SUBCATEGORY SECT - V
: SECTION V
WATER USE AND WASTEWATER CHARACTERISTICS
This section describes the characteristics of the wastewaters
associated with the secondary tin subcategory. Water use and
discharge rates are explained and then summarized in tables
at the end of this section. Data used to characterize the
wastewaters are presented. Finally, the specific source, water
use and discharge flows,, and wastewater characteristics for each
separate wastewater source are discussed. Data collection
portfolios (dcp) and field sampling results were used in the
development of effluent ;limitations and standards for this
subcategory. Data collection portfolios contain information
regarding wastewater flows and production levels.
L - - - " .
In order to quantify the;pollutant discharge from secondary
tin plants, a field sampling program was conducted. A complete
list of the pollutants considered and a summary of the
techniques used in sampling and laboratory analyses are included
in Section V of the General Development Document. Samples were
analyzed for 124 of the 126 priority pollutants and other
pollutants deemed appropriate. Because the analytical
standard for TCDD was judged to be too hazardous to be made
generally available, samples were never analyzed for this
pollutant. Samples were also not analyzed for asbestos. There
is no reason to expect that TCDD or asbestos would be
present in wastewater in the secondary tin subcategory. m
general, the samples were analyzed for cyanide and three
classes of pollutants: priority organic priority pollutants
priority metal pollutants, and criteria pollutants (which
includes both conventional and nonconventional pollutants).
Following proposal, additional data were gathered concerning
flow, production, and wastewater characteristics at one of
K! -tlT^ Pi311*3 identified in this study. These data were
obtained ;during a field sampling episode, and are contained in
the administrative record supporting this rulemaking.
In addition, EPA collected more economic information on plants in
the secondary tin subcategory, which is contained in the
aoministrative record supporting this rulemaking. Revisions to
the economics analysis are discussed in a separate document
Through the economic data gathering, EPA learned that one
secondary tin plant had changed discharge status following
proposal._ Using an evaporation system, plant 1014 changed from
being an indirect discharger to a zero discharge facility Due
to this process change, EPA decided to revise the subdivision
scheme^or this subcategory, by combining 2 subdivisions into 1
subdivision, namely, combining tin hydroxide supernatant from
spent plating_solutions and tin hydroxide supernatant from sludge
solids into tin hydroxide supernatant from plating solutions and
4059
-------
SECONDARY TIN SUBCATEGORY SECT - V
sludges. As discussed in Section IV, the PNP for this new
subdivision has also been appropriately revised. This revision
is being made for regulatory 'simplification reasons, and will not
affect the mass limitations with which any plant in this
subcategory must comply. This change is discussed in more detail
later in this section and als|o in section IX.
After proposal, EPA gathered additional wastewater sampling data
for two of the subdivisions in this subcategory, tin mud acid
neutralization filtrate and dealuminizing rinse. These data were
acquired through a self sampling program conducted at the
specific request of EPA. The data include analysis for the
priority metals antimony, arsenic, cadmium, chromium, copper,
lead, nickel, selenium, silver, thallium and zinc. The data
also include analyses for: cyanide and the nonconventional
pollutant tin. The data support the assumptions which EPA had
made at proposal concerning the presence and concentrations
of pollutants in these subdivisions where we did not have
analytical data for specific pollutants. For this reason,
the selection of pollutant parameters for limitation in this
subcategory (Section VI) has not been revised based on this new
data. i
As described in Section IV of this supplement, the secondary
tin subcategory has been- divided into 9 subdivisions or
wastewater sources, so that the promulgated regulation
contains mass discharge limitations and standards for _9
unit processes discharging process wastewater. Differences in
the wastewater characteristics associated with these
subdivisions are to be expected. For this reason, wastewater
streams corresponding to each subdivision are addressed
separately in the discussions that follow. These wastewater
sources are:
(a) Tin smelter SC>2 scrubber,,
(b) Dealuminizing rinse,
(c) Tin mud acid'neutralization filtrate,
(d) Tin hydroxide wash,
(e) Spent electrowinning solution from new scrap,
(f) Spent electrowinning solution from municipal solid waste,
(g) Tin hydroxide supernatant from scrap,
(h) Tin hydroxide supernatant from plating solutions and sludges,
and
(i) Tin hydroxide filtrate. ; .
