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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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-------
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-------
               PRIMARY BERYLLIUM  SUBCATEGORY
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-------
PRIMARY BERYLLIUM SUBCATEGORY
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-------
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             PRIMARY  BERYLLIUM SUBCATEGORY


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-------
      PRIMARY BERYLLIUM  SUBCATEGORY
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-------
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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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-------
              PRIMARY BERYLLIUM  SUBCATEGORY
                                                      SECT -  V
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-------
             PRIMARY BERYLLIUM  SUBCATEGORY      SECT  - V
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-------
PRIMARY BERYLLIUM SUBCATEGORY    SECT - V




















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-------
              PRIMARY BERYLLIUM  SUBCATEGORY
                                                        SECT -  V
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          PRIMARY BERYLLIUM SUBCATEGORY
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-------
       PRIMARY BERYLLIUM SUBCATEGORY
    SECT - V
BeO Calcining Caustic
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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
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               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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-------
PRIMARY BERYLLIUM SUBCATEGORY
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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

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         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

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             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

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            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

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PRIMARY BERYLLIUM SUBCATEGORY   SECT - VII
   THIS  PAGE  INTENTIONALLY  LEFT  BLANK
                     3748

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              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

-------
              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

-------
         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

-------
                 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

-------
                 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

-------
               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

-------
                 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

-------
               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

-------
                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

-------
               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

-------
                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

-------
               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













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-------
PRIMARY BERYLLIUM SUBCATEGORY
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                      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

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               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

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                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

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               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

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                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

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               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

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                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

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               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

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PRIMARY BERYLLIUM SUBCATEGORY    SECT  -  IX
                                                      0)
                                                      ;j

                                                      DO
                                                     •r-t
                                                     Cil
                                                         H
                                                         S5
                                                         W-
w
                                                         33
                   3773

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PRIMARY BERYLLIUM SUBCATEGORY   SECT - IX
THIS PAGE INTENTIONALLY LEFT BLANK
                 3774

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              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
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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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-------
              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

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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
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143
64
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106.
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10,240.
3,479.
produced
680
220
600
980
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 (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
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1 0.000
0.000
0.000
i 0.000
: 0.000
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o oon
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 (i) Chip Treatment Wastewater
      BAT
Pollutant or
pollutant property
; Maximum for
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                    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
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PRIMARY BERYLLIUM SUBCATEGORY
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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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                      3796

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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
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Beryllium
Chromium
Copper
Cyanide
Ammonia
Fluoride
mo o
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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

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 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
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,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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                                !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


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-------
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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

-------
     PRIMARY NICKEL AND  COBALT  SUBCATEGORY
                                                                SECT -  V
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-------
             PRID
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-------
PRIMARY NICKEL AND  COBALT  SUBCATEGORY      SECT -  V
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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

-------
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-------
       PRIMARY NICKEL  AND COBALT  SUBCATEGORY

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                             3879

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PRIMARY NICKEL AND COBALT SUBCATEGORY    SECT - VI






















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-------
  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

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PRIMARY NICKEL AND COBALT SUBCATEGORY   SECT - VI
            THIS  PAGE INTENTIONALLY LEFT BLANK
                             3884

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        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

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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

-------
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

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    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

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     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

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     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

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     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               .    . •   •   •

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    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

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    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   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

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    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

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    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

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PRIMARY NICKEL AND COBALT SUBCATEGORY  SECT - XI
           THIS PAGE INTENTIONALLY LEFT BLANK
                            3924

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          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
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                                                   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
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                     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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-------
      SECONDARY NICKEL SUBCATEGORY    SECT - V














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                SECONDARY NICKEL  SUBCATEGORY
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        SECONDARY, NICKEL  SUBCATEGORY
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SECONDARY NICKEL SUBCATEGORY
                                                   SECT - V
       Source
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         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

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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

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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

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         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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-------
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-------
SECONDARY NICKEL;SUBCATEGORY
SECT - XI
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                            4004

-------
           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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         SECONDARY  NICKEL|SUBCATEGORY      SECT  - XII
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                                                                                         6-1
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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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-------
           SECONDARY TIN  SUBCATEGORY
SECT - III
                           TAJBLE  III-2

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                                4050

-------
                  SECONDARY.TIN  SUBCATEGORY
                                                         SECT - III
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                                           4051

-------
         SECONDARY TIN SUBCATEGORY    SECT  -  III
Tin Concentrates
    and Residues
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Smelter
              Gas
                              1
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                              Figure III-1

              TIN SMELTING PRODUCTION PROCESS
                               4052

-------
SECONDARY TIN-SUBCATEGORY    SECT -  III
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                   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
 Recycle

     0
 Production
 Normalized
 Water Use

   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

Percent
Recycle
0
0
NR
0
0
0
0
NR
; Production
Normalized
Water Use
' • NR
: 24069
; NR
i 16609
15145
12489
10498
: NR
                                                     Production
                                                     Normalized
                                                   Discharge Rate

                                                          NR
                                                       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
Production
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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