WASTEWATER FLOW RATES
Data supplied by dcp -responses were evaluated, and two
flow-to-production ratios, \ water use and wastewater discharge,
were calculated for each stream." The two ratios are
differentiated by the flow lvalue used in the calculation. Water
use is defined as the volume of water or other fluid required for
a given process per mass of !tin product and is therefore based on
the sum of recycle and make-up flows to a given process to
further treatment, disposal, or discharge per mass of tin
4060
-------
SECONDARY TIN SUBCATEGQRY SECT - V
produced. Differences between the water use and wastewater flows
associated with a given stream result from recycle, evaporation,
and carry-over on the product. The production valSes used
in calculation correspond to the production normalizing
parameter, PNP, assigned , to each stream, as outlined in Section
IV. As an example, tin smelter SO2 scrubber water flow is
If. A* u ' Production of crude tapped tin. AS such,
metric ?oSS T* ^/^f6336^ in liters of scrubber water per
wt^CLar £pn °l crude tapped tin (gallons of scrubber
water per ton of crude tapped tin).
The production
statistically
normalized water
subdivision
normalized discharge flows were compiled and
analyzed.... by stream type. These production
use and discharge flows are presented by
. ^ Tables V-l through V-9 (pages 4068 - 4070).
Where appropriate, an attempt was made to identify factors
that could account for variations in water use and
discharge rates. These variations are discussed later in this
section^ by subdivision. A similar analysis of factors affecting
the wastewater flows is presented in Sections X, XI, and XII
where representative BAT; NSPS, and pretreatment flows
selected for use in calculating the effluent limitations.
are
»«o«-o USe a"d discharge rates shown do not include nonprocess
wastewater, such as rainfall runoff and noncontact cooling water.
WASTEWATER CHARACTERISTICS ;DATA
Data used to characterize the various wastewaters associated with
secondary tin production come from two sources .-- data collection
portfolios and analytical x3ata from field sampling trips.
DATA COLLECTION PORTFOLIOS V
In the data collection portfolios, the tin plants that discharge
wastewater were asked to specify the presence or absence of
priority pollutants in their wastewater. Three of the five
discharging plants responded. The responses are summarized
Pollutant
antimony
arsenic
cadmium
chromium
copper
cyanide
lead
mercury
nickel
selenium
silver
zinc
Known Present
i
1
1 '.'•-.
• . ' "- 1 :.. .
1.
1 •'••
1
1 -
0
2
0
': 1 ;
1 \
Believed Present
2
0
0
0
1
0
.1
1
0
1
0
1
4061
-------
SECONDARY TIN SUBCATEGORY SECT - V
FIELD SAMPLING DATA
In order to quantify the concentrations of pollutants present in
wastewater from secondary I tin plants, wastewater samples were
collected at five plants, which represent more than one-third
of the secondary tin plants in the United States. Diagrams
indicating the sampling sites and contributing production
processes are shown in Figures V-l through V-5 (pages 4210 -
4214).
Raw wastewater data are summarized in Tables V-10 through V-15
(pages 4071 - 4140). Data from samples of treated and partially
treated wastewater streams are presented in Tables _V-16
through V-22 (pages 4151 - 4205). The_ stream numbers listed
in the tables correspond to!those given in the individual plant
sampling site diagrams, Figures V-l through V-5. Where no
data are listed for a specific day of sampling, the wastewater
samples for the stream wer<5 not collected.
i • .
Several points regarding these tables should be noted. The data
tables include some samples measured at concentrations considered
not quantifiable. The base-neutral extractable, acid
extractable, and volatile prganics generally are considered not
Quantifiable at concentrations equal to or less than 0.010 mg/l.
Below this concentration, j organic analytical results are not
Quantitatively accurate; however, the analyses are useful to
indicate the presence of a| particular pollutant. The pesticide
fraction is considered not quantifiable at concentrations equal
to or less than 0.005 mg/l.
The detection limits shown o;n the data tables for priority metals
and conventional and nonconvientional pollutants are not the same
in all cases as the published detection limits for these
pollutants by the same analytical methods. The detection limits
used were reported with !the analytical data and hence are the
appropriate limits to applly to the data. Detection limit
variation can occur as a result of a number of laboratory-
specific, equipment-specific, and daily operator-specific
factors. These factors can include day-to-day differences in
machine calibration, variation in stock solutions, and variation
in operators. •
The statistical analysis of data includes some samples
measured at concentrations considered not quantifiable. For data
considered as detected but below quantifiable concentrations, a
value of zero is I used for averaging. Priority
orqanic, nonconventional, and conventional pollutant data
reported with a "less , than" sign are considered as
detected, but not further quantifiable. A value of zero is also
used for averaging. If one of these pollutants is
reported as not detected, it is assigned a value of zero in
calculating the average. : Finally, priority metal values
reported as less than a certain value were considered as below
quantification, and consequently were assigned a value of
I
4062
-------
SECONDARY TIN SUBCATEGORY SECT .- V
zero in the calculation of: the average.
Finally, appropriate source water concentrations are presented
with the summaries of the sampling data. The method by which
each sample was collected is indicated by number, as follows:
1
2
3
4
5
6
one-time grab
manual composite during intermittent process operation
8-hour manual composite
8-hour automatic composite
24-hour manual composite
24-hour automatic composite
WASTEWATER CHARACTERISTICS AND FLOWS BY SUBDIVISION
Since secondary tin production involves 9 principal sources of
wastewater and each has potentially different
characteristics and flows, the wastewater characteristics and
discharge rates corresponding to each subdivision will be
described separately. A brief description of why the associated
production processes generate a wastewater and explanations for
variations of water use within each subdivision will also be
discussed.
TIN SMELTER SO2 SCRUBBER
There_is one facility which produces tin metal through the
smelting of tin concentrates and residues. This facility
reported the use of a wet scrubbing system to control
s°2s emissions in the smelter flue gas. The scrubber
uses ^ a recirculating alkaline solution. A portion of the
solution =must be discharged in order to maintain effective
So? removal. The water use and wastewater discharge rates for
this stream are shown in liters per metric ton of crude
tapped tin in Table V-l (page 4049).
Following proposal, the one facility reporting this waste stream
was visited and the scrubber blowdown was sampled. It was
determined that this scrubber currently operates at greater than
90 percent recycle. The blowdown is directly discharged
following equalization, chemical precipitation and sedimentation.
Analytical data for this stream are presented in Table V-10
(page 4071). These data ; show treatable concentrations of
arsenic, cadmium, chromium, copper, lead, selenium, zinc
tin, and suspended solids.
DEALUMINIZING RINSE
Aluminum present in tin plated steel scrap may be removed by
leaching in a sodium hydroxide solution prior to alkaline
detinning. The aluminum dissolves in the caustic solution and
the scrap is then rinsed:and charged to the alkaline detinning
tanks. One plant reported this practice. A portion of their raw
material is tin plated steel scrap separated from municipal solid
waste. The spent caustic leaching solution and rinse water are
4063
-------
SECONDARY TIN SUBCATEGORY SECT - V
F
i • .
discharged as a waste stream. The one facility reporting this
waste stream is a direct discharger. The dealuminizing waste
stream is treated with sodium sulfide to precipitate metals,
chlorinated to destroy cyanide, and neutralized with, sulfuric
acid. Solids are removed1 from the neutralized stream in a
sedimentation pond prior to discharge. The water use and
discharge rates are presented in Table V-2 (page 4068) in liters
per metric ton of dealuminized scrap produced.
There was no analytical data for this stream available before
proposal and it was expected to be similar to the spent
electrowinning solution wit:h a very alkaline pH and treatable
levels of cyanide and certain toxic metals including arsenic,
lead, nickel and selenium. Data supplied to the Agency after
proposal corroborates the assumption that a treatable level of
cyanide is present.
TIN MUD ACID NEUTRALIZATION FILTRATE
One facility reported neutralization of tin mud with sulfuric
acid prior to dewatering in a filter press. The neutralized,
dewatered mud is sold as k by-product. The filtrate from the
dewatering step is discharged as a wastewater stream. Water use
and discharge rates are presented in Table V-3 (page 4068)
in liters per metric ton of neutralized, dewatered tin mud
produced.
Analytical data for thi£ wastewater stream were collected
after proposal through a sejlf sampling program at the specific
request of EPA. These datal are presented in Table V-23 (page
4209) and show that this stream contains treatable
concentrations of cyanide bnd zinc.
TIN HYDROXIDE WASH :
One facility reported the use of tin hydroxide, Sn(OH)4, as
a raw material in their electrolytic tin production process. The
tin hydroxide is wa|shed with water to remove
impurities, dissolved in a sodium hydroxide solution and mixed
with the tin solution f^rom the alkaline detinning operation
prior to entering the electrowinning cell. The tin
hydroxide wash water is discharged as a waste stream. The
one facility reporting this stream achieves zero discharge
through the use of an evaporation pond. The water use and
discharge rates are shown in liters per metric ton of tin
hydroxide washed in Table V-4 (page 4069).
There are no analytical data available for this stream. It is
expected to have an alkaline pH and a treatable level of total
suspended solids. Also, some priority metals may be present if
they are present in the tin hydroxide.
SPENT ELECTROWINNING SOLUTION FROM NEW SCRAP
Electrowinning is the principal method, for recovering tin from
4064
-------
SECONDARY TIN SUBCATEGORY SECT - V
the alkaline detinning solution. After the tin has been plated
onto the cathode and the solution has been depleted, the solution
is either recycled to the:detinning tank or discarded depending
on the amount and type of impurities present. Of the 10 plants
which practice alkaline: detinning, eight recover tin from
solution via electrowinning. Of these eight facilities, six
achieve zero discharge through various combinations of recycle,
evaporation, contractor disposal and sales. Of the two remaining
plants one is a direct discharger; and the other is an indirect
discharger. Water use and discharge rates are presented in Table
V-5 (page 4069) in liters:per metric ton of cathode tin produced.
Table V-ll (page 4082) summarizes the raw wastewater sampling
data for the priority and selected conventional and
nonconventional pollutants. It can be seen that there are
treatable concentrations of several priority metals present
including antimony, arsenic, lead, nickel, selenium, thallium
and zinc. Also, treatable concentrations of cyanide are present.
This wastewater stream has a very alkaline pH (approximately 12)
and high concentrations of total suspended solids.
SPENT ELECTROWINNING SOLUTION FROM MUNICIPAL SOLID WASTE
When tin plated steel scrap which was recovered from municipal
solid waste (MSW) is used as a raw material for alkaline
detinning and electrowinning, a significantly larger discharge of
spent electrowinning solution is necessary because of additional
impurities introduced into the solution. There is currently one
facility using MSW as a source of raw material. The water use
and discharge rates for this stream are shown in Table V-6
(page 4069) in liters per metric ton of MSW scrap used as raw
material. This flow rate is estimated using a procedure
described in Section IX of this document.
The facility reporting this extra discharge of spent
electrowinning solution :is a direct discharger after treatment
consisting of chlorination, acid neutralization and
sedimentation. The characteristics of this wastewater are
assumed to be similar ,to the characteristics of spent
electrowinning solution as discussed previously.
TIN HYDROXIDE SUPERNATANT ;FROM SCRAP
Tin may be recovered from solution by precipitation as tin
hydroxide, Sn(OH)4. Tin is present in solution as sodium
stannate, Na2SnO3. Tin hydroxide will precipitate when the pH is
lowered to 7.0 with sulfuric acid and sodium carbonate is added
to pH 7.8. The characteristics and production normalized flow
rates of the resultant supernatant stream are dependent upon the
raw material used. The three possible raw materials are tin
plated steel scrap, spent plating solutions, and plating sludge
solids. .
The water use and wastewater discharge rates for tin hydroxide
supernatant from scrap are shown in Table V-7 (page 4070) in
: : 4065
-------
SECONDARY TIN SUBCATEGORY SECT - V
liters per metric ton of tin metal recovered from scrap. The
one facility reporting this stream is a direct discharger after
treatment by sedimentation. Table V-12 (page 4102) summarizes
the raw wastewater sampling ^ata for the priority and selected
conventional and nonconventional pollutants. It can be seen that
treatable levels of priority metals are present, particularly
antimony at 4.4 mg/1. This|waste stream has a pH of 8.3 and
treatable levels of oil and;grease and total suspended solids
(TSS).
TIN HYDROXIDE SUPERNATANT FROM PLATING SOLUTIONS AND SLUDGES
Two plants reported the use of spent tin plating solutions as raw
material. One facility recovers tin as tin hydroxide from both
spent plating solutions and plating sludge solids. This facility
dissolves tin from the sludge'solids into the plating solution by
adding additional water, while heating and lancing with air. Tin
hydroxide is then precipitated from the resultant solution. The
second facility uses only jspent plating solutions. Following
proposal, the Agency learned that the second facility
revised their process for recovering tin from solution.
Instead of precipitating tin hydroxide using ammonia, and
discharging the liquids, the solution is completely evaporated in
an oven to produce a tin hydrate product. No process water is
discharged from this operation.
The Agency revised this subdivision for promulgation by combining
tin hydroxide supernatant from spent plating solutions with tin
hydroxide supernatant from : tin plating sludge solids to form a
new subdivision, namely tin hydroxide supernatant from plating
solutions and sludges. Thfe water use and discharge rates for
this subdivision are presented in Table V-8 (page 4070). This
revision was made to simplify the regulation, and will not
change the mass limitations with which any plant must comply.
Sampling data for tin hydroxide supernatant from tin plating
solutions and sludges is presented in Table V-13 (page 4113).
The samples were collected at the facility which uses both
spent plating solutions and tin sludge solids as raw materials
to tin hydroxide precipitation operations. It can be seen
that treatable concentrations of priority metals are
present, particularly antimony which was detected at a
maximum concentration of 3.1 mg/1. Cyanide is also
present with a maximum observed concentration of 16 mg/1.
Very high concentrations of ; fluoride are present in this
wastewater with concentrations from 12,000 to 15,000 mg/1.
This fluoride originates from tin fluoroborate and
fluoroboric acid which arei used in the tin plating baths.
This wastewater has a nearly-neutral
concentrations of suspended solids.
TIN HYDROXIDE FILTRATE
pH
and
treatable
When tin hydroxide slurry is separated from the supernatant
stream, it may be further dewhtered in a filter press prior to
4066
-------
SECONDARY TIN SUBCATEGORY SECT - V
drying. The resultant : filtrate is discharged as a wastewater
stream. Water use and discharge rates are presented in Table
V-10 (page 4071) in liters per metric ton of tin metal produced.
The one facility reporting this stream is a direct discharger
after treatment by sedimentation. Table V-14 (page 4129)
summarizes the sampling data for this waste stream. Treatable
concentrations of cyanide and priority metals are present
including antimony at 2;4 mg/1. Treatable concentrations of
fluoride and TSS are also present.
4067
-------
SECONDARY TIN SUBCATEGORY SECT - V
TABLE V-l
WATER USE AND DISCHARGE RATES
TIN SMELTER SC-2 SCRUBBER
(1/kkg of crude tapped tin produced)
Plant Code
1118
Percent
Recycle
>90
Production
Normalized
Water Use
NR
Production
Normalized
Discharge Rate
9198
TABLE V-2
WATER USE AND DISCHARGE RATES
DEALUlhNIZING RINSE
(1/kkg of dealuminized scrap produced)
Plant Code
1046
Percent
Recycle
0
Production
Normalized
Water Use
35
Production
Normalized
Discharge Rate
35
TABLE V-3
I
WATER USE AND DISCHARGE RATES
TIN MUD ACID NEUTRALIZATION FILTRATE
i
(1/kkg of neutralized, dewatered tin mud produced)
Plant Code
1046
Percent
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0
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Normalized
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5047
Production
Normalized
Discharge Rate
5047
4068
-------
SECONDARY TIN, SUBCATEGORY SECT - V
Plant Code
1049
: TABLE V-4
WATER USP AND DISCHARGE RATES
. .. . TIN; HYDROXIDE WASH
(1/kkg of tin hydroxide washed)
Percent
Recycle
Production
Normalized
Water Use
11953
Production
Normalized
Discharge Rate
11953
TABLE V-5
WATER USE AND DISCHARGE RATES
SPENT ELECTROWINNING SOLUTION FROM NEW SCRAP
(1/kkg of cathode tin produced)
Plant Code
1047
1049
1048
1054
1046
1056
1057
1144
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0
0
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0
0
0
NR
; Production
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: 24069
; NR
i 16609
15145
12489
10498
: NR
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Normalized
Discharge Rate
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24069
21982
16609
15145
12489
10498
NR
TABLE V-6
WATER USE;AND DISCHARGE RATES
SPENT ELECTROWINNING SOLUTION FROM MUNICIPAL SOLID WASTE
(1/kkg of MSW scrap used as a raw material)
Percent
Plant Code Recycle
1047
0
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Normalized
Water Use .
119
Production
Normalized
Discharge .
119
4069
-------
SECONDARY TIN SUBCATEGORY SECT - V
TABLE V-7
WATER USE &ND DISCHARGE RATES
TIN HYDROXIDE SUPERNATANT FROM SCRAP
(1/kkg of tin metal recovered from scrap)
Plant Code
1036
Percent
Recycle
Production
Normalized
Water Use
55640
Production
Normalized
Discharge Rate
55640
TABLE V-8
WATER USE!AND DISCHARGE RATES
TIN HYDROXIDE SUPERNATANT ; PROM PLATING SOLUTIONS AND SLUDGES
(1/kkg of tin metal recovered from plating solutions and sludges)
Plant Code
1036
Percent
Recycle
Production
Normalized
Water Use
115000
Production
Normalized
Discharge Rate
115000
TABLE V-9
WATER USE;AND DISCHARGE RATES
TIN HYDROXIDE FILTRATE
(1/kkg of tin metal produced)
Plant Code
1118
Percent
Recycle
>90
Production
Normalized
Water Use
NR
Production
Normalized
Discharge Rate
9198
4070
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